2 DX 2 DN VSD AIB EN Lille 1901077772

Instructions Book
2DX2-VSD
2DN2-VSD
(In Booster standalone or ZD or ZDXtend configuration)
ORIGINAL INSTRUCTION
Copyright note
All unauthorised use or copy of all or part of content is strictly

forbidden.
This particularly applies to manufacturing brands, model descriptions,

document and drawing descriptions.
Printing date...................... 10/2016
ATLAS COPCO
www.atlascopco.com
1901077772.02 1
Atlas Copco Crépelle S.A.S. A company Within the Atlas Copco Group
Atlas Copco Crépelle S.A.S. Adresse Visiteurs Tél. +(33) 03 20 52 47 11 S.A.S au capital de 4 784 000€
B.P. 29 2, place Guy de Dampierre Fax + (33) 03 20 53 76 51 R.C. Lille B 458 501 483
F-59008 Lille Cedex Lille E-mail : Siret 458 501 483 00085
www.atlascopco.com France Contact.crepelle@fr.atlascopco.com TVA FR 35 458 501 483
Instructions book
Contents
1. SAFETY PRECAUTIONS ....................................................................................................................................... 4
1.1 SAFETY PRECAUTION LEGEND ................................................................................................................................. 4
1.2 SAFETY PRECAUTIONS DURING INSTALLATION ........................................................................................................ 4
1.3 SAFETY PRECAUTIONS DURING OPERATIONS ........................................................................................................... 6
1.4 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIRS ..................................................................................... 8
2 GENERAL DESCRIPTION................................................................................................................................... 10
2.1 DESCRIPTION OF D BOOSTER ................................................................................................................................. 10
2.2 GENERAL VIEWS OF DX VSD AND DN VSD BOOSTERS ....................................................................................... 12
2.3 FLUID DIAGRAM .................................................................................................................................................... 17
2.4 AIR SYSTEM........................................................................................................................................................... 19
2.5 COOLING AND LUBRICATION SYSTEM .................................................................................................................... 24
2.6 REGULATION SYSTEM ............................................................................................................................................ 29
2.7 ELECTRIC CIRCUITS ............................................................................................................................................... 29
3 ELEKTRONIKON REGULATOR ....................................................................................................................... 33
3.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW.................................................................................................. 33
4 ELEKTRONIKON ® GRAPHIC PLUS CONTROLLER.................................................................................. 34
4.1 GENERAL DESCRIPTION ......................................................................................................................................... 34
4.2 CONTROL PANEL (FIG. 2.1) .................................................................................................................................... 37
4.3 DIGITAL OUTPUT CONTACTS .................................................................................................................................. 38
4.4 ICONS USED ........................................................................................................................................................... 40
4.5 MAIN SCREEN ....................................................................................................................................................... 44
4.6 CALLING UP MENUS ............................................................................................................................................... 50
4.7 SERVICE MENU ...................................................................................................................................................... 53
4.8 PROTECTIONS MENU .............................................................................................................................................. 59
4.9 WEEK TIMER MENU ............................................................................................................................................... 62
4.10 INFO MENU ....................................................................................................................................................... 73
4.11 TEST MENU ....................................................................................................................................................... 75
4.12 COUNTERS ........................................................................................................................................................ 76
4.13 MODIFYING THE SETPOINT................................................................................................................................ 79
4.14 INPUTS MENU .................................................................................................................................................... 82
4.15 OUTPUTS MENU ................................................................................................................................................ 87
4.16 EVENT HISTORY MENU ...................................................................................................................................... 90
4.17 MODIFYING SETTINGS....................................................................................................................................... 92
4.18 PROGRAMMABLE SETTINGS ............................................................................................................................ 100
4.19 WEB SERVER .................................................................................................................................................. 106
4.20 ZR SETTINGS (FOR ZD) .................................................................................................................................. 116
5 INSTALLATION .................................................................................................................................................. 117
5.1 DRAWING WITH MEASURES ................................................................................................................................. 117
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5.2 INSTALLATION PROPOSAL.................................................................................................................................... 117

5.3 D BOOSTER USE IN A ZDXTEND .......................................................................................................................... 118
5.4 MODIFICATION OF ZR IN CASE OF ZDXTEND INSTALLATION .............................................................................. 121
5.5 DIMENSIONS OF ELECTRIC CABLES ...................................................................................................................... 122
5.6 ELECTRIC CONNECTIONS ..................................................................................................................................... 124
5.7 COOLING WATER QUALITY REQUIREMENTS ......................................................................................................... 133
5.8 COOLANT ............................................................................................................................................................ 136
5.9 GENERAL PICTOGRAMS ....................................................................................................................................... 139
6 INSTRUCTIONS FOR USE ................................................................................................................................ 140
6.1 INSTALLATION..................................................................................................................................................... 140
6.2 INITIAL START-UP ................................................................................................................................................ 148
6.3 START-UP AFTER EMERGENCY STOP OR DEFAULT STOPPING ................................................................................ 154
6.4 DURING OPERATION ............................................................................................................................................ 155
6.5 SCREEN CHECK .................................................................................................................................................... 156
6.6 STOPPING AND DISCONNECTION OF THE MACHINE ............................................................................................... 157
6.7 DEFINITIVE END OF SERVICE................................................................................................................................ 157
7 MAINTENANCE .................................................................................................................................................. 159
7.1 PREVENTIVE MAINTENANCE PROGRAMME........................................................................................................... 159
7.2 LUBRICATION OF THE MOTOR .............................................................................................................................. 160
7.3 OIL SPECIFICATIONS ............................................................................................................................................ 161
7.4 STORAGE FOLLOWING INSTALLATION ................................................................................................................. 161
7.5 SERVICE KITS ...................................................................................................................................................... 162
7.6 TORQUES ............................................................................................................................................................. 162
8 MAINTENANCE PROCEDURE FOR D BOOSTER ....................................................................................... 163
8.1 AIR FILTERS......................................................................................................................................................... 163
8.2 OIL DRAINING AND REPLACING OF THE OIL FILTER .............................................................................................. 164
8.3 SAFETY VALVES .................................................................................................................................................. 165
9 RESOLUTION OF PROBLEMS RELATING TO D BOOSTER.................................................................... 166
10 MAIN CHARACTERISTICS .............................................................................................................................. 169
10.1 REFERENCE CONDITIONS ................................................................................................................................ 169
10.2 D BOOSTER READINGS .................................................................................................................................... 169
10.3 SAFETY VALVE SETTINGS FOR D BOOSTERS .................................................................................................... 170
10.4 CIRCUIT BREAKERS AND FUSES RATING FOR D BOOSTERS .............................................................................. 170
10.5 LIMITATIONS .................................................................................................................................................. 173
10.6 SPECIFICATIONS.............................................................................................................................................. 174
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Instructions book
1. Safety precautions
1.1 Safety precaution legend
Explanation of safety signs used in the notice
Mortal danger
Warning
Important remark
1.2 Safety precautions during installation
Atlas Copco refuses all responsibility in case of tangible damage or bodily harm
due to negligence in the application of these precautions, in non-compliance or
in a lack of elementary surveillance in installation, operating, maintenance and
repairs, even if no specific reference is made.
General precautions
1 The operator must use safe working methods and apply all local applicable safety regulations and
provisions.
2 If one of the following declarations does not comply with your local legislation, the stricter version
is applicable.
3 All installation, use, maintenance operations and repairs must be carried out by authorised, trained
and qualified personnel.
4 The compressor is not to be used for the production of breathable air. To be breathable,
compressed air must be appropriately filtered in accordance with legislation and local standards.
5 Prior to all maintenance operations, repairs, adjustments or exceptional checking or retightening,
stop the compressor, press the emergency stop button, cut the power supply and decompress. In
addition, the main disconnecting switch must be open and locked. Finally, to make sure that the
machine is isolated from the network of compressed air.
6 Never handle compressed air in an inappropriate manner. Never apply compressed air to the skin
or towards another person. Never use compressed air to clean clothing. Apply all precautions in
cleaning equipment using compressed air and wear protective goggles.
Precautions during installation

1 The machine must only be raised using the appropriate equipments according to local safety rules.
Use frame openings to move the machine with a lift truck. Unattached or pivoting parts must be
firmly fixed prior to lifting. It is strictly forbidden to transit or remain in the dangerous zone located
below a suspended load. When lifting, accelerations or braking must respect safety limits. Wear a
safety helmet during work in the zone with suspended equipment or lifting equipment.
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2 Install the machine in a building in which the atmosphere is as fresh and clean as possible. Install
a ventilation duct if necessary. Never block the air inlet. Reduce humidity in air admitted to a
maximum. Building ventilation conditions (See installation proposal in chapter 5).
3 Fixed flanges, plugs, caps and silicon sachets must be removed prior to connecting piping.
4 The diameter and type of flexible used to connect the machine to the air network must be
appropriate for operating pressure. Never use fritted, damaged or worn flexible piping. Distribution
pipes and connections must have the correct dimensions for the operating pressure.
5 Sucked air must be free of smoke, vapour and particles and inflammable and corrosive gases, e.g.
paint solvents likely to cause a fire or explosion on the premises.
6 Install the air inlet to ensure that the clothing of individuals working nearby is not sucked in.
7 Ensure that the unload pipe connecting the compressor to the final cooler or to the air network
supports dilatation due to heat and is not in contact with or near to inflammable materials.
8 The air outlet valve must be free of all external forces and connected piping must be free of all
stress.
9 If a remote control is installed, the following mention must appear: DANGER: This machine is
remote controlled and may start-up without warning.
10 Machine locations must guarantee the arrival of adequate cooling air and prevent the recycling of
air towards the air inlet for the compressor and cooling.
11 Electric connections must satisfy local regulations. Earth connections for machines are mandatory
and phases must be protected from short circuits via fuses. A lockable disconnecting switch for the
electric network must be installed near to the compressor.
12 "Sudden machine start-up" must be noted next to the instrument panel for machines equipped with
an automatic start/stop system or for which the automatic start function is activated.
13 In systems with multiple compressors, install manual control valves for the isolation of each
compressor. Do not rely on check valves to isolate pressurized circuits.
14 Never remove or handle safety, protection or isolation devices fixed on the machine. Each
pressurized or auxiliary tank installed outside of each machine and which must contain air at
higher than atmospheric pressure, must be protected by adequate decompression devices.
15 Monitor or isolate piping and other components with temperatures of more than 80°C (176°F) to
protect personnel against accidental contact. Clearly indicate other piping likely to reach high
temperatures.
16 If the floor is not entirely horizontal or has an irregular slope, consult the Atlas Copco Customer
services pole.
Also consult the following safety precautions: Safety precautions during operations
and Safety precautions during maintenance.
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1.3 Safety precautions during operations
Atlas Copco refuses all responsibility in case of tangible damage or bodily harm due
to negligence in the application of these precautions, in non-compliance or in a lack of
elementary surveillance in installation, operating, maintenance and repairs, even if no
specific reference is made.
General precautions
provisions.
is applicable.
3 Entrust the installation, operation, maintenance and repairs to authorised, qualified and competent
personnel.
5 Prior to all maintenance operations, repairs, or adjustments other than simple routine visual
checks, stop the compressor, press the emergency stop button, cut the power supply and
decompress. In addition, the disconnecting switch for the electric network must be open and
locked. Finally, to make sure that the machine is isolated from the network of compressed air.
6 Never play with compressed air. Never apply compressed air to the skin or towards another
person. Never use compressed air to clean clothing. Apply all precautions when cleaning
equipment and wear protective goggles.
Precautions during operations

1 Only use the appropriate sizes and types of flexible connections and sleeves. When applying a jet
of air into a flexible or air line, ensure that the free end is held firmly. During operations, the free
end may cause bodily harm. Ensure that the flexible is entirely decompressed prior to
disconnection.
2 When starting machines by remote control, the necessary precautions must be taken to ensure
that no individual is inspecting or working on the machine. To this end, place a clear sign on the
remote start device.
3 Never operate the machine at a lower or higher pressure than nominal limits.
4 For machines with a soundproof cover, close all cover gates during operation. Gates may only be
opened for short periods, e.g. for simple routine checks. It is imperative to wear ear protection
when opening a gate.
5 The wearing of ear protection is obligatory in environments or rooms in which sound levels reach
or exceed 85 dB (A).
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6 Regularly check that:

 All protection is in place and securely attached.
 All flexibles and/or piping present within the machine are in good condition, tightened and do
not rub each other.
Never intervene on a compressed flexible.
 Sealing has no defects.

 Bolting and collars are correctly tightened.
 Electric conductors are tightened and in good condition.
 Safety valves and other decompression devices are not blocked by dirt or paint.
 The air outlet valve and the air network, i.e. piping, connections, collectors, valves, flexibles,
etc. are in good condition.
7 Take safety measures against air pollution and possible contamination of breathable air in case of
recovery of hot cooling air from compressors, e.g. to install heating using workshop air.
8 Never remove or modify soundproofing equipment.
9 Never remove or handle safety, protection or isolation devices fixed on the machine. Each
pressurized or auxiliary container installed outside of each machine and which must contain air at
higher than atmospheric pressure, must be protected by adequate decompression devices.
Also consult the following safety precautions: Safety precautions during installation
and Safety precautions during maintenance.
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1.4 Safety precautions during maintenance or repairs
Atlas Copco refuses all responsibility in case of tangible damage or bodily harm due to
negligence in the application of these precautions, in non-compliance or in a lack of
elementary surveillance in installation, operating, maintenance and repairs, even if no
specific reference is made.
General precautions
provisions.
is applicable.
3 Entrust the installation, operation, maintenance and repairs to authorised, qualified and competent
personnel.
5 Prior to all maintenance operations, repairs, or adjustments other than simple routine visual
checks, stop the compressor, press the emergency stop button, cut the power supply and
decompress. In addition, the disconnecting switch for the electric network must be open and
locked. Finally, to make sure that the machine is isolated from the network of compressed air.
6 Never play with compressed air. Never apply compressed air to the skin or towards another
person. Never use compressed air to clean clothing. Apply all precautions when cleaning
equipment and wear protective goggles.
Precautions during maintenance or repairs

1 Always wear safety goggles.
2 Only use the appropriate tools to carry out maintenance and repairs.
3 Only use original spare parts.
4 Carry out all maintenance following cooling down of the machine.
5 A warning sign "Operations in process! Do not start!", must be displayed near to start-up
equipment.
6 When starting machines by remote control, the necessary precautions must be taken to ensure
that no individual is inspecting or working on the machine. To this end, place a clear sign on the
remote start device.
7 Before removing any component likely to include pressurized liquid, correctly isolate the machine
from all sources of pressure and fully decompress the system. A gauge will indicate the absence
of pressure.
8 Do not use inflammable solvents or carbon tetrachloride to clean components. Take safety
measures against toxic vapours from detergents.
9 Before carrying out maintenance work or operations, stop the machine, wait for the compressor to
stop and open the disconnecting switch (customer installation) to cut the current to the machine.
Close the air outlet valve and open the manual drain valves for condensates to decompress the
air system.
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10 Repairs in the start-up and speed regulation cabinet may only be executed by Atlas Copco.
Following the turning off the machine, wait for at least 6 minutes before beginning electrical
repairs as dangerously high voltage may remain up to 6 minutes in the capacitors of the start-up
and speed regulation system.
Repairs the control cabinet may only be executed by Atlas Copco.
11 Strictly comply with basic cleaning rules during maintenance and repairs. Avoid the entry of dirt by
covering exposed components and openings with clean cloths, paper or adhesive tape.
12 Never weld or carry out work involving a source of heat near to the oil circuit. Entirely bleed oil
tanks, e.g. using vapour, prior to carrying out such work. Never weld or modify a pressurized
container in any way.
13 Should any sign or risk of overheating of an internal component arise, stop the machine and open
the inspection traps following a reasonable cooling time. These precautions will avoid the
spontaneous inflammation of oil vapours upon contact with air.
14 Never use a bare flame as a source of light to inspect the inside of the machine, pressurized
container, etc.
15 Ensure that no tool, item or cloth is left inside of or on the machine.
16 Before authorising machine operation following maintenance or revision, check if operating
pressure, temperature and time settings are correct. Also check that control devices and the stop
button work correctly. If the compressor transmission protector is removed, check that it has been
re-installed.
17 Protect the motor, air filter, electric and regulation devices, etc. against the infiltration of humidity,
e.g. when cleaning with vapour.
18 Check the condition of soundproofing equipment, e.g. the cover, and air inlet and outlet systems
on the compressor. If damaged, replace with Atlas Copco equipment to prevent the amplification
of sound levels.
19 Never use caustic solvents which may damage materials in the air network.
20 When handling cooling liquid, carefully apply the following precautions :
 Never inhale cooling liquid vapours. The working area must be appropriately ventilated. Wear
a mask if necessary.
 Always wear special gloves. In case cooling liquid on the skin, rinse abundantly. If cooling
liquid comes into contact with the skin via clothing, never tear or remove the clothing. Rinse
abundantly with fresh water until all liquid is removed and apply first aid. (See Skid pump
notice).
21 Protect hands to avoid all burns, e.g. during oil draining.
Also consult the following safety precautions: Safety precautions during installation
and Safety precautions during operations.
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Instructions book
2 General description
2.1 Description of D booster

D Boosters are piston-type machines driven by an electric motor and providing oil-free air.
D Boosters are water-cooled.
Boosters (with soundproof canopy) mainly include the following components:
 Low pressure air filter
 Low pressure compression cylinder
 Intermediary cooler
 High pressure compression cylinder
 Final cooler
 Electric motor
 Belt drive
 Elektronikon® control system and power cabinet for motor start
 Safety valves (low, medium and high pressure circuit).
Elektronikon control system

The compressor is controlled by an electronic regulator which:
 controls the operating of the booster, reduces energy consumption;
 warns the operator of an abnormal operating condition, protects the booster;
 monitors components requiring maintenance;
 restarts automatically the booster following a power failure (at the request of the customer
only).
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Description of a ZD VSD
Presentation of the range of standard ZDs VSD:
Each ZDVSD includes a screw compressor (ZR VSD), a dryer (MD VSD) and a booster (D VSD).
For data and information concerning ZR VSD, see instruction book ZR VSD.
Description of a ZDXtend VSD
Each ZDXtend VSD includes a screw compressor (ZR VSD), a dryer (MD VSD), a booster (D VSD) and a
receiver (LTA).
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2.2 General views of DX VSD and DN VSD Boosters
Company data plate

Two possible alternatives:
12 1901077772.02
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Generals views of DX VSD and DN VSD boosters
AIB
AOB
W0B
WIB
Ref. Name
AOB Booster compressed air outlet
AIB Booster compressed air inlet
MK5 B Elektronikon regulator
S2 B Emergency stop button
WIB Cooling water inlet
WOB Cooling water outlet
1901077772.02 13
Instructions book
CYL HP
CYL LP
Picture non contractual

Inside front view of DX VSD booster

Inside front view of DN VSD booster
Ref. Name
CYL HP HP Cylinder (high pressure cylinder)

CYL LP LP cylinder (low pressure cylinder)
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Ref. Name Ref. Name
M Motor LP SV LP Safety valve (thermic expansion)

T Transmission HP SV HP safety valve
ICO Intermediate cooler M SV Safety valve, medium pressure
FCO Final cooler DPS Dew point sensor
CYL LP LP cylinder SVI Decompression Inter-stage
RAF Receiver 10 bars with air filter
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Instructions book
View of electric cabinets (D VSD booster)

Electric cabinet and
Elektronikon regulator D VSD Booster
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2.3 Fluid diagram
Air, water and oil circuits
Flow diagram
Standalone or ZDXtend
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Flow diagram
ZD
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2.4 Air system
Flow diagram in standalone configuration
1901071499.02
Flow diagram
Standalone
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Flow diagram in ZD configuration
1901071495.02
Flow diagram
ZD (ZR FF and Booster)
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Instructions book
1901071496.02
Flow diagram
ZD (ZR, MD and Booster)
For details of the ZR compressor, see corresponding notice.
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Flow diagram in ZDXtend configuration
1901071497.02
Flow diagram
ZDXtend (ZR FF and Booster)
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1901071498.02
Flow diagram
ZDXtend (ZR, MD and Booster)
1901077772.02 23
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2.5 Cooling and lubrication system
Flow diagram in standalone configuration
1901064177.03
Flow diagram
Standalone
1) Permissive start on oil temperature.

As long as oil temperature is below 0°C, compressor can’t start.
Flow diagram
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Flow diagram in ZD configuration
1901061206-10

Flow diagram
ZD (ZR FF and Booster)
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1901064721-04
Flow diagram
ZD (ZR, MD and Booster)
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Flow diagram in ZDXtend configuration
1901066583-02

Flow diagram
ZDXtend (ZR FF and Booster)
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1901067301-02
Flow diagram
ZDXtend (ZR, MD and Booster)
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2.6 Regulation system
See § 4.1.a
2.7 Electric circuits
Main components
Electrical cabinet with frequency converter and Elektronikon regulator
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Electric cabinet for DX VSD
A1
A11
K21
1X3
Detailed view of the converter cabinet

Electric cabinet of a Booster DX VSD of booster DX VSD
Ref. Name Ref. Name

A11 Frequency converter T2 Main transformer, 115-230 V/24 V
F3/4 Circuit breakers, control circuit T3 24 VDC power supply
K11 Auxiliary relay, charge indication K20 Fan contactor
Auxiliary relay, motor operating indicator X11 to
K13 Terminal / connector strip
Auxiliary relay, water stop valve X82
K21 Line contactor 1x4 to 1x8 Terminal strip
Q1 Circuit breakers, break the control circuit 1x3 Earth terminal
Q20 Circuit breakers, fan K54 Cooling Start / Stop relay
T1 Main transformer A1 RFI Filter
A12 Frequency converter I02 / I034 Mk V Expansion modules
A13 Main converter control unit
S10 Switch service
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Electric cabinet for DN VSD
Detailed view of electric cabinet and converter cabinet of a DN < = 250 VSD Booster
Ref. Name Ref. Name

A11 Frequency converter K20 Fan contactor
F3/4 Circuit breakers, control circuit 1x4 Terminal
K11 Auxiliary relay, charge indication 1x5 Terminal
K13 Auxiliary relay, motor operating indicator 1x6 Terminal
K21 Line contactor 1x7 Terminal
K31 Timer relay, auxiliary relay, water stop valve 1x8 Terminal
Q1 Circuit breakers, break the control circuit 1x3 Earth terminal
Q20 Circuit breakers, fan S10 Switch service
T1 Main transformer K54 Cooling start/stop relay
T2 Main transformer, 115-230 V/24 V A1 RFI filter
T5 24 VDC power supply A12 Frequency converter
I02 Elektronikon Expansion A13 Main converter control unit
I034 Elektronikon Expansion X… Terminal with connections
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Detailed view of electric cabinet and converter cabinet of a DN > = 250 VSD Booster
Ref. Name Ref. Name
S10 Service switch (Local/Remote control) F37 Fuses for HAT canopy fan
A14 RS232/RS485 converter F47 Thermal protection relay for HAT canopy fan
T3 Transformer 230Vac / 24Vac K26 Contactor for HAT canopy fan
K11 Loading auxiliary relay F36 Fuses for canopy fan
K54 Cooling Start/Stop relay F46 Thermal protection relay for canopy fan
K13 On operation auxiliary relay K25 Contactor for canopy fan
F1-F2 Fuses for T1 S2 Emegency stop
1X7 Terminal S21/S22 Protection door lock system
1X6 Terminal P1 Under voltage Red light
1X5 Terminal A12 Power drive converter
1X4 Terminal A13 Control unit drive converter
X… Connectors A19 Drive converter interface
K31 Timed relay water shut-off valve (op5) A1 EMC Filter
L11 Choke
Supply Customer power connection
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3 Elektronikon regulator
3.1 Elektronikon® controller type overview
Type overview
Elektronikon GraphicPlus controller for variable speed drive (VSD) compressors
ZD or ZDXtend configuration includes 2 elektronikon regulators :

- The first is installed on D booster (main)
- The second is installed on the ZR compressor (auxiliary)
Both regulators are connected via a CAN link or CAN 1 network.
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4 Elektronikon ® Graphic Plus Controller

4.1 General description
Generally speaking, the regulator carries out the following functions:
a. controlling the speed of the motor (Variable Speed Drive) – reduces the consumption of energy
b. machine protection
c. announcement of maintenance activities to be carried out
d. Automatic restart following a voltage failure (not activated)
a. Compressor speed control - reduced consumption of energy

The regulator adapts compressor air flow to air consumption and maintains variations in net pressure as
minimal.
The regulator continually adjusts motor speed and maintains net pressure at a value which remains as near as
possible to the programmed pressure set point. If air consumption decreases, motor speed decreases, as well
as the power consumption.
Unloading
If the motor operates at minimum speed (5) and net pressure (1) rises to a value equal to the sum of the
programmed pressure set point (3) and the programmed indirect stop level (10), the compressor will switch to
unload mode.
(See paragraph 2.6 for details on unloading system operating).
If the compressor continues to run unloaded (8) without interruption for 150 seconds, the regulator will stop the
motor (9). The regulator will restart the compressor when net pressure is below the pressure set point
Pressure (1)
Direct stop
Level (2)
Indirect stop
Level (10)
Setpoint (3)
Motor speed (4)
Minimum (5)
LOAD (7) UNLOAD (8) STOP (9)
0 150 Time (6)

sec
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If net pressure (1) falls below the set point (3) during this 150 second period, the compressor will switch to
load mode (7) and motor speed will increase to adjust air flow to air consumption.
Pressure (1)
Direct stop
Level (2)
Indirect stop
Level (10)
Setpoint (3)
Motor speed (4)
Minimum (5)
LOAD
LOAD (7) UNLOAD (8)
(7)
0 150 Time (6)
sec
Ref. Name
(1) Pressure
(2) Direct stop level
(3) Set point
(4) Motor speed
(5) Minimum motor speed
(6) Time
(7) Load
(8) Unload
(9) Stop
(10) Indirect stop level
Direct stopping
If net pressure (1) reaches a value equal to the sum of the programmed pressure set point (3) and the
programmed direct stop level (2), the compressor unloads and stops.
The regulator will restart the compressor when net pressure is below the pressure set point (3).
b. Protecting the compressor

Shutdown and motor overload
Several temperature and pressure sensors are fitted on the compression unit. If one of these
measurements exceeds the programmed shut-down level, the compression unit will be stopped. This will
be indicated on the control display. (See.3.2.fig.2.1).
The compressor will also be stopped in case of overload of the drive motor or fan motors.
Consult the section Preventive maintenance schedule and remedy the trouble. See also section
Protections menu.
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Shutdown warning
If the regulator detects a temperature or pressure exceeding the programmed

shutdown warning level, a message will be displayed on the control panel to inform
the operator before the shutdown level is reached.
The message disappears as soon as the warning condition disappears.
c. Monitoring components - Service warning
A number of service operations are combined into groups of contracts (known as

Service contracts A, B, C…). Each service contract has a programmed interval. If
this interval is exceeded, the operator is informed by a message displayed on the
screen and may carry out service action included in this contract.
The regulator continuously monitors critical components. Each input is compared to programmed limits.
Exceeding these limits causes a message on the control display to warn the operator either to replace the
component indicated. See the section Preventive maintenance schedule.
d. Automatic restart after voltage failure

The regulator has a built-in function to automatically restart the compressor when the voltage is restored
after voltage failure. This function is deactivated in compressors leaving in the factory. If desired, the
function can be activated. Consult Atlas Copco.
If activated and provided the module was in automatic operation, the compressor will automatically restart if
the supply voltage to the module is restored within a programmed time period (called power recovery time).
Start-up authorisation
Following a start-up order (either automatically via the Elektronikon regulator or via manual start-up), start-up
conditions are checked. If the programmed start-up conditions are not satisfied within a programmed interval,
the compressor will not start ("Start-check error" will appear on the screen).
Start-up orders during programmed stopping time and minimum stopping time
 Programmed stopping time
If the stop button is activated (see 3.2 fig 2.1), the compressor will switch to unload mode for the
programmed period. The compressor will then stop. All start-up orders will be ignored during this period.
 Minimum stopping time
Following a stop, the Elektronikon regulator will prevent any motor start-up during a programmed delay.
During this period, a start-up order will be memorised and executed following expiry of the programmed
delay.
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4.2 Control panel (Fig. 2.1)
Elektronikon regulator
Control panel
Parts and functions
Reference Designation Function
Shows the compressor operating condition and a number of

1 Display
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) lits, indicating that the
Elektronikon controller is operational
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4.3 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.
Expansion Module IO2 for Elektronikon Mk5 GraphicPlus
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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K04 3 x 30 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
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4.4 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.
Compressor status Motor Stopped
Local start / stop
Machine control mode

Remote start / stop
Network control
Automatic restart after

Automatic restart after voltage failure is enabled
voltage failure
Week timer Week timer is active
Emergency stop
Active protections
Shutdown
functions
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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Menus icons
Icon Description
Service
Alarms (warnings, shutdowns)
Week timer
Info
Test
Counters
Regulations setpoints
Inputs
Outputs
Event history (saved data)
Settings
Booster 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
ZD setup
Booster timing setup
Depressurization
Drains
Oil heater
Vent circulation
Water cooling pump
Suction depressurization
Navigation icons
Icon Description
Up
Down
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4.5 Main Screen
Control panel
Control Panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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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)
Two and four value views
Typical Main screen of compressor without aftercooler (Four value lines)
Typical Main screen (Two value lines)
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Typical Main screen (Four value lines)

Text on Figures
(1) Compressor outlet
(2) Flow in %
Loaded hours
(3) Text varies upon the compressor’s actual condition
(4) Menu
(5) Running hours
(6) Element outlet
(7) Load
 Section A displays information regarding the compressor operation (e.g. outlet pressure (1),
temperature at compressor outlet (2). On variable speed drive compressors, the load degree (air
flow) is also given as % of the maximum flow / compressor stage speed.
 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).
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 Control mode icons

These icons are always shown in the main screen. If the icon is selected and the Enter key
is pushed, the screen jumps to the control mode menu. Following control modes are
available:
Local Control
Remote control
Network control
 Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer,
automatic restart after failure, etc.)
 Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdown, 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
chart dot represents a 1 minute average value.
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When the Chart (Low Resolution) display is selected, a chart with an X-axis covering 10 days is
chart dot represents 1 hour average value.
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4.6 Calling up menus
Control panel
Control Panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Description
When the voltage is switched on, the main screen is shown automatically (see section Main screen):
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 To go the Menu screen, highlight the Menu button (4), using the Scroll keys.
 Press the Enter key to select the menu. Following screen appears :
 The screen shows a number of icons. Each icon indicates a menu item. The status bar shows the
name of the menu that corresponds with the selected icon.
 Use the Scroll keys to select an icon.
 Press the Enter key to activate the menu or press the Escape key to return to the Main screen.
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4.7 Service menu
Control panel
Control Panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Service
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:
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 Use the Scroll keys to move the cursor to the Service icon.
 Push the Enter key and following screen appears:
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.
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Overview
Text on figure
(1) Overview
(2) Running Hours
(3) Real Time Hours
(4) Reset
Running hours are the clocked times during which the compressor stage motor has been running. Real
Time Hours are programmable timers which keep counting even when the compressor isn’t running. E.g.
when a customer would like to change a part yearly or every 4000 running hours, service level A can be
put on Running Hours 4000 hours and Real Time Hours 8800 (8760 hours = 1 year). A service warning
will be displayed after one year or sooner (after 4000 running hours) if the compressor has been running
a lot.
The figures at the left of the progress bars are the programmed service interval Running or Real Time
Hours. Those at the right count down and show the number of hours that need to be covered to reach the
next service intervention.
Colored letters indicate the next upcoming service level.
Service plans
A number of service operations are grouped (called Level A, Level B, etc…). Each level represents a
number of service actions to be carried out at the time intervals programmed in the Elektronikon
controller.
When a service plan interval is reached, a message will be displayed.
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:
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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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4.8 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 press the Enter key. Following screen appears:
 Using the scroll keys (1), move the cursor to the protections icon.
 Press the enter key (2). Following screen appears:
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A number of icons is shown, allowing to display and reset following protections:

 General:
 Compressor outlet pressure
 Ambient air temperature
 Emergency stop status
 Dynamic pressure limit control
Typical example of a general alarm screen
Text on figure
(1) General
(3) Level high
(4) Shutdown warning
(5) Shutdown
(6) Reset
(7) Modify
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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
 Elements:
 Element outlet temperature
 Fan
 Overload fan motor status
 Converter(s)
 Main motor converter alarm
 Filters
 DP air filter
 Oil circuit
 Oil pressure
 Oil temperature
Depending on the installed optional equipment a number of extra icons and/or extra
relevant underlying menus are displayed.
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4.9 Week timer menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Service
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 opens. 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 start-up 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 start-up 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 Modifying 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
(9) Sunday
Push the Escape key on the controller to leave this screen.
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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
(6) Week 3
(8) Off
(9) Modify
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Press 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

(3) Week Cycle
(4) Status
(5) Week Timer Inactive
(7) Off
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 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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4.10 Info menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Info
Function
To Show the Atlas Copco internet address.
Procedure
Starting from the Main screen (see Main screen).
 Move the cursor to the Menu action button and push the Enter key. Following screen appears:
 Scroll the cursor to the Info icon (see above, section Menu icon)
 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
 License ESi
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4.11 Test menu
Control panel
Menu icon, Test
Function
 To perform output test and a drain test. Both actions can only be performed by authorized
personnel and are protected by a security code.
Depending on the installed optional equipment following items appear
 Output test: only a factory test.
 Drain Test
All mentioned actions can only be performed by authorized personnel and are protected by a
security code.
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4.12 Counters
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Counters
Function
To display:
 The running hours
 The loaded hours (air delivery)
 The number of motor starts
 The number of load cycles
 Information regarding the average motor speed
 Dryer starts (if dryer is installed)
 The accumulated volume
 The number of hours that the controller has been powered (module hours)
Procedure
Text on figure
(1) Menu
(2) Regulation
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 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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4.13 Modifying the setpoint
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Setpoint
Function
In this menu, two different setpoints can be programmed. This menu is also used to select the active
setpoint.
Procedure
 The setpoint menu can be called-up in two different ways:
 either highlight the Menu action key using the Scroll keys and press the Enter key. Following
screen appears:
Text on figure
(1) Menu
(2) Regulation
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Activate the setpoint menu by pressing the enter key.

 or select the shortcut icon (Running loaded or motor stopped) and press the enter button,
see section Main screen.
 A screen similar to the one below appears:
Text on figure
(1) Regulation
(2) Setpoint 1
(3) Indirect stop level 1
(4) Direct stop level 1
(5) Setpoint 2
(6) Modify
 The screen shows the actual settings

To modify the settings, move the cursor to the action button Modify and press the Enter key.
Following screen appears:
 Setpoint 1 is highlighted. Use the Scroll keys (3) to highlight the setting to be modified and press
the Enter key (1). Following screen appears:
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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 press the Enter key to accept.
If necessary, change the other settings as required in the same way as described above.
Indirect stop: occurs when the pressure rises to the pre-set Indirect stop setpoint (=setpoint plus Indirect
stop level). The motor will decelerate to minimum speed and the compressor will switch to unloaded
condition.
Direct stop: occurs when the compressor runs at a speed between minimum and maximum and the net
pressure rises above the direct stop setpoint (=setpoint plus Direct stop level).
Both settings (Indirect stop level and Direct stop level) are programmable, see section Programmable
settings.
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4.14 Inputs menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Inputs
Function
To display the current values and the status of a number of digital and analogue inputs.
Procedure
Text on figure
(1) Menu
(2) Regulation
 Using the Scroll keys, move the cursor to the Inputs icon (see above, section Menu icon)
 Press the Enter key and the screen below appears:
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Depending on the installed optional equipment less or more icons may appear.
Text on figure
(1) Inputs
(2) Cooler
 The inputs are categorized under a number of representative icons. Push the Enter key to show
the actual inputs.
 If an input reaches a warning or shutdown level, the original icon is replaced by the warning or
shutdown icon, respectively.
Setting an input as main chart (see section Main screen)

 Navigate to the input screen as described above.
 Push the Enter key; the first input on the screen will be highlighted in grey.
 Using the arrow keys, scroll to the input to be set as main chart.
 Push the Enter key; following screen appears:
Text on figure
(1) Inputs
(2) Main chart signal
(3) Set as main chart signal
(4) Modify
 Push the Enter key; the active input is now set as main chart.
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Changing the main chart input

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

(2) Are you sure to change the main chart signal? All current chart data will be lost!
(3) Yes
(4) No
 Select the Yes key to confirm or the No key to cancel the modification operation.
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Removing the main chart input

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

(2) Remove from main chart

(2) Are you sure to change the main chart signal? All current chart data will be lost!
(3) Yes
(4) No
 Select the Yes key to confirm or the No key to cancel the modification.
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4.15 Outputs menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Outputs
Function
To display information regarding the current status of the digital outputs.
Procedure
Text on figure
(1) Menu
(2) Regulation
 Move the cursor to the Outputs icon (see above, section Menu icon), using the Scroll keys.
 Press the Enter key.
 The outputs are categorized under a number of representative icons. Push the Enter key to show
the actual outputs.
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 The screen displays the status of following contacts under the general output icon:
 Running
 Fan motor
 Load/Unload
 Automatic operation
 General warning
 General shutdown
 Run enable fan motor
General
 Load/Unload
 Automatic operation
 General warning
 General shutdown
Drain(s)
 Condensate drain IC
 Condensate drain AC
Main Motor
 Line contactor
 Start contactor
 Delta contactor
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4.16 Event history menu
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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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
 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.
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4.17 Modifying settings
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
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Menu icon, Settings
Function
To display and modify a number of settings (e.g. Time, Date, format, Language, units…).
Procedure
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 Using the Scroll keys, move the cursor to the Settings icon (see above, section Menu icon).
 Push the Enter key. Following screen appears:
 The screen displays following icons:
Icon Function
Network settings
Regulation settings
General settings
Automatic restart after voltage failure settings
Access key
User password
Main chart
 Move the cursor to the icon of the function that needs to modified and push the Enter key.
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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. Following Screen appears.
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).
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Regulation settings
This menu allows to view and modify the regulation settings; see section Modifying the pressure band.
General settings
 Select the General settings icon as described above and push the Enter key (1). Following
screen appears:
Text on figure
(1) General
(2) Language in Use
(3) Time
(4) Date
(5) Date Format
 The screen displays the first 4 items of a list of all settings. Scroll through the list to display all
other items.
 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.
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Automatic restart
 Select the Automatic restart settings icon as described above and push the Enter key (2).
Following screen appears:
Text on figure
(1) Automatic restart
(2) Maximum Power Down Time
(3) Restart Delay
(4) Modify
 The screen displays 3 adjustable settings.

 Push the Enter key (1), scroll to the setting to be modified and push the Enter key once again.
 A screen appears. the required parameter is adjustable and confirmed by pushing the Enter key
once more.
Access key
A number of security levels are set in the controller (e.g. user, service technician, etc). The Access key
menu item is used to change the security level.
 Scroll to the correct icon using the scroll key and push the Enter key.
 Push the Enter key twice to modify the security level code and push the 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 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.
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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 follow:
 Select the Main chart settings icon as described above and push the Enter button (1). Following
screen appears:
Text on figure
(1) Main chart
(3) Chart range
(4) Minimum
(5) Maximum
(6) Chart band
(7) Low
(8) High
(9) Off
The screen shows the main chart signal, the current chart range and band settings. To modify these
settings, proceed as follows:
Push the Enter key, select chart range or chart band as desired and confirm.
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Modifying the chart range

Select the chart range as described above and proceed as follows:
 Push the Enter key; the minimum setting becomes highlighted. Push the Enter key to modify the
minimum setting or use the arrow down key to modify the maximum setting.
 Push the Enter key to confirm the modification.
Modifying the chart band

Select the chart band as described above and proceed as follows:
 Push the Enter key; the low band setting becomes highlighted. Push the Enter key to modify the
on/off setting or use the arrow down key to modify the low setting.
 Push the Enter key to confirm the modification.
 Proceed to modify the high band setting.
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4.18 Programmable settings
Compressor/motor
Minimum Factory Maximum

setting setting setting
Setpoint 1/2 bar 25 38 / 40 42

Indirect stop level bar - - 42.6
Direct stop level bar 0.1 0.6 1.9
Proportional band % 0.5 10.0 50.0
Integration time sec 0.5 25.0 50.0
Minimum motor speed (DX85VSD) rpm 600 600 1500
Minimum motor speed (DX110VSD) rpm 525 525 1500
Minimum motor speed (DN160VSD) rpm 700 700 1500
Minimum motor speed (≥DN250VSD) rpm 600 600 1500
Maximum rpm reduction % 75 100 100
Start Check Timer sec 5 10 20
Nota : Delta pressure between Direct Stop and Indirect Stop must be 1 bar Minimum.
Parameters

Minimum stop time sec 10 20 255

Communication time-out sec 10 20 40
Restart delay sec 0 3 255
Unload to stop time sec 22 150 200
Manual / Remote stop delay sec - 20 -
Unload to load time sec 9 15 16
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Booster parameters

ZR Pre-running period (1) sec 1 2 255

ZR Communication Timeout (1) sec 2 5 20
ZR Start Timeout (1) sec 5 30 255
ZR Stop Timeout (1) sec 7 15 210
ZR Load Timeout (1) sec 4 8 11
ZR Unload Timeout (1) sec 3 7 12
Booster Load delay (DX) (2) ms 0 400 3000
Booster Load delay (DN) (2) ms 1 1 3000
Booster Unload delay (DX) (2) / (DN) (2) ms 1 1500 3000
Depressurize level low bar 20 20 30
Depressurize level high bar 20 23 30
Suction depressurization level low bar 6 9.5 11
Suction depressurization level high bar 6 10 11
Oil heater control low (3) °C 8 8 10
Oil heater control high (3) °C 8 10 10
Protections

Compressor outlet (warning level) bar 41 43 43.9

Compressor outlet (shut-down level) bar 43.1 44 44
Delay at signal compressor outlet sec 0 2 5
Oil pressure (warning level) bar 1.1 1.4 5
Oil pressure (shut-down level) bar 1 1 5
Delay at start oil pressure sec 6 15 20
Delay at signal oil pressure sec 0 3 5
High suction pressure (warning level) (4) bar 7.5 7.5 8
High suction pressure (warning level) (4) bar 8.6 8.6 10
High suction pressure (warning level) (4) bar 10 10 11
High suction pressure (shut-down level) bar 7.5 7.7 8
High suction pressure (shut-down level) bar 8.6 9.2 10
High suction pressure (shut-down level) bar 10 10.5 11
Delay at signal high suction pressure sec 0 60 60
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Low suction pressure (warning level) (5) bar 4 4 10
Delay at signal low suction pressure sec 0 2 5
Element 2 inlet (warning level) bar 10 14 17
Delay at start element 2 inlet sec 60 900 1800
Delay at signal element 2 inlet sec 0 2 5
Element 1 Outlet (warning level) °C 100 160 160
Element 1 Outlet (shut-down level) °C 100 170 170
Delay at signal element 1 outlet sec 0 2 5
Element 2 Outlet (warning level) °C 100 165 170
Element 2 Outlet (shut-down level) °C 100 170 170
Delay at signal element 2 outlet sec 0 2 5
High element 1 inlet temp. (warning level) (6) °C 100 130 140
Delay at signal high element 1 inlet temperature sec 0 2 5
Element 1 inlet (warning level) °C 100 130 140
Element 1 inlet (shut-down level) °C 100 140 140
Element 2 inlet (warning level) °C 50 70 75
Element 2 inlet (shut-down level) °C 50 75 75
Compressor outlet (warning level) °C 20 50 65
Compressor outlet (shut-down level) °C 20 55 65
Delay at signal compressor outlet sec 0 2 5
Cooling water in (warning level) (7) °C 20 47 52
Cooling water in (warning level) (1) °C 20 40 45
Cooling water in (shut-down level) (7) °C 20 52 52
Cooling water in (shut-down level) (1) °C 20 45 45
Delay at signal cooling water in sec 0 2 5
Cooling water out (warning level) °C 30 60 65
Cooling water out (shut-down level) °C 30 65 65
Delay at signal cooling water out sec 0 2 5
Oil temperature (warning level) °C 40 70 90
Oil temperature (shut-down level) °C 40 80 90
Delay at signal oil temperature sec 0 2 5
Oil temperature (warning level) (3) °C 4 8 9
Oil temperature (warning level) °C 5 5 10
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Delay at signal oil temperature sec 0 2 5

Start check oil temperature (3) °C 4 7 7
Start check oil temperature °C 0 0 5
Booster dewpoint security (warning level) (8) °C 5 10 15
Booster dewpoint security (shut-down level) (8) °C 5 5 15
Delay at start booster dewpoint security sec 0 300 1800
Delay at signal booster dewpoint security sec 0 5 180
Cooler 1 approach (warning level) °C 11 15 20
Cooler 1 approach (shut-down level) °C 11 20 20
Delay at start cooler 1 approach sec 0 120 120
Delay at signal cooler 1 approach sec 0 2 5
Pressure dewpoint (warning level) (9) °C 0 5 10
Delay at start pressure dewpoint sec 0 1800 3600
Delay at signal pressure dewpoint sec 0 2 5
Rod drop element 1 *
Rod drop element 2 *
(1) Only for ZD and ZDXtend

(2) Only for ZD
(3) Only for oil heater option. As soon as power is turned on, booster standstill, oil heater is operating (oil temperature
is maintained between 8 and 10°C). As long as booster is running, oil heater is off
(4) High suction pressure warning force unloading on ZR when ZD or ZDXtend are activated
(5) Low suction pressure. When the alarm limit is reached the booster is programmed to unload
(6) Element 1 inlet temperature. When the alarm limit is reached and the booster is unloaded, the booster is
automatically stopped (stand-by). The booster start order is then initiated if temperature is lower than alarm limit
and outlet pressure decreases.
(7) Only for standalone
(8) This security is the difference (directly calculated by elektronikon) between temperature and dewpoint under
pressure at element 2 inlet
(9) Dewpoint under pressure at element 2 outlet (40bar). (option)
* Factory setting. Contact Atlas Copco for more information.
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Monitoring option

Packing element 1 (warning level) l/s 4 15 17

Delay at start packing element 1 sec 600 1800 2700
Delay at signal packing element 1 sec 2 10 15
Packing element 2 (warning level) l/s 4 15 17
Delay at start packing element 2 sec 600 1800 2700
Delay at signal packing element 2 sec 2 10 15
DT inlet valves element 1 high (warning level) °C 5 10 25
Delay at start DT inlet valves element 1 high sec 0 300 600
Delay at signal DT inlet valves element 1 high sec 0 2 5
DT inlet valves element 1 low (warning level) °C -25 -10 -5
Delay at start DT inlet valves element 1 low sec 0 300 600
Delay at signal DT inlet valves element 1 low sec 0 2 5
DT outlet valves element 1 high (warning level) °C 5 10 25
Delay at start DT outlet valves element 1 high sec 0 300 600
Delay at signal DT outlet valves element 1 high sec 0 2 5
DT outlet valves element 1 low (warning level) °C -25 -10 -5
Delay at start DT outlet valves element 1 low sec 0 300 600
Delay at signal DT outlet valves element 1 low sec 0 2 5
DT inlet valves element 2 high (warning level) °C 5 10 25
Delay at start DT inlet valves element 2 high sec 0 300 600
Delay at signal DT inlet valves element 2 high sec 0 2 5
DT inlet valves element 2 low (warning level) °C -25 -10 -5
Delay at start DT inlet valves element 2 low sec 0 300 600
Delay at signal DT inlet valves element 2 low sec 0 2 5
DT outlet valves element 2 high (warning level) °C 5 10 25
Delay at start DT outlet valves element 2 high sec 0 300 600
Delay at signal DT outlet valves element 2 high sec 0 2 5
DT outlet valves element 2 low (warning level) °C -25 -10 -5
Delay at start DT outlet valves element 2 low sec 0 300 600
Delay at signal DT outlet valves element 2 low sec 0 2 5
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Service plan

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
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 Centre.
Terminology
Term Explanation
Shutdown warning The regulator does not accept illogical limits, e.g. if the warning level is
and Shutdown level programmed at 205°C/401°F, the minimum limit for shutdown level is
206°C/403°F. The recommended difference between the warning level
and the shutdown level is 10°C/50°F.
Minimum stop time Following automatic stopping of the compressor, stopping will continue
for the minimum stop time (approx 20 seconds) independently of the net
air pressure condition. In automatic mode, the compressor is stopped by
the regulator only if a total stop period equal to at least the minimum stop
time plus the required stopping period is programmed. However, if a drop
in net air pressure requires a compressor re-start, the regulator will
restart the compressor after the minimum stop time.
Power recovery Period during which the voltage must be re-established to obtain an
time automatic re-start. Available with the automatic re-start function. To
activate this function, consult Atlas Copco.
Loading/unloading The regulator will not accept illogical settings. E.g., if the unloading
pressure pressure is programmed at 7.0 bars/102 psig, the maximum unloading
pressure limit goes to 6.9 bars//100 psig. The minimum recommended
difference between loading pressure and unloading pressure is 0.6 bars /
9 psig.
Default at shutdown Period during which the delay at shutdown signal must exist prior to
signal Shutdown of the compressor. Consult Atlas Copco if this setting must be
programmed to another value.
Delay time Period after start-up during which the alarm signal is ignored (oil
pressure).
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4.19 Web server
All Elektronikon controllers have a built-in web server that allows direct connection to the company
network or to a dedicated PC via a local area network (LAN). This allows to consult certain data and
settings via a PC instead of via the display of the controller.
Getting started
Make sure you logged in as administrator.
 Use the internal network card from your computer or a USB to LAN adapter (see picture below).
USB to LAN adapter
 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 My Network places (1).
 Click on View Network connections (1).
 Select the Local Area connection (1), which is connected to the controller.
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 Click with the right button and select properties (1).
 Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck other
properties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change
settings.
 Use the following settings:

 IP Address 192.168.100.200
 Subnetmask 255.255.255.0
Click OK and close network connections.
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Configuration of the web server

Configure the web interface
The internal web server is designed and tested for Microsoft® Internet Explorer 6, 7
and 8. Other web browsers like Opera and Firefox do not support this internet web
server.
When using Opera or Firefox, a redirect page opens. Click on the hyperlink to
connect to the download server from Microsoft® to download the latest version of
Internet Explorer, and install this software.
 When using Internet Explorer:

Open Internet Explorer and click on Tools – Internet options (2).
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 Click on the Connections tab (1) and then click on the LAN settings button (2).
 In the Proxy server Group box, click on the Advanced button (1).
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 In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can
be given but they must be separated with semicolons (;).
Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2).
Now you add 192.168.100 and separate the 3 IP addresses by putting semicolons between them
(1) (see picture). Click OK (2) to close the window.
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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:
Navigation and options

 The banner shows the compressor type and the language selector. In this example, three
languages are available on the controller.
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 On the left side of the interface you can find the navigation menu (see picture below).
If a license for ESi is foreseen, the menu contains 3 buttons.
 Compressor (or machine): shows all compressor settings.
 ES: shows the ESi status (if a licence is provided).
 Preferences: allows to change temperature and pressure units.
Compressor settings
All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest
and it will be displayed. Only the machine status is fixed and can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference button
from the navigation menu.
Counters
Lists all current counter values from controller and compressor.
Info status
Machine status is always shown on the web interface.
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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 compressor.
Service plan
Displays all levels of 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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ES screen controller
If an ESi license is provided, the ES button is displayed in the navigation menu. At the left all
compressors in the ES are shown. At the right the ES status is shown.
A possible ESi screen
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4.20 ZR Settings (for ZD)
Before initial start-up of ZD, following ZR factory settings shall be modified (in ZR Elektronikon) to enable ZR
to run in ZD configuration.
ZR Settings
Regulation pressure set point Bar eff 9.5

Indirect stop level Bar eff 0.5
Direct stop level Bar eff 1.5
Proportional band % 25
Integration time Sec 10
And
Follow booster must be switched on (in full access)

Menu / Settings / Remote Control / Follow booster
Change “High Speed Unload” on ZR from “Allowed from minimum speed only” to “Allowed at any
speed”
With Modi5 in expert mode: General Setting / Converters / Motor Speed Setup / High Speed
Unload.
(See Installation procedure)
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5 Installation
5.1 Drawing with measures
See general arrangement drawing attached at the end of this instruction book.
5.2 Installation proposal
See installation proposal drawing attached at this instruction book.
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5.3 D Booster use in a ZDXtend
A ZDXtend includes:
 a screw compressor (ZR)
 a dryer (MD)
 a LTA air receiver
 a booster( D).
The low pressure air receiver (LTA receiver) can be fitted with following additional equipment:
a. An additional low pressure air outlet (with suitable LP control valve) for extra air requirements for
instrument air or for labelling and packaging machines. (option)
In that case, capacity of the ZR compressor is generally higher than such of the D Booster.
LP air outlet with LP control valve
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D Booster protection with LP control valve:
1. The LP Control Valve is only intended to prevent D booster stopping in case low pressure
additional consumption becomes too high.
When air pressure is too low inside LTA receiver, the LP Control Valve closes, stopping that
way additional low pressure air consumption, so that air pressure at D booster inlet is always
maintained to an acceptable level.
Recommended LP Control Valve pressure setting: 0.5 bar below ZR loading pressure to
assure maximum air flow at D booster outlet (see § 5.3, ZR settings).
2. LP Control Valve
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3. LP Control Valve installation

- no elbow (only straight pipe lines) shall be connected directly or close to the LP
Control Valve (upstream or downstream),
- check that the LP Control Valve mounting sense is correct (see arrow on it),
- LP Control Valve shall be mounted with inlet / outlet flanges in horizontal direction
and membrane below piping axis (adjusting wheel towards the ground).
4. LP Control Valve setting

- LP Control Valve is factory preset before dispatch at 8.5 bar. Final adjustment
shall be operated at first start-up of installation,
- LP Control Valve final setting (before ZD initial start-up) instruction :
- close the insulating valve (1) (at customer charge) located
downstream the LP Control Valve (2),
- start ZR and let it running till the LTA receiver (3) is under pressure
(at ZR loading pressure), then stop ZR,
- if ZR loading pressure is 9 bar (for example), recommended LP
Control Valve setting is 0.5 bar below (so at 8.5 bar),
- open small air vent (4) (at customer charge) located just between the
LP Control Valve (2) and the insulating valve (1),
- use LTA receiver pressure gauge (5) or compressor outlet pressure
displayed on ZR Elektronikon (for more accuracy) to monitor inlet
pressure of LP Control Valve (2) during adjustment,
- check that LP Control Valve (2) closes at 8.5 bar (air leakage through
air vent (4) shall stop at 8.5 bar),
- if not :
- close air vent (4),
- turn the adjusting wheel (6) clockwise to increase pressure
or counter clockwise to decrease pressure setting,
- start ZR and let it running till LTA receiver pressure
increases up to ZR loading pressure (9 bar in the
example), then stop ZR,
- and check again LP Control Valve closing pressure as
explained in small instruction here above,
- start again the procedure till adjustment is completed,
- small air vent (4) is only used for LP Control Valve setting and shall
always be closed during normal operation of installation.
5. Note : Insulating valve (1) and air vent (4) are at customer charge.
Pressure reducing valve and safety valve for additional low pressure circuit are at
customer charge (See Air System Flow Diagram § 2.4).
Eventually a by-pass (at customer charge) can be installed on LP Control Valve to
allow additional low pressure air consumption, at ZR full flow, when D booster is
stopped during minimum several days. In that case ZR, D booster and cooling system
shall be configured on “Local control” and “ZR LAN Link” in D booster Elektronikon is
deactivated (see § 6.2).
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b. A low pressure air re-injection (with suitable filter and non-return valve). (option)
That way compressed air coming from Air Recovery System (ARS) (available nowadays on more and more
several blow moulding machines) can be reinjected in LTA air receiver at D Booster inlet.
In this case, ZR compressor is used at a lower rate, enabling substantial energy savings.
LP air re-injection with filter

and no-return valve.
Note: LP control valve, pressure reducing valve and safety valve for re-injection circuit are at customer charge.
(See Air system flow diagram § 2.5).
Reinjected air shall be clean and dry:

 Minimum allowable air dew point at pressure 9 bar (g) = - 40°C
 Maximum allowable air dew point at pressure 9 bar (g) = - 15°C
5.4 Modification of ZR in case of ZDXtend installation
For ZR VSD compressors:
Please consult your Atlas Copco “Customer Service Pole” to carry out:
 ZR by-pass throttle valve modification

 Apply following ZR settings :
Unload at high speed Unload allowed

10 bar ZR VSD
Set point 9,5 bar(e)
8,6 bar ZR VSD

Set point 8 bar(e)
In case of air re-injection (see § 5.3.b), check ZR settings so that ZR set point is 0,5 bar below re-injected air
pressure.
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5.5 Dimensions of electric cables
Electric ground cables D VSD booster (50 m maximum)
 Local regulations must be applied if stricter than the values below

 The section is valid for multi-conductor core cables in 90°C copper.
A drop in voltage must not exceed 5% of nominal voltage. In compliance with the
former "the use of cables with larger dimensions than those recommended may be
necessary".
IEC Cables :
Multicore copper conductors, with 70°C insulation.
Installation method : on perforated tray.
Cables may not be grouped with other circuits or cables.
CSA/UL :
Multicore copper conductors, with 75°C insulation.
Installation method : on perforated tray.
Maximum 3 current-carrying conductors in raceway or cable.
Below are the dimensions of cables for compressors designed to operate at air temperatures of up to 40°C (for
HAT option _ of up to 50°C _ please contact Atlas Copco) and associated fuses according chapter 10.4.
2DX2-85VSD
Voltage 2DX2-85VSD at room temperature 40°C
(104°F)
400 V – 50 Hz 2 x (3x50+25) mm²
440 V – 60 Hz 2 x (3x50+25) mm²
460 V – 60 Hz 2 x (3xAWG1+AWG4)
2DX2-90VSD (only in HAT VERSION)
2DX2-110VSD
Voltage 2DX2-110VSD at room temperature 40°C
(104°F)
400 V – 50 Hz 2 x (3x70+35) mm²
440 V – 60 Hz 2 x (3x70+35) mm²
460 V – 60 Hz 2 x (3xAWG1/0+AWG4)
2DN2-145VSD (only in HAT VERSION)
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2DN2-160VSD
Voltage 2DN-160VSD at room temperature 40°C
(104°F)
400 V – 50 Hz 2 x (3x120+70) mm²
440 V – 60 Hz 2 x (3x120+70) mm²
460 V – 60 Hz 2 x (3xAWG4/0+AWG2/0)
2DN2-250VSD
Voltage 2DN2-250VSD at room temperature 40°C
(104°F)
400 V – 50 Hz 4 x (3x70+35) mm²
440 V – 60 Hz 4 x (3x70+35) mm²
460 V – 60 Hz 4 x (3xAWG2/0+AWG2)
2DN2-275VSD
(104°F)
400 V – 50 Hz 4 x (3x95+50) mm²
440 V – 60 Hz 4 x (3x70+35) mm²
460 V – 60 Hz 4 x (3xAWG2/0+AWG2)
2DN2-315VSD
(104°F)
400 V – 50 Hz 4 x (3x95+50) mm²
440 V – 60 Hz 4 x (3x95+50) mm²
460 V – 60 Hz 4 x (3xAWG3/0+AWG0)
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5.6 Electric connections
5.6.1 General instructions for the electrical installation of VSD compressors

 Electrical equipment of Atlas Copco compressors complies with the safety regulations of the following
standards: IEC60204-1 or CSA/UL according your order.
 The installation of the compressor in accordance with safety regulations in order to protect users in
direct or indirect contact with electric discharges is the responsibility of the customer.
 With drive systems with frequency converters, current leaks along EFI filters and cables, particularly at
motor start-up. Class A anti-leakage protection systems will stop the machine. The use of class A
systems is therefore recommended with frequency converters.
5.6.2 Installation instructions for TN, TT, and IT network systems

In each network system (TN, TT or IT), the customer must protect the installation against over current using
fuses or an automatic breaker.
Additional installation instructions for the energy distribution system are supplied.
Network type TN (TN-S, TN-C and TN-C-S)

No additional protection is required. If the customer installs a leakage detection system, this system must be of
type B and comply with IEC755 amendment 2 "General requirements for residual current-operated protective
devices". Atlas Copco recommends that its customers install the ground leakage detection device BENDER
RCMA 470LY integrating an external current transformer (consult the site at http://www.bender.org/prod.html)
Network type TT
With TT systems, most safety regulations recommend the use of an earth leakage circuit breaker (ELCB). In
addition to frequency converters, type B protective devices against residual current must be used. Atlas Copco
recommends that its customers install the ground leakage detection device BENDER RCMA 470LY integrating
an external current transformer (consult the site at http://www.bender.org/prod.html)
Network type IT
On IT network systems, power supply may not be cut in case of initial ground leakage during a motor phase.
However, the customer must detect the initial ground leakage. Leakage must be indicated by an alarm. If this is
not the case, initial ground leakage must automatically lead to a cut in power supply (EN 60204-1 §.: 6.3).
However, high frequency capacitive leakage current caused by frequency converters is not detected by
standard ground leakage detection systems. Atlas Copco recommends that its customers install the BENDER
IRDH 275/435 system (consult the site at http://www.bender.org/prod.html).
Atlas Copco strongly recommends that its customers not connect the neutral conductor to the power supply
and the compressor. Exposed conductors of the installation must be grounded at the same location. (EN
60204-1 §.7.2.3)
Energy distribution systems (TN, TT, IT)

According to IEC 60950, three main types of distribution exist: TN, TT and IT. Instructions on the electric
installation depend on the type of power supply network used by the customer.
Network type TN (Terra Neutral) :
The TN power distribution system provides direct grounding for exposed conductors in the installation.
Connection occurs via the PEN conductor. Three sub-types of the TN energy distribution system exist:
TN-S, TN-C and TN-C-S. Between 85 and 90% of industrial networks are of TN type.
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TN-S network type (Terra Neutral-Separate):

The TN-S energy distribution system includes neutral and direct ground conductors.
A Grounding of the energy system

B Exposed conductors
TN-C network type (Terra Neutral - Combined)

With the TN-C energy distribution system, neutral and protective ground functions are combined in one single
conductor.

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TN-C-S network type (Terra Neutral - Combined - Separate)

With the TN-C-S energy distribution system, neutral and protective ground functions are combined in one
single conductor to a certain extent. Exposed conductors in the installation are also grounded directly.
Connection occurs via the PEN conductor.

Network type TT (Terra Terra)

The TT energy distribution system is grounded at one single point. In addition, exposed conductors in the
installation are connected to an earth electrode acting independently of the energy system earth electrode.

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Network type IT (Impedance Terra)

The IT energy distribution system is not directly connected to Equipotential Protection (EP). It is grounded via a
high ohmic impedance, therefore the network acts as a floating network without grounding. Exposed
conductive sections of the installation are grounded directly. Power supply is not cut in case of initial ground
leakage during a motor phase. However, the customer must detect the initial ground leakage. Leakage must
be indicated by an alarm.

C Impedance
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Schema
Extract of 1901072894.00
Electric connections for 2DX-85 VSD booster
128 1901077772.02
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Extract of 1901072892.00
Electric connections for DX - DN≤250 VSD booster
1901077772.02 129
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Extract of 1901072893.00
Electric connections for DN≥250 VSD booster
Text for figures of « electric connections for D VSD booster »
Reference Text for figures Reference Text for figures

A1 RFI Filter Q20 Circuit breakers, fan motor power supply
A11 Frequency converter, compressor X1 Terminal
L1 Switch reactor 1X3/1x4 Earth strip
M1 Driving motor CPE Customer installation
Q1 Circuit breakers, control ciruit M20 Canopy fan motor
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Typical example of electrical installation (Booster and ZDXtend)

Noted: All cables supplied by others
Power distribution board:

Equipped with one main switch. Each component
(Booster, compressor, ancillaries) is protected by
fuses.
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Typical example of electrical installation (ZD)

Noted: All cables supplied by others
Power distribution board:

Equipped with one main switch. Each component
(Booster, compressor, ancillaries) is protected by
fuses.
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5.7 Cooling water quality requirements
Recommendations
To ensure that the compression unit can operate in optimal conditions, it is primordial to control the quality of
the cooling water used.
Water must be free of solid impurities and the anti-scaling and anti-corrosion properties of the water circuit
must be ensured.
The following paragraphs give details of the cooling water conditions required to avoid numerous problems
during the operation of the compression unit.
Refer to paragraph 10.5 for water temperature and pressure recommendations.
Refer to paragraph 10.6 for the water flow required for the compression unit.
System type
To begin with, it is important to check that the system is closed. In a closed system, the same cooling water
circulates in a circuit without contact with the air.
NB: Refer to the cooling unit notice (tower or central) for recommendations on water treatment and circuit
maintenance for the good operating order of the unit. According to the country, it may be necessary to
request operating authorisation for the cooling tower from the competent authorities.
Ryznar Stability Index (RSI)
The Ryznar Stability Index (RSI) is a parameter which determines if the water will dissolve or precipitate
calcium carbonates. The adhesion of scale and their effects vary according to the material, but the water
balance (presence of scale or corrosion) can only be determined by current pH value and saturation pH value
(pHs).
The saturation pH value is determined by the relativity of the hardness of calcium, total alkalinity, the total
concentration of solid particles and temperature.
The Ryznar index is calculated as follows:

RSI = (2 * pHs) - pH
Symbol Explanation
pH water sample pH (measured at unit temperature)
pHs pH at saturation
PHs is calculated using the following formula:

pHs = (9.3 +A + B) - (C + D)
Symbol Explanation
A Depends on the total concentration of dissolved solids (mg/l)
B Depends on the highest temperature of cooling water (°C), (T=65°C)
C Depends on the hardness of calcium (ppm CaCO3)
D Depends on the concentration of HCO3 - or the alkalinity M (mval/l)
1901077772.02 133
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Values of A, B, C and D are shown below
Total dissolved Ca hardness Alkalinity M

A Temperature B C D
solids (ppm CaCO3) (mval/1)
(mg/l) (°C)
50 - 300 0,1 0-1 2,6 10-11 0,6 0,20 - 0,22 1,0
400 - 1 000 0,2 2-6 2,5 12-13 0,7 0,24 - 0,26 1,1
7-9 2,4 14-17 0,8 0,28 - 0,34 1,2
10-13 2,3 18 - 22 0,9 0,36 - 0,44 1,3
14-17 2,2 23 - 27 1,0 0,46 - 0,54 1,4
18-21 2,1 28 - 34 1,1 0,56 - 0,70 1,5
22 - 27 2,0 35 - 43 1,2 0,72 - 0,88 1,6
28 - 31 1,9 44 - 55 1,3 0,90 - 1,10 1,7
32 - 37 1,8 56 - 69 1,4 1,12 - 1,38 1,8
38 - 44 1,7 70 - 87 1,5 1,40 - 1,76 1,9
45 - 50 1,6 88 - 110 1,6 1,78 - 2,20 2,0
51 - 56 1,5 111 - 138 1,7 2,22 - 2,78 2,1
57 - 63 1,4 138 - 174 1,8 2,80 - 3,54 2,2
64 - 71 1,3 175 - 220 1,9 3,54 - 4,40 2,3
72 - 80 1,2 230 - 270 2,0 4,6 - 5,4 2,4
280 - 340 2,1 5,6 - 7,0 2,5
350 - 430 2,2 7,2 - 8,8 2,6
440 - 550 2,3 9,0-11,0 2,7
560 - 690 2,4 11,2 - 13,8 2,8
700 - 870 2,5 14,0 -17,6 2,9
880 - 1000 2,6 17,8 - 20,0 3,0
Interpretation of the value obtained
RSI Water condition Action

RSI < 3.9 Very high level of scale The water must not be used.
4.0<RSI<5.5 High level of scale Regular inspection and scale-removal required.
5.6<RSI<6.2 Low level of scale Water treatment not required.
Occasional inspection recommended.
Water treatment not required.
6.3<RSI<6.8 Neutral water
Occasional inspection recommended.
Low corrosion at a higher Water treatment not required.
6.9<RSI<7.5
temperature Occasional inspection recommended.
Substantial corrosion Regular inspection required. Use of a corrosion
7.6<RSI<9.0
inhibitor recommended.
Regular inspection required. Use of a corrosion
9.1<RSI<11 Very substantial corrosion
inhibitor required.
Very substantial corrosion in the The water must not be used
RSI>11
entire water system
The table indicates that distilled or demineralised water must never be used, as RSI is > 11.
The RSI only indicates scale/removal of scale balance. Cooling water with acceptable RSI factors may be
unusable for other reasons.
According to the following data, the RSI must be between 5.6 and 7.5. If this is not the case, contact a
specialist.
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pH
pH is included in the calculation of the Ryznar index.
Cooling water pH must also imperatively be between 6.8 and 8.5.
Total dissolved solids (TDS)

This refers to the total amount of ions in the water. This calculation is based on dry residue following
evaporation (not including suspended solids) or electric conductivity.
In a closed system, the following limits apply: TDS < 3000 mg/l ( <3800 S/cm).
Chlorides (CI ¯)
Chloride ions will lead to pitting corrosion on stainless steel. Concentration must be limited:
Closed cooling system: chlorides < 500 ppm.
With scale in water, lower limits must be satisfied. (See Ryznar Stability Index (RSI)).
Free chlorine (CI2 )

A level of 0.5 ppm must not be continuously exceeded.
For high impact treatment, a maximum of 2 ppm and 30minutes/day maximum applies.
Sulphates (S04-- )
Closed cooling system: sulphates < 400ppm.
Hardness of carbonates
Closed cooling system: 50-1000ppm CaC03
HC03 - / S04 2- must be > 1
Ammoniac
<0,5 ppm
Copper
< 1 ppm
Iron and manganese

< 1 ppm
Organic components
No alga
No oil
Suspended solids
Non-soluble particles, dimension < 1 mm.
Concentration < 10 ppm
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5.8 Coolant
5.8.1 General
The type of coolant to use is LTC 131. This antifreeze coolant, of food grade, anti-corrosive and environment-
friendly, is especially designed for cooling of PET compressors. It can be mixed in any proportion with water.
Supplied as a concentrate, it will be mixed with drinking water according to the degree of antifreeze protection
desired (freezing point), depending on the minimum temperature of the place of installation.
Important notes: Before first filling, rinse the circuit with water, then drain.
Every two years, empty water circuit and fill again with new mixture water + coolant.
This antifreeze agent has the properties of an excellent cooling fluid coupled with environment
friendly qualities:
- Protection of metals. - High boiling point.
- Good physicochemical stability. - Low point of freezing.
- Stability in presence of acid. - Durability.
- Good thermal conductibility. - No toxicity.
This antifreeze agent has been approved by the French Ministry for Social Affairs, General Directorate of
Health, under N° DGS/DPGE/iD N° 733 and 910.
5.8.2 Precautions for handling coolant LTC 131
The undiluted antifreeze liquid is not classified as ' inflammable' but can nevertheless burn. It reacts violently
with oxidants with risks of fire and explosion. Based on EC criteria, this product is not dangerous.
At high concentration or prolonged exposure, it can cause irritations of eyes and respiratory system.
When handling the product, provide adequate ventilation especially in closed places. Do not eat, drink or
smoke when using the product. In the event of insufficient ventilation, it is recommended to use an individual
breathing apparatus.
In all cases, wear PVA gloves, face protector and protection equipment.
In the event of inhalation:

- Bring the person outside and make it rest.
- If symptoms do not disappear, call a doctor.
In the event of contact with the skin:

- Take off any soiled or splashed clothing.
- Wash the body thoroughly with water.
In the event of contact with the eyes:

- Wash immediately and thoroughly with water, including under the eyelids, for at least 15 minutes.
- Consult an oculist.
In the event of ingestion:

- Wash the mouth.
- Consult a doctor.
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In the event of fire:

- Use suitable means of extinction:
Dry chemicals
Foam resisting to alcohols
Water jet
Carbon dioxide (CO2)
halon
- Cool the expansion tanks with water spraying.
- Use a breathing apparatus and a complete protective clothing.
- Collect the extinction contaminated water separately and eliminate in accordance with the local
regulations.
- The mixtures of air / vapour can be explosive.
In the event of accidental dispersion:

- Use individual protection equipment.
- Prevent infiltration in surface water and sewerage system.
- Recover the largest part of the product immediately and store it in adequate barrels, before thoroughly
diluting the remainder and eliminate though the sewer.
- When filling barrels with product, wear individual breathing equipment as the risk of fire and explosion
remains.
For handling and storage:

- Take normal precautions for flammable products and ensure adequate ventilation.
- Preserve in a dry and cool place.
- Prevent contact with the skin, the eyes and clothing and do not breathe spray mist.
- Maintain adequate ventilation at floor level and hold keep away from oxidants.
Packaging equipment:
- Stainless steel
- Polyethylene HD
- Glass
- Polypropylene.
5.8.3 Freezing point of aqueous mixtures with LTC 131

LTC 131 WEIGHT % 10 20 30 40 50 60
H2O % 90 80 70 60 50 40
FREEZING T° IN °C -3 -7 -12 -20 -32 -47
Table: 'Freezing Temperature of aqueous mixtures using LTC 131'
If the minimum temperature at the place of installation is for instance -22°C, we advise for safety reasons that
you use a mixture with freezing temperature higher than this freezing point. Therefore in this case use a
mixture made up of approximately 50 % of LTC 131 and 50 % of drinking water. It is desirable to adjust the
glycol proportion to local outside temperature conditions (summer - winter). Thus 10% glycol will make it
possible to operate all summer long (minimum temperature -3°C); while in the winter season 40% glycol will
allow operating down to -20°C. We recommend saving mixtures to have exact proportions at your disposal
for the coming new period. In no case should the glycol proportion be lower than 10% in order to preserve
coolant's corrosion inhibiting properties.
5.8.4 Boiling point of aqueous mixtures with LTC 131 under atmospheric pressure
LTC 131 WEIGHT % 100 80 50 40 30 20 10 0

H2O % 0 20 50 60 70 80 90 100
BOILING T° IN °C 150 120 110 107 105 103 101 100
Table: 'Boiling Temperature of aqueous mixtures of LTC 131'
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5.8.5 Density of aqueous solutions
Densimetry can be used to control contents of LTC 131, using the following table:
LTC 131 WEIGHT % 10 20 30 40 50 60 70 80 90 100

H2O % 90 80 70 60 50 40 30 20 10 0
DENSITY 1,008 1,017 1,026 1,035 1,042 1,047 1,050 1,051 1,050 1,048
Table: 'Density of aqueous solutions of LTC 131'
Caution, the relation between density level and percentage of glycol contents is not a linear function, since
the mixture shrinks for certain values of the proportions. Refractometry may also be used to measure water
and provides much more precise results.
5.8.6 Viscosity
A low temperature the viscosity of LTC 131 is higher but remains in acceptable value ranges without causing
too significant pressure losses.
5.8.7 Thermal conductivity
It is very close to the usual values of cooling agents.
5.8.8 Corrosion
Tested according to ASTM D 1384, the LTC 131 gives very good anti-corrosion results. It has no effect on
iron, aluminium, cast iron, copper, brass, and welds.
5.8.9 Physicochemical characteristics of 100% concentrated pure product
LTC 131 VALUES METHOD

COLOUR red
ASPECT clear
CORROSION INHIBITOR + H2O 6% +/-0.2 ASTM D1123
ASH CONTENT 1 ASTM D1119
DENSITY AT 20°C 1.048 ASTM D1122
FLASH POINT °C 107°C ASTM D92
BOILING POINT IN PURE STATE ** 150°C ASTM D1120
PH IN PURE STATE  8.5 ASTM D1287
RÉSERVE OF ALCALINITÉ RA  10 ASTM D78101
FOAMING
VOL ML 4 ASTM D1881
DISAPPEARANCE OF FOAM DRY 1
COMPATIBILITY WITH PURE WATER No cloud
Table: 'Physico-chemical characteristics of LTC 131'
**: See table for aqueous solution
ATTENTION: CHANGE THE COOLING FLUID (LTC131) EVERY 2 YEARS.
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5.9 General pictograms
or 22
16 17 18 19 20 21
Symbole Explanation
5 Warning : Under tension
6 Consult the instructions manual prior to start the compressor.
7 Switch off and decompress before maintenance operations or repairs
Before connecting the compressor to the power supply, consult the instructions
8
manual to identify the direction of rotation of the engine.
9 Torque for steel (Fe) or brass (CuZn) bolts
10 Consult the instructions manual prior to lubrication.
11 Turn off before removing the protective cover inside the electric cabinet.
12 Oil the gaskets, screw on the filters and tighten by hand (approx.one half turn)
13 Consult the instructions manual before maintenance operations or repairs.
14 Cooling water outlet
15 Cooling water inlet
16 Fluid ejection: avoid areas into which the booster ejects gas
17 Moving components
18 Hot components
19 Do not lift
20 Oil content and type in the booster
21 Oil cooler
22 Cooling fan rotation direction
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6 Instructions for use

6.1 Installation
Safety precautions
The user must apply all appropriate Safety precautions. See paragraph 1.
We particularly reiterate the following precautions:
1. Install the machine in a building in which the atmosphere is as fresh and clean as
possible. Install a fan ventilation duct if necessary. Never block the air inlet.
Reduce humidity in air admitted to a maximum. Building ventilation conditions
(See installation proposal in chapter 5).
2. Fixed flanges, plugs, caps and silicon sachets must be removed prior to
connecting piping.
3. The diameter and type of flexibles used to connect the machine to the air network
must be appropriate for operating pressure. Never use fritted, damaged or worn
flexible piping. Distribution pipes and connections must have the correct
dimensions for the operating pressure.
4. Electric connections must satisfy local regulations. Machines must have earth
cables and phases must be protected from short circuits via fuses. A lockable
disconnecting switch for the electric network must be installed near to the
compressor.
5. Never remove or handle safety, protection or isolation devices fixed on the
machine. Each pressurized or auxiliary tank installed outside of each machine and
which must contain air at higher than atmospheric pressure, must be protected by
adequate decompression devices.
Operating conditions
The compression unit is designed to operate indoors, with an air ambient temperature between + 0°C / 32°F
and + 40°C / 104°F and at an altitude of 1000 metres maximum.
With HAT option (high ambient temperature), compressor can operate indoors with air ambient temperature
from + 0°C / 32°F till + 50°C / 122°F.
Should the compressor require operating in other conditions, immediately consult the Atlas Copco Customer
Services pole.
Moving/lifting
To protect the concrete base, the compressor must be moved using a lift truck or lifting equipment, as shown
below.
Use concrete base openings to move the compressor with a lift truck. Forks must absolutely cross to the other
side of the concrete base. Insert the cross beams in the openings to move the compressor with lifting
equipment. Avoid all movement of cross beams. They must cross the concrete base at equal length. Chains
must be suspended parallel to the covers via the spreaders to protect the compressor. Place the lifting
equipment to ensure that the operation remains perpendicular. Lift the compressor slowly and avoid swinging.
If the machine must be lifted, the fork holes must be used (e.g.: using jacks directly under the lower surface of
the concrete slab is prohibited).
See compressor net mass in general arrangement drawing (at the end of this instruction book).
140 1901077772.02
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Handling procedure
Lifting with forks only
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Handling for D Boosters
ESTIMATED STEEL BAR SIZE
l h
D BOOSTER 250 100
ZR COMPRESSOR 250 80
142 1901077772.02
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Handling for D boosters
LIFTING TOOL x 4
DIRECT CONTACT
NOT ALLOWED
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Handling for D boosters
144 1901077772.02
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General preparation
See Installation procedure N° 1901077765 (supplied inside Electrical Cubicle).

 Ensure that the compression unit is correctly installed. See Drawing with measures, Installation
proposal and dimensions of electric cables (§ 5 of this instruction).
 This assembly must be free of all forces and free of all stress.
 Tighten all the screws according to the torques table (§ 7.6).
 Check connection by a tightness test.
Room ventilation
Compressor room ventilation (to limit compressor room temperature)
The inlet grid(s) and ventilation fan should be installed in such a way that any recirculation of cooling air to the
compressor is avoided. The minimum temperature at the compressor intake opening is 0°C, the maximum
suction or cooling air is 40°C.
(With HAT option: minimum = 0°c / maximum = + 50°C).
a Required fan flow rate can be calculated from:
Qv  0.1N / T
Symbole Explanation
Qv Required fan flow rate (m3/s)
Shaft input of the booster (kW) if stand alone
N
Shaft input of the booster + ZR (kW) if ZD or ZDXtend
∆T Compressor room over the outdoor temperature (°C)
b Ventilation air intake gratings:

The air velocity to the grid(s) has to be limited to 3m/s.
The free area of the air intake opening in the wall is calculated as follows:
If booster alone
S  Qv  / v
If ZDXtend or ZD
S = (Qv + FAD) /v
Symbol Explanation Symbol Explanation
S Grid’s free area (m2) FAD Air flow FAD of the ZR compressor (m3/s)
Qv Required fan flow rate (m3/s) v Allowable air velocity (= 3 m/s)
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Compressed air circuit

Connecting air piping
Ensure that each pipe is free to expand under heat.
No external force may be exerted on each air flange.
The connected pipe must be free of all stress.
Install correct support if necessary.
The maximum total pipe length can be calculated from:
P  d 5  P
L
450  Qc1.85
Symbol Explanation
L Length of the pipe (m)
∆P Max. allowable pressure drop (recommended 0.6 bar)
d Inner diameter of piping (mm)
P Absolute pressure at the compressor outlet (bar)
Qc Free air flow from the compressor (I/s)
a. We advise to install the HTA receiver (40 bar air receiver) as close as possible of the booster (length of
the pipe must not exceed 2,5 meters).The pulsation level at the booster outlet on a no resonant line is
less than 3% peak to peak of the average pressure (in case operating pressure is 40 bar).
b. We advise to install the LTA receiver (low pressure receiver) as close as possible of the booster to limit
pressure loss between both items to 0,2 bar maximum (only in ZDXtend VSD configuration).
Floor characteristics
Floor specifications:
The compressor should be installed on a level floor able to taking its weight. Specific load of the floor shall be
minimum of:
 1700 daN/ m2 for a DX Booster VSD
 2100 daN/m2 for a DN booster VSD
Concrete skid of D boosters is foreseen to be simply put on the floor (no anchor at all). Floor shall be as flat
and smooth as possible: maximum defect of ± 3 mm/2 m. Slope of the floor shall not be more than 0.5 cm/m.
Water circuit
It is recommended to install:
- A filter at compressor water inlet (600 microns)
- Insulating valves on inlet and outlet of each equipment, for easy maintenance
- Additional vent valves (with plugs) on each high point of water circuit (on piping) for evacuation of air
- Cooling water circuit is to be protected against over pressure over 6 bar.
- Cooling water circuit shall be closed. Cooling water drain valves must be closed.
- Connect water piping between all components to the water circuit (customer installation)
- Open water inlet and outlet valves (customer installation)
- Check water flow and pressure (see § 10.6).
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Drain
Drain pipes of ZR compressor (in case of ZD or ZDXtend installation).
Condensate collector must be open.
Drain pipes shall be always above condensate level.
Condensate collector proposal:
Reinjected air (only for ZDXtend configuration)
Reinjected air in LTA receiver (10 bar receiver) shall be clean and dry:
 Minimum allowable air dew point at pressure 9 bar eff = - 40°C.
 Maximum allowable air dew point at pressure 9 bar eff = - 15°C.
Electric checks
Step Action
1 Check the compliance of electric connections with regard local regulations. The
grounding of the installation is obligatory and all phases must be protected from short
circuits via fuses. A disconnecting switch must be installed.
2 Check the connections on the primary sides of transformers
3 Check circuit breaker settings
4 Check overload relay settings and fuses (see §. 10.4)
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6.2 Initial start-up
Checking and operations to be carried out on the booster prior to initial start-up or following extended
storage
These checks are carried out with and without power supply
1 Check the general condition of equipment.

2 Remove protection (caps on air and water inlet/outlet flanges) and VCI-paper (Volatile Corrosion
Inhibitor) (in the electric cabinet or inside the canopy).
3 Remove protecting grease with a rag on:
 crossheads, crossheads slide.
 big end bolt (connecting rod)
 crossheads nuts
 oil packing plates (crosshead side).
4 Check oil level (¾ of sightglass) and pre-oil crossheads and slides by manual projection. (See § 8.2).
5 Re-assemble any components removed (motor, transmission belt, etc….). Check the tension of belts
(consult Atlas Copco for value).
6 Check the isolation and oiling of the electric motor.
7 Remove the blocking screw of the engine shaft (if present).
8 Manually check the rotation "without blockage" of the booster by turning the flywheel.
9 Manually check the rotation "without blockage" of the electric motor.
Prior to initial start-up
The user must apply all Safety measures concerned, including those indicated in
this manual. (see paragraph 1)
1 Read the user Manual for the Elektronikon® regulator to become familiar with all regulator functions.
(Paragraph 4 of the instruction book).
2 Execute all checks indicated in paragraph 6.1 of the instruction book when installing the machine.
Prior to start-up
1 Check that the level of oil is at ¾ of sightglass for D booster. If necessary, add oil of the specified
type. (see § 7.3)
2 Close all drain valves and place water circuit plugs.
3 Check connections of air and water circuit, electric connections.
4 Open water inlet and outlet valves (customer installation). Maximum customer water pressure must
not exceed 6 bars.
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Initial start-up
1 Check:
 limits set for measuring equipment (oil pressure, air temperature …) in the Elektronikon.
2 Check the direction of rotation of water pump. Fill the water circuit (See Installation procedure N°
1901077765 (supplied inside D Booster) or water pump skid instruction book (chapter.3)); ensure the
circuit is watertight, do correct venting and check the flow and pressure (maxi water pressure = 6 bar).
3 Check water is circulating (start-up water pump in local mode) and check water circulation controller
(see water pump notice – option).
4 Remove suction valves on each cylinder of D booster. Switch booster in standalone mode (menu / ZD
/ ZD Setup / ZD mode), to change this parameter, you have to be in full user mode (contact Atlas
Copco).
5 Check of the direction of engine rotation of D booster: Turn on. Start and immediately stop the
booster. Check that the direction of rotation is correct while the motor is stopping. The correct
direction of rotation is indicated by an arrow on the booster. If the direction of rotation is incorrect, turn
off and reverse two electric input connections.
6 Check the direction of rotation of canopy fan of D booster (see arrow) (with HAT option, two fans in
the canopy for DN boosters). It must blow fresh air towards the canopy.
7 Start D booster and let it operating without suction valves during 15-30 minutes.
8 Check that oil pressure is correct.
9 Leakages of about 2 droplets of oil per hour is acceptable through oil wiper rings.
In case of higher leakages, verify assembly, clean (don't use any solvent on PTFE oil rings), turn
wiper ring 1/3 round, refit and test again for 1 hour.
In all cases, oil leakage mustn't introduce oil into the piston rod air packing (thrown droplets, oil
running along the rod, etc…).
10 Stop the booster and re-assemble valves.
In case booster working mode is booster:
11 D booster Elektronikon shall stay on local control configuration and in “standalone” mode (menu / ZD /
ZD setup / ZD mode) with full access level, like on the § 4.
12 Required pressure shall be reached in the low pressure intermediate receiver. Then start the D
booster. Caution: Do not start without water circulation.
In case booster working mode is ZDXtend or ZD:
11 ZR Elektronikon shall be configured now on LAN control (use the shortcut on yhe main screen).
Switch the booster in ZDXtend mode (menu / ZD / ZD setup / ZD mode), with full access level, like on
the § 3 (contact Atlas Copco for this). “Follow booster” must be switched on (ZR side).
Change configuration of water pump on “remote control”.
12 Then start the compression unit from the D booster Elektronikon regulator. Caution: Do not start
without water circulation.
13 Modify settings in D booster Elektronikon so that operating outlet pressure is maximum 25 bar at a
first step (during approx. 15 mn).
Modify settings for 2nd step at 30 bar, then at 35 bar and finally at 40 bar (during approx. 15 mn for
each step).
Procedure for settings modification: Menu / Regulation / setpoint 1 or setpoint 2
14 Check outlet pressure at each stage.
15 Identify the limit set for air temperature sensors (see Elektronikon chapter.4) and check working order
by lowering the pre-set value until the limit is reached. Following checking, return the setting to the
initial value.
16 Use water adjusting valves and temperature indicators (supplied on ZR and D Booster
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connection pipe) to regulate water temperature difference between inlet and outlet at 15°C (± 2°C) at
maximum speed (for D VSD Booster and ZR VSD).
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17 Operate the compression unit for a few hours and check normal working order.
18 Stop the compression unit. If necessary, add oil (See § 8.2).
19 At first start of the installation, your ATLAS COPCO Maintenance operator will proceed with a
tightness test of air circuit and a vibration test.
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Operating mode for use
Description
The D booster may be connected to a ZR (ZD or ZDXtend configuration) screw and a MD dryer (integrated or
not in the ZR).
The D Booster is water-cooled therefore a cooling system with water pump may be connected to booster in a
closed circuit.
Start-up
Control panel
To Ensure automatic operating in standalone: (see installation procedure)

D booster operates in local mode (“standalone” on Menu / ZD / ZD setup/ ZD mode). Cooling system and
water pump operate on “local control”. An automatic start – up is launched by pressing on “I” of the D booster
Elektronikon.
To Ensure automatic operating in ZD or ZDXtend: (see installation procedure)

Booster side: the “ZD” function must be activated in the Elektronkon.
ZR side : the control mode must be LAN.
“Follow booster” must be switched on (full access needed) on the ZR side.
Menu / Settings / Remote control / Follow booster on the ZR.
Change “High Speed Unload” on ZR from “Allowed from minimum speed only” to “Allowed
at any speed” with “Modif5” in Expert Mode: General setting / Converters / Motor Speed
setup / High Speed Unload.
The Can network must be connected between the ZR and D booster on Can1.
The unit has an automatic start-up sequence launched by pressing on “I” (rep 14) of the D booster
Elektronikon.
The start-up sequence is as follows:
- the cooling water system starts,
- following a time period of 60 seconds, the ZR starts,
- following a time period of 20 seconds, the D booster starts.
The ZD or ZDXtend operates in automatic mode according to consumption of HP air. The ZR compressor
charges when the booster is in charge mode.
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Regulation
The D Booster charges the HP network via a regulation sensor placed on the HP piping of D booster.
D Booster operates in automatic mode according to consumption of HP air. D Booster adapts its speed to the
air demand.
Stop
Booster standalone
To stop the D Booster, simply press on the button “0” (rep 13) of the D booster Elektronikon.
ZD or ZDXtend
To stop the unit, simply press on the button “0” (rep 13) of the D booster Elektronikon.
The stop sequence will occur as follows:
- Simultaneous stop of the ZR and D booster,
- Following a programmed time period of 5 mn, stopping of the water pump.
If the ZR or D enter error mode, the ZR and D booster stop simultaneously. Stopping of the water pump
occurs 5 mn later. The displayed on one of the 2 Elektronikons (on ZR or D booster) must then be corrected
and confirmed before the ZD or ZDXtend may be re-started.
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6.3 Start-up after emergency stop or default stopping
Control panel
Control panel of the MkV regulator

Procedure
Step Action
1 Press on the emergency stop button (S2) (if not executed).
2 Turn off and decompress the compression unit. (*)
3 Correct the error on the compression unit.
4 Unlock the emergency stop button by pulling and reset the screen of the Elektronikon.
5 Restart the compression unit. See operating mode for use (§ 6.2)
If the automatic re-start function is activated after a power cut and the repair time is
shorter than the programmed energy recovery time, reset the screen following
correction of the error. Reset the protections and the compressor may be re-started.
(*) see § 6.6
Minimum stopping time

Starting of compression unit will not be possible within the limits of a programmed period (20s) following a
stop, independently of circumstances. A start-up order given during the minimum stopping time will be
memorised, the automatic mode LED lights up (7). The compression unit starts following expiry of minimum
stopping time.
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6.4 During operation

If the automatic mode LED (7) light is lit, the Elektronikon regulator of D booster automatically controls
compression unit, adapting air discharge pressure to air consumption, and starting and stopping the
compression unit if necessary.
Screen check
1 Check readings and messages on the screen each day. Check if no alarms, services or protections
are displayed on shortcuts on main screen.
2 Always check the screen and correct if the LED alarm light (4) is lit or flashing. (See section 4.5)
3 The screen indicates a maintenance message if one of the components under surveillance requires
maintenance. Reset the timer in question after maintenance, check also the blue LED (6) is not lit.
Before carrying out maintenance work or operations, stop the compression unit, press the
emergency stop button, wait for the compressor to stop and open the disconnecting
switch (customer installation) to cut the current to the compression unit.
Close the air outlet valve and open the manual drain valves for condensates to
decompress the air system.
Repairs in the start-up, speed regulation and control cabinets may only be executed by
Atlas Copco. Following the turning off of the machine, wait for at least 6 minutes before
beginning electrical repairs as dangerously high voltage may remain up to 6 minutes in the
capacitors of the start-up and speed regulation unit.
4 Rapidly consult the compressor status: the compressor checking mode, start/stop timer status, all
measured temperatures and pressures.
When automatic operation LED (7) is alight, starting and stopping the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
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6.5 Screen check
Control panel
Control panel of the MkV regulator
Consult information on the status of D booster
Step Action
1 Regularly check messages on the screen. The main screen is normally
displayed, indicating the compressor outlet pressure, compressor status and
functions of keys at the bottom of the screen.
2 Always check the screen and correct if the LED alarm (7) is lit or flashing.
3 The screen indicates a maintenance message if one of the components under
surveillance requires maintenance. Replace the component, change the oil or
oil the driving motor if necessary. Reset the counter concerned.
4 Regularly get to menu / inputs to display information on the current compressor
condition:
 pressures
 temperatures
 digital inputs
Should a warning, maintenance required, defective sensor or motor overload be

displayed, the corresponding icon will be displayed.
Consult information on the status of compressor ZR

See ZR Instruction Book.
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6.6 Stopping and disconnection of the machine

This procedure is to be applied particularly in machine intervention maintenance.
1 Press the stop button (13): the compressor stops and the LED light (7) goes off.
In case of emergency, to stop the compressor immediately, press the emergency stop button (S2).
2 Wait for the compressor to stop and open disconnecting switch (customer installation) to cut the
current to the unit.
3 Close the air inlet and outlet valves for D booster (customer installation).
4 Decompress the compressor (via the HP receiver bleeder).
5 Close the water inlet and outlet valves if the circuit is in charge mode.
Should the circuit freeze in winter, empty water cooling circuit in the compressor.
With machine stops, the installation must not be pressurized at temperatures of

less than – 10°C.
6.7 Definitive end of service

Definitive end of service procedure of the machine:
1 Press the stop button (13): the compressor stops and the LED light (7) goes off.
In case of emergency, to stop the compressor immediately, press the emergency stop button (S2).
2 Wait for the compressor to stop and open disconnecting switch (customer installation) to cut the
current to the unit.
3 Close the air inlet and outlet valves for D booster (customer installation).
4 Decompress the compressor (via the HP piping bleeder valve of D booster or via the HP receiver
bleeder).
5 Close the water inlet and outlet valves if the circuit is in charge mode.
6 Unplug and disconnect the machine from the electric network.
7 Wait several hours if necessary, till oil, water and air circuit in the machine reach an acceptable
temperature.
8 Disconnect D booster from the air network.
9 Empty the water circuit in the compression unit (open vent valves on the machine during this
operation).
10 Disconnect cooling water piping from the compression unit.
11 Compressor dismounting for recycling is then possible
All recycling operations shall be carried out by a specialized company.
The waste and material must be destroyed according to the local legislation.
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12 Following parts of the D booster shall be removed before any grinding:

 Bleed the oil carter of D Booster (see §.8.2)
 Remove the oil filter (see §.8.2)
 Disassemble the piston rings, the packings and oil wipers (contact your customer service pole for
assistance)
 For compressors with a concrete base, it is necessary to separate the concrete block from the
compressor.
 Remove foam inside canopy panels
 Copper salvage can be done in the motor, the oil cooler, the electrical components, gaskets under
valves, oil piping inside the crankcase and electrical cables.
13 For information, other material are used and can be found in the list below:
 Stainless steel: air coolers, air flexible piping, regulation circuit (damper), piston rods,
pistons.
 Cast iron, steel: crankcase, connecting rods, crossheads, crankshaft, distance pieces,
crossheads sliding rails, motor frame, cylinders, flywheel, counter bearing, supports, canopy
panels, belt housing, inlet air receiver, cylinder heads, final outlet air pipe, cooler shell and its
connections, motor plate, electrical cubicle housing, inlet and outlet water manifolds, motor
sliding rails, suction and discharge valves.
These components are generally painted. Most of the paints used have bi-components with the
possibility of adding or diluting agents. (To know paint composition, see “appendix 1” below).
Some components have been tightened (Ex: threaded components of water or air piping) with a
specific product.
(To know composition of this specific product, see “appendix 1” below)
 Aluminium: pistons, electrical cables.

 Bronze and its alloys: bearings, safety valves.
 Plastic components, rubbers and others: rilsan piping (regulation circuit), foam inside
canopy panels, air filter cartridges, belts, water flexible piping, fan blades, cables and
electrical components coating.
Appendix 1
Possible paints components: methyl ethyl ketone-oxime, ethylbenzene, N-Butanol, heavy

naphtha, hydrogen sulfide, zinc phosphate, xylene, acetate of 1-méthoxy-2-propryl, isobutanol,
acetate of butyl, ethanol, epoxydic resins, tris (dimethylaminomethyl) phenol, triethylenetétramine,
trimethylbenzene, mesitylene, light naphtha solvent, disocyanate of hexamethylene,
homopolymer of HDI, cobalt ethylhexanaote.
Possible tightness product components: dodecyle methacrylate, acetyl, phenylhydrazine.
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7 Maintenance
7.1 Preventive maintenance programme
Safety precautions
Before carrying out maintenance work or operations stop the compression unit, press the
Close the air outlet valve and open the manual drain valves for condensates to
decompress the air system.
Repairs in the start-up, speed regulation and control cabinets may only be executed by
Atlas Copco. Following the turning off of the machine, wait for at least 6 minutes before
beginning electrical repairs as dangerously high voltage may remain up to 6 minutes in
the capacitors of the start-up and speed regulation system.
Maintenance plans
Atlas Copco Customer Service Poles provide various maintenance plans according to requirements:
 An inspection plan
 A Preventive maintenance plan
 A Total liability plan
Contact your Customer Services Pole to agree on a customized maintenance plan. Such a plan guarantees
optimal operational effectiveness, minimises stopping time and reduces all operating costs.
Guarantee - Product liability

Only use authorised parts. All damages or defective operating due to the use of unauthorised parts is not
covered by the Guarantee or commitments on Product liability
Maintenance kits
Atlas Copco Customer Service Poles will be delighted to provide you with a wide range of maintenance kits.
Maintenance kits include all parts required in component maintenance, which ensures the provision of Atlas
Copco spare parts and the reduction of maintenance costs.
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Regular checks
The following checks must be carried out on D booster at regular intervals in order to guarantee safe
operating and a maximum life cycle.
Frequency Operation
Daily Check the status of the compressor (Elektronikon reading) and filters (clogging
indicator). Change or clean the filters, if necessary (see § 8.1).
Daily Check that the solenoid valve SVi (see §2) is closed when the D booster is
unloaded. If the solenoid valve is open, check HP cylinder discharge valves and
1st stage unloader.
Daily Check oil level. Top up is needed / minimum oil level: half of the sight glass.
Check that there is no oil in the spacer of D booster.
Daily During charge, check the emission of condensates from ZR and MD (If present).
Daily Check the dew point of the booster suction. (If present).
Weekly Check programmed settings and check that there is no condensate in LP or HP
receiver (by opening briefly bleeder valve of each receiver). If any, check air
drying system upstream of D Booster.
Every 3 months Check belt tensions.
Every 3 months Check sealing air and water circuit.
Every 4 000 h (*) Replace air packing and oil wipers at HP side (only DN booster with 160 mm
stroke).
Every 8 000 h (*) Change the valves, air packing, piston rings, oil wipers and LP filters.
Oil draining and replacing of the oil filter.
Check cleanliness of electrical cubicles air filters. Replace them if needed.
Change dew point sensor filter at second stage inlet and calibration of this dew
point sensor.
Check torques on distance pieces and crank end cylinder head.
Vibration checking.
Every 16 000 h (*) Change internal parts of unloader.
Every 16 000 h or 3 years (*) Change the belts
According to display Carry out service actions according to displayed service instructions.
Every 5 years (*) Replace every air flexible piping.
7.2 Lubrication of the motor
General remarks
Stop the compressor before oiling.

Do not mix different oil brands and qualities
Lubrication of the motor

Contact your Customer Services Pole for information on the type of recommended oil, quantity and
recommended frequency for motor bearings.
_________________________________________________________________________________________________________________________________________________
Notes
(*) Parts changes frequency correspond to AC recommendations for normal run of D Booster.
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7.3 Oil specifications
RECIPOIL oil
For D booster, use Recipoil Atlas Copco oil, which is specifically designed for alternative compressors. The
extended life cycle of this oil maintains the excellent service conditions of D booster.
Recipoil Atlas Copco oil may be ordered in the following quantities:
Quantity (litres) Quantity (Us gaI) Quantity (lmp gal) Quantity (cu.ft) N° of the article
20-litre container 5.28 US gal container 4.40 Imp gal container 0.70 cu. ft container 1901 0555 34
Barrel Barrel Barrel Barrel 1901 0555 35
209 litres 55.18 US gal 45.98 lmp gal 7.32 cu.ft
7.4 Storage following installation

When compressor has to be kept on storage for 1 week till 3 months, following procedure shall be applied:
the compressor must operate hot, e.g twice a week during 2 hours minimum to keep it in a good state.
If the possibility to operate the compressor occasionally does not exist, or if storage period exceeds 3
months, protective measures must be taken for the compressor:
The following recommendations apply:
 Protect the mechanical components (crankshaft, connecting rods, crossheads and pistons) using a
SHELL ALVINIA EP2 or DARINA 2 type grease;
 Dismount pistons and piston rods and store them in a dry area (separate packing + desiccating
sachets);
 Spray cylinder bores with PTFE spray to protect them (Contact Atlas Copco for PTFE spray
recommendations);
Do not forget to clean cylinder before restart.
 Carefully blank off openings such as filters, gas outlet discharge collar, water intake, water outlet,
automatic and manual condensation drains, motor gas intake grill;
 Immobilise the motor shaft by mans of the locking bolt when fitted;
 Monitor anti-rust protection of unpainted external surfaces;
 If possible, carry out a dry air or nitrogen sweep before finally blanking off all orifices;
 Blank off all orifices and particularly the safety valve opening;
 Place VCI-paper (Volatile Corrosion Inhibitor) inside housings;
 Clearly indicate the presence of VCI-paper.
 Remove belts.
 Belts should be stored in a cool and dry environment with no direct sunlight. Ideally, less than 30°C
(85°F) and 70% relative humidity.
 Belts should not be stored near heaters, radiators.
 Do not store belts on the floor unless they are in a protective container.
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7.5 Service kits

Service kits include all parts required in component maintenance, which ensures the provision of Atlas Copco
spare parts and the reduction of maintenance costs.
7.6 Torques
Table of recommended torques

The following table concerns general bolting and studs (torque in daN.m).
DIAMETER M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
CLASS 6.8 2.6 4.4 7.1 10.9 15.1 21.2 28.9 36.7 53.3 72.9
CLASS 8.8 3.5 5.9 9.4 14.5 20.1 28.3 38.5 48.9 71 97.2
CLASS 10.9 4.5 8.3 13.2 20.3 28.4 39.8 54.2 68.8 99.9 136.7
CLASS 12.9 5.9 10.0 15.8 24.5 34.0 47.7 65.0 82.5 119.9 164.0
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8 Maintenance procedure for D booster

8.1 Air filters
Location of air filters
1 3
3 4
Air filters
For DX boosters : 2 filters elements. For DN boosters : 3 filters elements.
Procedure
Replace or clean filters regularly. Consult the preventive maintenance programme section.
Never install damaged or blocked filters.
Step Action Step Action

Stop the compressor and press the emergency Replace the support and elements (with new
1* stop button.
7
gaskets, if necessary).
Turn off (the electric switch must be opened
2* and locked).
8 Retighten screws (1).
Isolate and bleed the booster till completely

3* decompressed.
9 Turn on and open the vent valves.
Unlock the emergency stop button and reset the

4* Remove screws (1). 10 maintenance notification of the air filter in
Elektronikon.
Check the tightness and reading of the blocking
Remove the filters support (2) containing the
5 11 indicator (4) of the filters when re-starting of the
filters elements (3).
booster.
6 Replace the filters elements. * LO – TO Procedure
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8.2 Oil draining and replacing of the oil filter
Oil circuit of the DX booster Oil circuit of the DN booster
OO
OO
OC
OF
SG
SG
OD
OD
OC
OCD
Components of the oil circuit Components of the oil circuit
Check the oil level via the oil marker (SG). Check the oil level via the oil marker (SG).
Oil cooler (OC). Oil cooler (OC).
Oil bleeder tap (OD) for compressor. Oil bleeder tap (OD) for compressor.
Oil bleeder tap (OCD) for cooler. Opening with breather for adding oil (OO).
Opening with breather for adding oil (OO). For all information on oil, consult paragraph 7.3.
For all information on oil, consult paragraph 7.3. Oil Filter (OF) in crankcase.
Oil Filter (OF).
Procedure
Step Action
1 Operate the booster for 15 - 30 min to heat the oil.
2 Stop the compression unit and press the emergency stop button.
3 Turn off. (LO - TO)
4 Bleed the oil carter of D booster by opening the drain valve (OD) and the cooler
drain valve (OCD).
Close drain valves and replace plugs after draining.
5 Clean the inside of the oil carter (particularly the bottom).
6 Remove the oil filter (OF). Clean the filter slot, oil the gasket of the new filter. Fill
the new filter with oil. Hand tighten the filter until the gasket and the slot are in
contact. Fill the oil cooler.
7 Fill, via the breather (OO), the crankcase with new oil up to ¾ of the sight glass
(SG).
See oil specifications (§ 7.3) to select the appropriate type of oil.
8 Clean the breather (OO).
9 Turn the compression unit on.
Unlock the emergency stop button and reset maintenance notifications for oil and
the oil filter in Elektronikon.
10 Let the compression unit operate for a few minutes, check oil pressure.
11 Stop the compression unit.
12 Check the oil level reaches ¾ of the sight glass (SG).
If necessary, add oil.
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8.3 Safety valves
Test
Valves may be tested on a separate compressed air line. If the valve does not open at the pressure specified
in the Settings section of safety valves (paragraph 10.3), consult Atlas Copco.
Never use the compressor without safety valves.

No adjustments are authorised
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9 Resolution of problems relating to D booster
Before carrying out maintenance work or repairs stop the compression unit, press the
Repairs in the start-up and control cabinet may only be executed by Atlas Copco.
Close the air outlet valve and decompress the air system using manual bleeder
valves.
Apply all Safety measures concerned, including those indicated in this manual.
The booster does not start-up
SYMPTOMS CAUSES SOLUTIONS

START-UP IMPOSSIBLE Defective power supply or Check power supply and/or correct error.
existing error.
Permissive start not achieved Check working condition . Check status of
belts the belts and belt tension.
The booster stops

DEFAULT STOP Defective sensor or value Identify and correct the error.
beyond limits
Discharge pressure not reached

BOOSTER IN Too high air requirements Disconnect the compressor from the
CONTINUOUS OPERATING network. Seek air leaks. Check that network
MODE air consumption has not increased
(PRESSURE NOT accidentally. Check the cleanliness of air
REACHED) filters
Defective regulatory solenoid Check and replace if necessary.

valve
Clogged air suction filter Replace or blow the element.
Defective valves, piston rings Check the condition of parts. Replace if
necessary
Safety valve leak Remove the defective valve and check.
Inlet pressure too low Check LP compressor or LP network.
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Nominal discharge pressure higher than that expected

BLOW OFF NOISILY AT Regulatory solenoid valve stays Check the regulatory solenoid valve.
RECEIVER SAFETY VALVE opened
Safety Valve setpoint Check safety valve setpoint pressure. Check
regulatory limits for D booster.
Defective 2nd stage unloader Check, repair or replace
Defective pressure transducer Replace
Blow off noisily at intermediary valve

BLOW OFF NOISILY AT Defective safety valve Remove and check valve.
INTERMEDIARY VALVE
Defective suction valves Particularly check 2nd stage discharge

suction valves and replace if necessary.
Discharge system for defective Check discharge for 1st stage suction valves
1st stage suction valves Check inter-stage pressure.
Too high discharge temperature (intermediary or final)

TOO HIGH TEMPERATURE Defective temperature Check and replace.
transmitter
Inadequate water circulation Check the water circuit
Default and alarm limits Check the default and alarm limits
incorrectly programmed programmed in the regulator.
Defective suction valves Check the condition of suction valves.
Inlet temperature too high Check LP compressor
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Oil pressure problems

ABNORMALLY OIL Oil level too low Top up
PRESSURE
Oil temperature too high Check the oil cooler and water circuit.
Defective oil pump. Replace
Defective oil circuit Check the oil circuit (filter, connections…)
Defective main shaft bearing or Check and replace.
connecting rod big end bearing
ABNORMALLY VARYING Oil level too low Top up
PRESSURE
Strainer or filter clogged Clean or replace.

Defective oil pump Replace the spring and the pin of the
pump.
Noisy operating

IMPACT Wear and/or incorrect operating Check the condition of mechanical parts
play. (piston, rod..).
VIBRATIONS Specific floor load not adequate Check the characteristics of the floor under
the D booster.
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10 Main characteristics
10.1 Reference conditions
Component Condition
Air inlet temperature ..................................................................... °C 40
..................................................................... °F 104
Actual nominal operating pressure ............................................... bars (actual) 40
Cooling water inlet temperature .................................................... °C 20
...................................................................................................... °F 68
Air inlet pressure ........................................................................... bar (g) 9.5
...................................................................................................... psi (g) 139
Compressed air inlet dewpoint ..................................................... °C -15
....................................................... °F 5
10.2 D Booster readings

Important
The following readings are valid if operating at reference conditions. See reference
conditions. (See paragraph 10.1)
Pressure readings
Component Reading Reading

Maximum operating pressure 42 bar (g) 609 psi g
Air filter DP (new) Less than 0.1 bar Less than 1.45 psi
Intermediary cooler air pressure 20 bar(g) 290 psi g
Oil pressure (according to climatic conditions) 2 - 3 bar(g) 29 - 43.5 psi g
Temperature readings
DX booster DN Booster DX Booster DN Booster

Component Reading Reading
Oil temperature Approx. 50°C Approx. 122°F
Air temperature, low pressure outlet
115 – 122°C 112 – 120°C 239 - 252°F 234 - 248°F
component (component 1)
Air temperature, high pressure outlet
93 - 100°C 95 - 102°C 199 - 212°F 203 - 216°F
component (component 2)
Air temperature, high pressure inlet component
30°C 86°F
(component 2)
Air outlet temperature Approx. 30 ° C Approx. 86 °F
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10.3 Safety valve settings for D boosters
DX DN DX DN
booster Booster Booster Booster
Component Opening pressure Opening pressure
Low pressure safety valves 11 bar (g) 160 psi g
Intermediate pressure safety valve 24.5 bar (g) 23.5 bar (g) 355 psi g 341 psi g
High pressure safety valve 45 bar (g) 653 psi g
10.4 Circuit breakers and fuses rating for D boosters

Circuit breakers
Circuit breakers Value (A)

Control circuit (Q1) 2,5 A
Fan (Q20) 400 V – 50 Hz 3,0 A
Fan (Q20) 440 V – 60 Hz / 460 V – 60 Hz 3,3 A
Boosters 2DX2-85VSD
Main fuses
Maximum rating for fuses Maximum rating for fuses

Power supply voltage (V) gL / gG Type2 (A) CSA/UL Classe RK5 (A)
400 V – 50 Hz 3x250
440 V – 60 Hz 3x250
460 V – 60 Hz 3x250
Boosters 2DX2-90VSD (only in HAT version)

Main fuses

400 V – 50 Hz 3x250
440 V – 60 Hz 3x250
460 V – 60 Hz 3x250
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Booster 2DX2-110VSD
Main fuses

400 V – 50 Hz 3x315
440 V – 60 Hz 3x315
460 V – 60 Hz 3x315
Booster 2DN2-145VSD
Main fuses
Please contact Atlas Copco.
Booster 2DN2-160VSD
Main fuses

Power supply voltage (V)
gL / gG Type2 (A) CSA/UL Classe RK5 (A)
400 V – 50 Hz 3x400
440 V – 60 Hz 3x400
460 V – 60 Hz 3x400
Booster 2DN2-250VSD
Main fuses

400 V – 50 Hz 3x500
440 V – 60 Hz 3x500
460 V – 60 Hz 3x500
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Booster 2DN2-275VSD
Main fuses

400 V – 50 Hz 3x630
440 V – 60 Hz 3x630
460 V – 60 Hz 3x500
Booster 2DN2-315VSD
Main fuses

400 V – 50 Hz 3x630
440 V – 60 Hz 3x630
460 V – 60 Hz 3x500
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10.5 Limitations
50Hz and 60 HZ compressors
Maxi elevation m 1000

Maximum air inlet pressure bar (g) 10.7
Psi (g) 155.2
bar (g) 42
Maximum operating pressure
Psi (g) 609
Minimum air inlet pressure Bar (g) 6.5
Psi (g) 94.3
Minimum operating pressure 1) bar (g) 25
Psi (g) 363
Maximum air inlet temperature °C 55
°F 131
Minimum air inlet temperature °C 10
°F 50
Maximum ambient air temperature °C 40
°F 104
Minimum ambient temperature °C 1
°F 33.8
Maximum allowed cooling water inlet temperature °C 35 (3) 42 (4)
°F 95 108
Minimum allowed cooling water inlet temperature °C 20
°F 68
Maximum allowed cooling water outlet temperature 2) °C 57
°F 134.6
Maximum actual cooling water inlet pressure Bar (g) 6
Psi (g) 87
Maximum n° of load/unload cycles Min -1 3
Allowable voltage variation for motor and speed converter V From 360 to 500
Dry and oil free air is needed at D Booster inlet
Minimum allowable air dew point at pressure 9 bar eff = - 40°C

Maximum allowable air dew point at pressure 9 bar eff = - 15°C
_________________________________________________________________________________________
Notes chapter 9.5
1) Continuous operation of compressor at a pressure below 30 bar (g) may decrease life time of the 2nd stage discharge valves.
2) Must be higher than ambient temperature minus 5 °C (for HAT version)
3) Only for ZD or ZDXtend
4) Only for Standalone
1901077772.02 173
Instructions book
10.6 Specifications
Important remark
The following values are valid at reference conditions. See reference conditions. § 10.1
2DX2-85VSD
D Booster 2DX2-85VSD
Nominal operating pressure bar (g) 40
Psi g 580
Air outlet temperature 1) (approx.) °C 30
°F 86
Electric power input 1)
At effective motor speed at 602 r/min KW 37.0
HP 49.6
at 702 r/min KW 41.9
HP 56.2
HP 63.3
HP 70.6
at 1001 r/min KW 58.4
HP 78.3
at 1101 r/min KW 64.4
HP 86.4
at 1201 r/min KW 70.7
HP 94.8
at 1300 r/min KW 77.2
HP 103.5
at 1400 r/min KW 84.0
HP 112.6
at 1500 r/min KW 91.0
HP 122.0
D Booster oil capacity L 15
US gal 3.96
Imp gal 3.3
Cu.ft 0.53
Cooling water consumption (for a rise in water temperature of L/s 1.3
15°C) 2) cfm 2.8
Sound pressure level (with canopy) 3) dB (A) 75
min. - max. motor speed D r/min 602 - 1500
min. - max. speed D r/min 350 - 872
D booster water capacity L 100
Cu.Ft 3.53
_________________________________________________________________________________________
Notes chapter 10.6
1) At reference conditions, unless otherwise stated and according to ISO 1217
Supply voltage 400 v (for 50 hz units); 460 v (for 60 hz units) Data may differ 0.5 % maximum at other supply voltages.
2) With 30% of glycol in the water.
3) A-weighted sound pressure level LpA, sound power level LwA, uncertainty +3dB, reference 20 µPa, according to ISO 3746.
174 1901077772.02
Instructions book
2DX2-90VSD
Nominal operating pressure bar (g)
Psi g
Air outlet temperature 1) (approx.) °C
°F
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
D Booster oil capacity L
US gal
Imp gal
Cu.ft
Cooling water consumption (for a rise in water temperature of L/s
15°C) 2) cfm
Sound pressure level (with canopy) 3) dB (A)
min. - max. motor speed D r/min
min. - max. speed D r/min
D booster water capacity L
Cu.Ft
_________________________________________________________________________________________
Notes chapter 10.6
1901077772.02 175
Instructions book
2DX2-110VSD

Psi g 580
°F 86
HP 50.3
HP 58.1
HP 66.6
HP 75.7
HP 85.3
at 1069 r/min KW 71.3
HP 95.6
at 1177 r/min KW 79.4
HP 106.5
at 1284 r/min KW 88.0
HP 118.1
at 1392 r/min KW 97.1
HP 130.2
at 1500 r/min KW 106.6
HP 143.3
US gal 3.96
Imp gal 3.3
Cu.ft 0.53
15°C) 2) cfm 3.4
Sound pressure level (with canopy) 3) dB (A) 75.3
min. - max. motor speed D r/min 530 – 1500
min. - max. speed D r/min 350 – 990
Cu.Ft 3.53
_________________________________________________________________________________________
Notes chapter 10.6
176 1901077772.02
Instructions book
2DN2-145VSD
D Booster 2DN2-145VSD
Nominal operating pressure bar (g)
Psi g
Air outlet temperature 1) (approx.) °C
°F
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
KW
HP
D Booster oil capacity L
US gal
Imp gal
Cu.ft
Cooling water consumption (for a rise in water temperature of L/s
15°C) 2) cfm
Sound pressure level (with canopy) 3) dB (A)
min. - max. motor speed D r/min
min. - max. speed D r/min
D booster water capacity L
Cu.Ft
_________________________________________________________________________________________
Notes chapter 10.6
1901077772.02 177
Instructions book
2DN2-160VSD
Psi g 580
°F 86
HP 102.1
HP 113.5
HP 125.4
at 975 r/min KW 102.8
HP 137.9
at 1062 r/min KW 112.6
HP 151.0
at 1150 r/min KW 122.7
HP 164.6
at 1237 r/min KW 133.3
HP 178.7
at 1325 r/min KW 144.3
HP 193.5
at 1412 r/min KW 155.7
HP 208.7
at 1500 r/min KW 167.5
HP 224.6
US gal 9.24
Imp gal 7.7
Cu.ft 1.24
15°C) 2) cfm 5.3
Cu.Ft 6
_________________________________________________________________________________________
Notes chapter 10.6
178 1901077772.02
Instructions book
2DN2-250VSD

Psi g 580
°F 86
HP 100.8
HP 117.2
at 796 r/min KW 100.3
HP 134.5
at 897 r/min KW 113.9
HP 152.7
at 997 r/min KW 128.0
HP 171.7
at 1098 r/min KW 142.9
HP 191.6
at 1198 r/min KW 158.4
HP 212.4
at 1299 r/min KW 176.4
HP 234.1
at 1399 r/min KW 191.4
HP 256.6
at 1500 r/min KW 208.8
HP 280.0
US gal 9.24
Imp gal 7.7
Cu.ft 1.24
Cooling water consumption (for a rise in water temperature of L/s 3
15°C) 2) cfm 6.4
Cu.Ft 6
_________________________________________________________________________________________
Notes chapter 10.6

1901077772.02 179
Instructions book
2DN2-275VSD

Psi g 580
°F 86
HP 136.7
at 678 r/min KW 116.1
HP 155.6
at 760 r/min KW 130.6
HP 175.2
at 843 r/min KW 145.7
HP 195.3
at 925 r/min KW 161.2
HP 216.1
at 1008 r/min KW 177.2
HP 237.6
at 1090 r/min KW 193.6
HP 259.6
at 1173 r/min KW 210.6
HP 282.4
at 1255 r/min KW 228.0
HP 305.7
at 1338 r/min KW 245.8
HP 329.7
US gal 9.24
Imp gal 7.7
Cu.ft 1.24
15°C) 2) cfm 7.8
Cu.Ft 6
_________________________________________________________________________________________
Notes chapter 10.6

180 1901077772.02
Instructions book
2DN2-315VSD

Psi g 580
°F 86
HP 136.7
at 696 r/min KW 119.2
HP 159.8
at 796 r/min KW 137.1
HP 183.9
at 897 r/min KW 155.7
HP 208.9
at 997 r/min KW 175.1
HP 234.8
at 1098 r/min KW 195.1
HP 261.7
at 1198 r/min KW 215.9
HP 289.5
at 1299 r/min KW 237.7
HP 318.2
at 1399 r/min KW 259.5
HP 348.0
at 1500 r/min KW 282.3
HP 378.6
US gal 9.24
Imp gal 7.7
Cu.ft 1.24
15°C) 2) cfm 9.1
Cu.Ft 6
_________________________________________________________________________________________
Notes chapter 10.6

1901077772.02 181

2 DX 2 DN VSD AIB EN Lille 1901077772

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2 DX 2 DN VSD AIB EN Lille 1901077772

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Instructions Book

(In Booster standalone or ZD or ZDXtend configuration)

All unauthorised use or copy of all or part of content is strictly

This particularly applies to manufacturing brands, model descriptions,

Printing date...................... 10/2016

5.2 INSTALLATION PROPOSAL.................................................................................................................................... 117

1.1 Safety precaution legend

Explanation of safety signs used in the notice

1.2 Safety precautions during installation

Precautions during installation

1.3 Safety precautions during operations

Precautions during operations

6 Regularly check that:

Never intervene on a compressed flexible.

 Sealing has no defects.

1.4 Safety precautions during maintenance or repairs

Precautions during maintenance or repairs

2.1 Description of D booster

Elektronikon control system

Description of a ZDXtend VSD

2.2 General views of DX VSD and DN VSD Boosters

Company data plate

Generals views of DX VSD and DN VSD boosters

Picture non contractual

Picture non contractual

CYL HP HP Cylinder (high pressure cylinder)

Ref. Name Ref. Name

M Motor LP SV LP Safety valve (thermic expansion)

View of electric cabinets (D VSD booster)

Picture non contractual

2.3 Fluid diagram

Air, water and oil circuits

2.4 Air system

Flow diagram in standalone configuration

Flow diagram in ZD configuration

For details of the ZR compressor, see corresponding notice.

Flow diagram in ZDXtend configuration

For details of the ZR compressor, see corresponding notice.

2.5 Cooling and lubrication system

Flow diagram in standalone configuration

1) Permissive start on oil temperature.

Flow diagram in ZD configuration

1) Permissive start on oil temperature.

For details of the ZR compressor, see corresponding notice.

Flow diagram in ZDXtend configuration

1) Permissive start on oil temperature.

For details of the ZR compressor, see corresponding notice.

2.6 Regulation system

2.7 Electric circuits

Picture non contractual

Electrical cabinet with frequency converter and Elektronikon regulator

Electric cabinet for DX VSD

Detailed view of the converter cabinet

Ref. Name Ref. Name

Electric cabinet for DN VSD

Ref. Name Ref. Name

Ref. Name Ref. Name

T3 Transformer 230Vac / 24Vac K26 Contactor for HAT canopy fan

K11 Loading auxiliary relay F36 Fuses for canopy fan

K13 On operation auxiliary relay K25 Contactor for canopy fan

F1-F2 Fuses for T1 S2 Emegency stop

1X7 Terminal S21/S22 Protection door lock system

1X6 Terminal P1 Under voltage Red light