ZH 6000-10000 MK 4 İnst Book

Instruction book
Atlas Copco Stationary Air Compressors
ZH6000 – ZH10000 - Three-stage
With Elektronikon regulator MK IV
Instruction book
Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.
This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.
No. 2920 1498 00
Registration code: APC ZH≥4000 3-stage / 38 / 981
2003-09 www.atlascopco.com
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Instruction book
This instruction book describes how to handle and operate the subject machine(s) to ensure safe
operation, optimum working economy and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation
and proper maintenance from the beginning. The maintenance schedule comprises measures for
keeping the compressor in good repair.
Keep the book available for the operator(s) and make sure that the compressor is operated and that
maintenance is carried out according to the instructions. Follow all applicable safety precautions,
amongst others those mentioned in this book.
Repairs must be carried out by trained personnel from Atlas Copco who can also be contacted for any
further information.
In all correspondence mention the type and the serial number, shown on the data plate.
The company reserves the right to make changes without prior notice.
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Instruction book
CONTENTS Page
1 LEADING PARTICULARS................................................................................................................... 5
1.1 General description........................................................................................................................ 5
1.2 Air flow ........................................................................................................................................... 8
1.3 Condensate drain system .............................................................................................................. 8
1.4 Oil system ...................................................................................................................................... 8
1.5 Cooling system (Fig. 1.3) ............................................................................................................. 14
1.6 Electrical system .......................................................................................................................... 14
1.7 Elektronikon regulator .................................................................................................................. 14
1.7.1 Controlling the capacity of the compressor........................................................................... 14
1.7.2 Protecting the compressor .................................................................................................... 16
1.7.3 Monitoring components - service warning ............................................................................ 16
1.7.4 Checking the start conditions ................................................................................................ 17
1.7.5 Controlling the lubricating oil system..................................................................................... 17
1.7.6 Start commands during minimum stop time.......................................................................... 17
1.7.7 Automatic restart after voltage failure ................................................................................... 17
1.7.8 External compressor status indication .................................................................................. 18
1.7.9 BUS connection system ........................................................................................................ 18
1.8 Control panel................................................................................................................................ 19
1.8.1 Display (2-Fig. 1.7) ................................................................................................................ 20
1.8.2 Function keys (3-Fig. 1.7) ..................................................................................................... 20
1.8.3 Scroll keys (4-Fig. 1.7) .......................................................................................................... 21
1.8.4 Emergency stop button (7-Fig. 1.7)....................................................................................... 21
1.9 Menu-driven control programs..................................................................................................... 23
1.9.1 Function of control programs ................................................................................................ 23
1.9.2 Main screen........................................................................................................................... 23
1.9.3 Calling up other menus ......................................................................................................... 25
1.9.4 Quick look at actual compressor status ................................................................................ 25
1.9.5 Returning to the Main screen or other menus....................................................................... 26
1.9.6 Main screen menu................................................................................................................. 26
1.9.7 Status data menu .................................................................................................................. 27
1.9.8 Measured data menu ............................................................................................................ 30
1.9.9 Counters menu...................................................................................................................... 30
1.9.10 Test menu ........................................................................................................................... 31
1.9.11 Modify parameters menu .................................................................................................... 32
1.9.12 Modifying parameters.......................................................................................................... 32
1.9.13 Modifying protections .......................................................................................................... 33
1.9.14 Modifying service plans....................................................................................................... 35
1.9.15 Programming Clock function ............................................................................................... 35
1.9.16 Configuration menu ............................................................................................................. 40
1.9.17 Service menu ...................................................................................................................... 41
1.9.18 Saved data menu ................................................................................................................ 43
2 INSTALLATION ................................................................................................................................. 44
2.1 Dimension drawings (Figs. 2.1 and 2.2) ...................................................................................... 44
2.2 Installation proposal (Fig. 2.3) ..................................................................................................... 47
2.3 Mounting of outlet piping.............................................................................................................. 51
2.3.1 Rubber compensator types ................................................................................................... 51
2.3.2 Alignment tolerances (Fig. 2.5) ............................................................................................. 51
2.4 Cooling water requirements......................................................................................................... 53
2.4.1 Type of the system ................................................................................................................ 53
2.4.2 Cooling water parameters ..................................................................................................... 53
2.5 Pictographs .................................................................................................................................. 56
3 OPERATING INSTRUCTIONS .......................................................................................................... 58
3.1 Preparation for initial start-up....................................................................................................... 58
3.2 Compressor control modes.......................................................................................................... 59
3.3 Before starting.............................................................................................................................. 60
3.4 Starting......................................................................................................................................... 62
3.4.1 Routine starting ..................................................................................................................... 62
3.4.2 Starting after emergency stopping or shut-down .................................................................. 62
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3.4.3 Number of motor starts ......................................................................................................... 63

3.5 During operation .......................................................................................................................... 64
3.5.1 Checking the display ............................................................................................................. 64
3.6 Manual control of compressor operation ..................................................................................... 65
3.7 Stopping....................................................................................................................................... 65
3.8 Taking out of operation ................................................................................................................ 66
4 MAINTENANCE ................................................................................................................................. 67
4.1 Preventive maintenance schedule for the compressor 1) .......................................................... 67
4.1.1 Regular service operations ................................................................................................... 67
4.1.2 Service kits ............................................................................................................................ 68
4.1.3 Service agreements .............................................................................................................. 68
4.1.4 Service plan........................................................................................................................... 68
4.2 Motor greasing ............................................................................................................................. 68
4.3 Lubricant specifications................................................................................................................ 69
4.4 Storage after installation .............................................................................................................. 70
4.5 Service kits................................................................................................................................... 70
5 SERVICING PROCEDURES ............................................................................................................. 71
5.1 Air filters (Fig. 5.1)........................................................................................................................ 71
5.2 Oil and oil filter change (Figs. 5.2 and 5.3) .................................................................................. 71
5.3 Demister (Fig. 5.5) ....................................................................................................................... 73
6 PROBLEM SOLVING ........................................................................................................................ 74
7 PRINCIPAL DATA ............................................................................................................................. 75
7.1 Readings on display (2-Fig. 1.7) 1)............................................................................................. 75
7.2 Programmable settings ................................................................................................................ 75
7.3 Settings of overload relay - motor types ...................................................................................... 75
7.3.1 Settings of overload relay...................................................................................................... 75
7.3.2 Motor types............................................................................................................................ 76
7.4 Compressor specifications........................................................................................................... 77
7.4.1 Design conditions .................................................................................................................. 77
7.4.2 Limitations ............................................................................................................................. 77
7.4.3 Sound pressure level 3) ........................................................................................................ 77
7.4.4 Specific data of 7 bar - 50 Hz compressors 2)...................................................................... 77
7.4.7 Specific data of 10.4 bar - 50 Hz compressors 2)................................................................. 79
7.4.8 Specific data of 100 psi - 60 Hz compressors 2) .................................................................. 79
7.4.9 Specific data of 115 psi - 60 Hz compressors 2) .................................................................. 80
7.4.10 Specific data of 130 psi - 60 Hz compressors 2) ................................................................ 80
7.4.11 Specific data of 150 psi - 60 Hz compressors 2) ................................................................ 81
7.5 Conversion list of SI units into British/American units ................................................................. 81
8 PROGRAMMABLE SETTINGS......................................................................................................... 82
8.1 Regulation settings - See section 1.9.12 ..................................................................................... 82
8.2 Protection settings - See section 1.9.13 ...................................................................................... 83
8.3 Service settings - See section 1.9.14 .......................................................................................... 84
9 Options .............................................................................................................................................. 85
10 PED Instructions............................................................................................................................. 86
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1 LEADING PARTICULARS
1.1 General description
ZH6000 and ZH10000 three-stage are water-cooled centrifugal compressors which deliver oil-free,
pulsation-free air. The compressors are driven by an electric motor.
The compressors are available either fully enclosed in a sound-insulated bodywork or on a base frame
without bodywork.
ZH10000 are 50 Hz compressors designed for following nominal working pressures: 7, 8, 9 and 10.4
bar(e).
ZH6000 are 60 Hz compressors designed for following nominal working pressures: 100, 115, 130 and
150 psig.
Six capacities are available for all pressure variants.
Example of compressor designation

ZH10000-1-10.4 stands for:
- Compressor type ZH10000 - 50 Hz
- Capacity size 1
- Nominal working pressure 10.4 bar(e)
Main components (Figs. 1.1, 1.2 and 1.3)

- Air filters
- Compressor core
- Blow-off valve
- Drive coupling
- Oil reservoir
- Auxiliary oil pump
- Electrical system (see section 1.6)
The compressor core comprises:

- Inlet guide vanes
- Gearbox
- First compressor element
- First intercooler
- Second compressor element
- Second intercooler
- Third compressor element
- Aftercooler
- Check valve
- Oil cooler
- Main oil pump
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1 Drive motor 8 Compressed air outlet 14 Aftercooler

2 Actuator, blow-off valve 9 Cooling water outlet 15 Condensate trap,
3 Blow-off valve 10 Cooling water inlet aftercooler
4 Coupling 11 Condensate drains 16 Oil reservoir
5 Third compressor element 12 Condensate trap, second
6 Air filters intercooler
7 Auxiliary oil pump 13 Check valve
Fig. 1.1 Front view
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1 Air filters 8 Dual oil filters (optional) 14 Cooling water outlet pipe
2 Inlet guide vanes 9 Thermostatic by-pass 15 Second compressor
3 Actuator, inlet guide vanes valve element
4 First compressor element 10 Oil cooler 16 Condensate trap, first
5 Drive motor 11 First intercooler intercooler
6 Demister, oil reservoir 12 Auxiliary oil pump
7 Oil reservoir 13 Cooling water inlet pipe
Fig. 1.2 Rear view
1 Blow-off valve 9 Water regulating valve, 15 Auxiliary oil pump

2 Third compressor element second intercooler circuit 16 Condensate trap, second
3 Gear casing 10 Thermostatic by-pass intercooler
4 Oil pump valve 17 Cooling water inlet
5 Positioner, inlet guide 11 Water regulating valve, 18 Cooling water outlet
vanes first intercooler circuit 19 Aftercooler
6 Inlet guide vanes 12 First intercooler 20 Water regulating valve,
7 First compressor element 13 Oil cooler aftercooler circuit
8 Second intercooler 14 Motor, auxiliary oil pump 21 Compressed air outlet
Fig. 1.3 Core
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1.2 Air flow
Air drawn through filters (1-Fig. 1.2) and inlet guide vanes (2-Fig. 1.2) is compressed in first
compressor element (4-Fig. 1.2) and discharged to first intercooler (11-Fig. 1.2). The cooled air is
further compressed in second compressor element (15-Fig. 1.2) and blown through second intercooler
(8-Fig. 1.3) towards the third compressor element (2-Fig. 1.3) where the air is compressed to its final
pressure. The compressed air leaving the third compressor element is cooled in aftercooler (14-Fig.
1.1) and is blown via check valve (13-Fig. 1.1) towards the air net.
1.3 Condensate drain system
Three moisture traps are installed, one downstream of the first intercooler (16-Fig. 1.2) to prevent
condensate from entering the second compressor element, one downstream of the second intercooler
(16-Fig. 1.3) to prevent condensate from entering the third compressor element and one downstream
of the aftercooler (15-Fig. 1.1) to prevent condensate from entering the air outlet pipe. Each trap is
provided with a float valve to automatically drain condensate and a manual drain valve.
1 Oil filler cap

2 Oil strainer
3 Oil level sight-glass
4 Oil drain valve
5 Oil heater
6 Oil reservoir
7 Inspection cover, oil reservoir
Fig. 1.4 Oil reservoir
1.4 Oil system
The system mainly includes:

- Oil reservoir (6-Fig. 1.4)
- Strainer (2-Fig. 1.4)
- Oil heater (5-Fig. 1.4)
- Oil demister (6-Fig. 1.2)
- Main oil pump (4-Fig. 1.3) driven by the main shaft
- Auxiliary oil pump (15-Fig. 1.3) driven by electric motor (14)
- Oil cooler (10-Fig. 1.2)
- Oil filter(s) (8-Fig. 1.2)
- Thermostatic valve (10-Fig. 1.3)
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During normal operation, oil is sucked up by the main oil pump from the reservoir through the strainer
and is supplied to all bearings and gears. The operation of the auxiliary oil pump is automatically
controlled by the Elektronikon regulator (see section 1.7.5) to ensure sufficient oil pressure during
start-up and shut-down, and also in case the oil supply pressure should become too low.
The heater will warm up the oil in the reservoir to the required minimum temperature. The heater is
automatically controlled by the Elektronikon regulator (see section 1.7.5).
The thermostatic valve mixes heated oil from the reservoir and cooled oil from the oil cooler to
maintain the temperature of the oil to the lubricating points as constant as possible.
At starting, the temperature of the oil in the gearbox and the oil pressure are checked by the
Elektronikon regulator. If the permissive start conditions are not fulfilled, the compressor will not start
(see section 3.3).
Oil fumes from the oil reservoir are sucked in by the oil demister and filtered inside the demister. Oil
droplets are drained back to the oil reservoir.
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Instruction book
(9)
(10) (11)
(20) (19)
(18)
(13)
(12)
(12)
(12)
(16)
(1)
(2)
(17)
(3)
(4)
(5)
(6)
(15) (7)
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Instruction book
100 Air filters 133 Manual condensate drain valve

101 Air inlet silencer 140 Oil reservoir
102 Joint 141 Oil strainer
103a Inlet guide vanes 142 Main oil pump
104 Flexible coupling 143 Drive coupling, main oil pump
103e Actuator, inlet guide vanes 145 Oil cooler
105 First compressor element 146 Thermostatic by-pass valve
106 Flexible coupling 147a Oil filter
108 First intercooler 147b Dual oil filter (optional)
109a Condensate trap, first intercooler 148 Auxiliary oil pump
109b Electronic condensate drain (optional) 149 Motor, auxiliary oil pump
110 Flexible coupling 150 Non-return valve
111 Second compressor element 152a Oil demister
112 Flexible coupling 152b Fan motor, oil demister
113 Second intercooler 153 Pressure control valve
114a Condensate trap, second intercooler 154 Oil reservoir heater
114b Electronic condensate drain (optional) 154a Oil reservoir heater (only for ZH9000-
115 Flexible coupling 15000)
116 Third compressor element 155 Oil drain valve
117 Flexible coupling 156 Non-return valve
118 Aftercooler 157 Flexible coupling
119a Condensate trap, aftercooler 158 Restriction
119b Electronic condensate drain (optional) 159 Manually operated valve
120 Check valve 160 Drive motor
121a/b Compensator 161 Drive coupling
122 Flexible coupling 172 Compensator
123a Blow-off valve 173 Compensator
123c Actuator, blow-off valve 174 Cooling water flow reverse valve (optional)
125 Silencer 175 Water shut-off valve (optional)
126 Condensate drain receiver 176 Water regulating valve, first intercooler
127 Manual condensate drain valve circuit
128 Non-return valve 177 Water regulating valve, second intercooler
129 Condensate drain receiver circuit
130 Manual condensate drain valve 178 Water regulating valve, aftercooler circuit
131 Non-return valve 191 Regulator
132 Condensate drain receiver
Transducers/Sensors/Timers/Positioners/Solenoid valve
ESHH91 Overload relay, drive motor PDT20 DP, element 2 pressure

ESHH94 Overload relay, auxiliary oil pump PDT46 Oil filter pressure drop
motor PT32 Outlet pressure, third compressor
ESHH152 Overload relay, oil demister motor element
ESHH153 Overload relay, oil heater PT39 Delivery air pressure
KSH02 Air filter lifetime PT49 Gearbox oil pressure
KSH41 Oil demister lifetime R96 Anti-condensation heater (optional)
KSH48 Oil filter lifetime T61 Transformer drive motor (customer
KSH49 Oil lifetime supply)
KSH93 Drive motor regreasing time TT18 Air inlet temperature, second
LSHL17 Condensate drain level, first intercooler compressor element
(automatic drain is optional) TT29 Inlet temperature, third compressor
LSHL28 Condensate drain level, second element
intercooler (automatic drain is optional) TT36 Aftercooler outlet temperature
LSHL34 Condensate drain level, aftercooler TT43 Oil reservoir temperature
(automatic drain is optional) TT44 Gearbox oil supply temperature
LI41 Oil reservoir level (indicator) TT51 Cooling water inlet temperature
LT42 Oil reservoir level (switch) TT60 Drive motor inlet temperature
PDT02 Air filter pressure drop TT95a Motor winding temperature U1-U2 (T1-
PDT19 DP, element 2 nozzle pressure T4) (optional)
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TT96a Motor winding temperature V1-V2 (T2- VP10 Vibration, first compressor element
T5) (optional) VP20 Vibration, second compressor element
TT97a Motor winding temperature W1-W2 (T3- VP30 Vibration, third compressor element
T6) (optional) Y2 Positioner, inlet guide vanes
TT98 Motor bearing temperature, drive end Y3 Positioner, blow-off valve
(optional) Y59 Solenoid valve, cooling water shut-off
TT99 Motor bearing temperature, non-drive (optional)
end (optional)
Fig. 1.5 Instrument and piping diagram
Text on Fig. 1.5
(1) Ventilation line

(2) Drain
(3) Air
(4) Oil
(5) Water
(6) Signal air
(7) Signal electrical
(8) Only with dual oil filter (optional)
(9) From transducers, transmitters, sensors
(10) Motor winding temperature protection (optional)
(11) Motor bearing temperature protection (optional)
(12) Only with electronic drain (optional)
(13) Only with anti-condensation heaters (optional)
(14) Atlas Copco installation
(15) Customer’s installation
(16) Water shut-off valve (optional)
(17) Cooling water flow reversing valve (optional)
(18) For compressors without starter, current transformer XA-SA to be supplied by customer
(19) Sleeve bearings only
(20) ZH9000-15000 only
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Instruction book
A Air inlet 4 First compressor 13 Oil demister

B Air element 14 Oil reservoir
C Air outlet 5 First intercooler 15 Oil reservoir heater
D Oil 6 Second compressor 16 Oil strainer
E Water inlet element 17 Main oil pump
F Water 7 Second intercooler 18 Auxiliary oil pump
G Water outlet 8 Third compressor 19 Non-return valve
H Condensate element 20 Oil cooler
1 Air filters 9 Aftercooler 21 Thermostatic by-pass
2 Air inlet silencer 10 Check valve valve
3 Inlet guide vanes 11 Blow-off valve 22 Oil filter
12 Silencer 23 Pressure control valve
Fig. 1.6 Air-oil-water flows
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1.5 Cooling system (Fig. 1.3)
A piping system is provided to supply the intercoolers (8 and 12), aftercooler (19) and oil cooler (13)
with cooling water.
Following flow regulating valves are provided:

- downstream of the first intercooler (11)
- downstream of the second intercooler (9)
- downstream of the aftercooler (20)
1.6 Electrical system
The system mainly includes:

- Electric cubicle (Fig. 1.9)
- Elektronikon regulator (Fig. 1.7) with control panel
- Pressure, temperature, vibration and oil level sensors (Fig. 1.5)
- Drive motor (5-Fig. 1.2)
- Motor for auxiliary oil pump (14-Fig. 1.3)
- Motor for fan of oil demister (1-Fig. 5.5)
- Oil heater (5-Fig. 1.4)
- Positioner, inlet guide vanes (5-Fig. 1.3)
- Positioner, blow-off valve (2-Fig. 1.1)
1.7 Elektronikon regulator
In general, the Elektronikon regulator has following functions:
- Controlling the capacity of the compressor

- Protecting the compressor
- Monitoring components subject to service
- Checking the start conditions
- Controlling the lubricating oil system
1.7.1 Controlling the capacity of the compressor
The system includes:

- Elektronikon regulator (Fig. 1.7)
- Inlet guide vanes (6-Fig. 1.3)
- Blow-off valve (3-Fig. 1.1)
The regulator continuously regulates the capacity of the compressor from maximum air capacity to a
minimum capacity by controlling the position of the inlet guide vanes and blow-off valve.
The compressors are as standard provided with the AUTO-DUAL control system. As an option, the
compressors may be provided with the constant pressure control system.
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Instruction book
AUTO-DUAL control system (standard)

The system is designed for applications with a large compressed air volume where the fluctuations in
air demand are generally within the throttle range capability of the compressor, combined with
occasional requirements for lower air flows.
The regulator will regulate the position of the inlet guide vanes (IGV) to match the air delivery to the air
consumption while maintaining the net pressure as close as possible to the programmed value (called
Regulation setpoint).
If the air consumption decreases causing the net pressure to exceed the programmed unloading
pressure, the inlet guide vanes (IGV) will close to their minimum open position while simultaneously
the blow-off valve (BOV) will be opened completely; the compressor runs unloaded.
If the net pressure drops below the programmed loading pressure, the inlet guide vanes (IGV) will be
completely opened while simultaneously the blow-off valve (BOV) will be fully closed. The Elektronikon
regulator will again regulate the position of the inlet guide vanes (IGV) as described above.
The regulator takes into account a number of programmable settings such as the unloading pressure,
loading pressure, minimum stop time and maximum number of motor starts.
The compressor is stopped when possible (depending on the setting of the maximum number of motor
starts) to reduce the power consumption. The compressor is restarted automatically when the net
pressure drops below the programmed loading pressure.
Idling time
This function is de-activated ex-factory. If the setting is modified (between 10 and 255 minutes), the
compressor will be stopped after running completely unloaded for the programmed time (idling time).
The compressor will automatically restart when the pressure decreases to the loading pressure. See
also section 8.1.
Constant pressure control system (option)

The constant pressure control system is designed to continuously control the air output while keeping
the net pressure fluctuations to a minimum.
The regulator will continuously regulate:

- the position of the inlet guide vanes (from 100 % open to a minimum open position)
- the position of the blow-off valve (from 100 % closed to a minimum closed position)
The air delivery will be matched to the air consumption while the net pressure is maintained as close
as possible to the programmed pressure setpoint.
The regulator takes into account a number of programmable settings such as the minimum stop time
and maximum number of motor starts.
In case the net pressure should rise to a programmed pressure, the compressor will be switched to
completely unloaded running.
Idling time
This function is de-activated ex-factory. If the setting is modified (between 10 and 255 minutes), the
compressor will be stopped after running completely unloaded for the programmed time (idling time).
The compressor will automatically restart when the pressure decreases to the loading pressure. See
also section 8.1.
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Instruction book
1.7.2 Protecting the compressor
1.7.2.1 Shut-down and shut-down warning
Several temperature, pressure, vibration and oil level sensors are provided on the compressor. They
are connected in the control circuit of the Elektronikon regulator.
Shut-down warning
The shut-down warning level is a programmable setting below the shut-down level. If an abnormal
operating condition arises, an alarm LED on the compressor control panel will light up to warn the
operator.
Check and remedy. See section 1.9.7.
Warning
Before starting any maintenance or repair, stop the compressor, switch off the voltage and
depressurize the compressor. Apply all relevant safety precautions, including those mentioned in
this book.
Shut-down
In case of a malfunction, the compressor is shut down and an alarm LED on the compressor control
panel will blink to warn the operator.
Switch off the voltage and remedy. See section 1.9.7.
1.7.2.2 Surge control
Surge is recognized by rapid, rhythmic fluctuations of the discharge pressure. In case of prolonged
unstable running, this operating condition may cause damage to the compressor. To prevent surging,
the regulator has a surge anticipation system.
The limit between stable and unstable operation is referred to as "surge line". To prevent the
compressor from entering the unstable operating range, a safety margin to this surge line must be
kept. This is called the “control line” and is set up during commissioning.
1.7.3 Monitoring components - service warning
The Elektronikon regulator continuously monitors critical components subject to service:

- motor grease
- oil
- oil filter
- oil demister
- coolers
- air filters
Each input is compared to the programmed limits. Exceeding these limits causes a message on the
control display to warn the operator.
Stop the compressor, replace the indicated component or take the necessary service action. Reset
the service timer. See section 1.9.17.
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Warning
Before starting any maintenance or repair, stop the compressor, switch off the voltage and
depressurize the compressor. Apply all relevant safety precautions, including those mentioned in
this book.
1.7.4 Checking the start conditions
At starting, the programmed permissive start conditions (such as the minimum temperature of the oil in
the gearbox and minimum oil pressure) are checked. If these conditions are not fulfilled, the
compressor will not start. See section 3.3.
1.7.5 Controlling the lubricating oil system
The Elektronikon regulator automatically controls the lubricating oil system, i.e.:
- Energize the oil heater (5-Fig. 1.4)

- Start and stop the auxiliary oil pump (15-Fig. 1.3)
When the compressor is not running and with the voltage switched on, the oil in the oil reservoir will be
kept at the correct temperature by switching on and off the oil heater, and the auxiliary oil pump will
periodically circulate the oil.
1.7.6 Start commands during minimum stop time
Minimum stop time

After stopping, the motor is prevented from restarting within a programmed time period, which is set
ex-factory at 240 seconds. A start command during this period is memorized and executed after
running out of this period.
1.7.7 Automatic restart after voltage failure
For compressors leaving the factory, this function is made inactive. If desired, the function can be
activated. Consult Atlas Copco.
Warning
- Automatic restarting after voltage failure is not allowed for medium-voltage motors.
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1.7.8 External compressor status indication
Auxiliary contacts are provided for external compressor status indication:
Indication Relay Terminals on strip 1X7 Max. load
Automatic operation K07 11-12 10 A / 230 V AC

Warning K08 13-14 10 A / 230 V AC
Shut-down K09 15-16 10 A / 230 V AC
Compressor loaded K11 17-18 5 A / 230 V AC
Compressor running K13 19-20 5.6 A / 230 V AC
Medium-voltage starter control K13 21-22 10A / 230 V AC
Start pulse signal K32 23-24 10A / 230 V AC
Stop pulse signal K33 25-26 10A / 230 V AC
Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas
Copco.
1.7.9 BUS connection system
As sales kit, a BUS connection system can be provided to enable the controller to communicate with a
plant monitoring system (through MODBUS or PROFIBUS connections). Consult Atlas Copco.
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Instruction book
1.8 Control panel
Fig. 1.7 Control panel, typical example
Ref. Designation Function
1 Start button Push button to start the compressor. LED (10) lights up
indicating that the Elektronikon regulator is operative.
2 Display Indicates messages concerning the compressor operating
condition, a service need or a fault.
3 Function keys Keys to control and program the compressor.
4 Scroll keys Keys to scroll upwards or downwards through the display.
5 Reset button (if provided) Button to reset the emergency stop.
6 Tabulator key Key to select the parameter indicated by a horizontal arrow.
Only the parameters followed by an arrow pointing to the
right are accessible for modifying.
7 Emergency stop button Push button to stop the compressor immediately in case of
emergency. After remedying the trouble, unlock the button
by pulling it out.
8 Voltage on LED Indicates that the voltage is switched on.
9 General alarm LED Is alight if a shut-down warning condition exists.
9 General alarm LED Blinks if a shut-down condition exists, if an important sensor
is out of order or after an emergency stop.
10 Automatic operation LED Indicates that the regulator is automatically controlling the
compressor.
11 Stop button Push button to stop the compressor. LED (10) goes out.
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Instruction book
1.8.1 Display (2-Fig. 1.7)
The display has four lines of 40 characters. A typical display is shown in Fig. 1.8. It indicates:
On the first three lines:

- the name of the sensor and the actual reading
- the percentage of open position of inlet guide vanes (IGV)
- the percentage of closed position of blow-off valve (BOV)
- messages regarding the compressor operating condition (e.g. Automatically Loaded), a service
need or a fault
On the fourth line, just above the three function keys (F1/F2/F3), the actual functions of these keys.
Compressor outlet 10.4 bar

IGV % open 85 BOV % closed 100
Automatically Loaded
Menu Unload
F1 F2 F3
Fig. 1.8 Main screen, typical example
1.8.2 Function keys (3-Fig. 1.7)
The keys are used:

- to manually load and unload the compressor
- to call up or program settings
- to reset an active motor overload, shut-down or service message, or an emergency stop
- to have access to all data collected by the regulator
The functions of the keys vary depending on the displayed menu. The actual function is indicated on
the bottom line of the display just above the relevant key.
The most common functions are listed below:
Designation Function
Back To return to a previously shown option or menu

Cancel To cancel a programmed setting when programming parameters
Delete To delete compressor start/stop commands
Extra To find information regarding the installed modules
Help To find the Atlas Copco internet address
Limits To show the limits for a programmable setting
Load To load the compressor manually
Mainscreen To return from a menu to the main screen (Fig. 1.8)
Menu Starting from the main screen (Fig. 1.8): to have access to submenus
Menu Starting from a submenu: to return to a previous menu
Modify To modify programmable settings
Program To program modified settings
Reset To reset a timer or message
Return To return to a previously shown option or menu
Unload To unload the compressor manually
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1.8.3 Scroll keys (4-Fig. 1.7)
The keys allow the operator to scroll through the display.
As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll
key with the same symbol can be used to see the next item.
As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll
key with the same symbol can be used to see the previous item.
1.8.4 Emergency stop button (7-Fig. 1.7)
In case of emergency, press the button to stop the compressor immediately.
Warning
- Before starting any maintenance or repairs, wait until the compressor has stopped and open
the isolating switch (customer's installation) to switch off the voltage to the compressor.
- Close the air outlet valve and open the manual condensate drain valves to depressurize the
air system.
Apply all relevant safety precautions, including those mentioned in this book.
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B61 Current transmitter, drive motor current K25 Contactor, auxiliary oil pump motor M25
B63 Current transmitter, inlet and blow-off K27 Contactor, oil demister fan motor M27
valve positioner K29 Contactor, oil heater R29
F0/1 Fuses, control circuit K31 Time relay, water shut-off delay
F3/4/5 Circuit breakers, control circuit T1 Main transformer
F10/17/28/34 Circuit breakers, control circuit T2 Transformer 115-230 / 24V
F11/12/13 Fuses, 3-phase low-voltage supply U1 Power supply, 24V DC
F25 Overload relay, auxiliary oil pump motor VT10/20/30 Vibration transmitters,
M25 compressor elements
F27 Overload relay, oil demister fan motor 1X0 Terminal strip, supply
M27 1X3 Earth bolt, earth terminals
F29 Overload relay, oil heater R29 1X4 Terminal strip, 115V/230V AC
K10 Auxiliary relay, overload oil demister 1X5 Terminal strip, 24V AC
M27 1X6 Terminal strip, 24V DC
K11 Auxiliary relay, load/unload 1X7 Terminal strip, voltage-free contacts
K13 Auxiliary relay for drive motor starter
Fig. 1.9 Electric cubicle, without starter (typical example)
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1.9 Menu-driven control programs
In order to facilitate programming and controlling, menu-driven control programs have been
implemented in the regulator.
A simplified menu flow is shown in Fig. 1.11.
1.9.1 Function of control programs
Program/Function Description
Main screen Shows in short the operation status of the compressor. Is the gateway to all
functions.
Status data Calling up the status of the compressor protection functions:
- shut-down
- shut-down warning
- service warning - warning
Resetting of a shut-down, motor overload and service condition.
Measured data Calling up:
- actually measured data
- the status of a number of inputs
Counters Calling up the running hours, loaded hours, module hours and number of motor
starts.
Test Allows a display test.
Modify parameters Modifying the parameters for:
- parameters: loading and unloading pressures
- protections: compressor outlet pressure, air filter pressure drop, .... (see Fig.
1.11)
- service plans: timers for service plans
- clock functions: automatic compressor start/stop/pressure setting commands
- configuration: time, date, display language, …
Service Calling up service plans and resetting the timers after carrying out the service
actions belonging to a plan. See section 4.
Saved data Calling up the saved data: last shut-down, last emergency stop data and last
surge data.
Unload/Load To manually load and unload the compressor.
1.9.2 Main screen
When the voltage is switched on, the Main screen is shown automatically, showing in short the
operation status of the compressor.

Automatically Loaded
Menu Unload
F1 F2 F3
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Fig. 1.11 Menu flow (simplified)
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1.9.3 Calling up other menus
Starting from the Main screen:
- Use the ↓ key (4) for a quick look at the actual status of the compressor (see section 1.9.4)
- Press the key Menu (F1). The option Status data will be followed by a horizontal arrow:
- either press the tabulator key (6) to select the Status data submenu
- or use scroll keys (4) to scroll until the desired submenu is followed by a horizontal arrow and
then press tabulator key (6) to select it
1.9.4 Quick look at actual compressor status
Procedure
1. Starting from the Main screen (see section 1.9.2), press the ↓ key: A screen similar to the one
below appears:
Automatic Operation
Local Control
The Week Timer is not Active ↓
Mainscreen Help Extra
F1 F2 F3
Fig. 1.12 Example of an actual compressor status display
Line 1 indicates the automatic or manual operation status of the regulator:
<<Automatic operation>> means that the regulator automatically adapts the operation of the
compressor, i.e. matching the compressor output to the air consumption.
Line 2 indicates whether the regulator operates in local control, remote control or LAN control mode:
<<Local control>> means that the start/stop buttons on the keyboard are activated.
<<Remote control>> means that these functions are controlled remotely. Consult Atlas Copco.
<<LAN control>> means that the compressor can be controlled by an ES controller.
Line 3 indicates whether the timer, which generates time-based start and stop commands, is activated
or not. See section 1.9.15.
See section 1.8.2 for the functions of keys Mainscreen, Help and Extra.
2. Press the ↓ key to get other data (actual compressor conditions of the compressor) as shown in
Fig. 1.11.
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1.9.5 Returning to the Main screen or other menus
Whenever displayed on the bottom line of a submenu, press the key Menu (F1) to return to a previous
menu.
Whenever displayed, press the key Mainscreen to return the Main screen (Fig. 1.10).
1.9.6 Main screen menu
Function
The Main screen shows in short the compressor operation status and is the gateway to all functions
implemented in the regulator.
If the function keys or arrow keys are not used for about 4 minutes, the regulator will automatically
return to the Main screen.
Exception is made when the screen is left untouched when modifying data in the regulator. In this
case, the screen will remain unchanged, since the regulator does not take a decision whether to
accept or refuse the new data.
1.9.6.1 Procedure
The main screen is shown automatically when the voltage is switched on.

Automatically Loaded ↓
Menu Unload
F1 F2 F3
The menu shows:

- the compressor outlet pressure
- the compressor operation status
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1.9.7 Status data menu
Function
The Status data submenu gives information regarding the status of the compressor protection
functions (shut-down, shut-down warning, service warning and warning) and allows resetting of a shut-
down, motor overload and service condition.
1.9.7.1 Procedure
Starting from the Main screen (see section 1.9.6):

- Press key Menu (F1): the option Status data will be followed by a horizontal arrow. Following
screen appears:
Status Data →
Measured Data
Counters ↓
Mainscreen
F1 F2 F3
Fig. 1.14 Example of a menu
No shut-down warning message or shut-down message exists
General alarm LED (9) is out.
After pressing tabulator key (6), a message will appear indicating that all conditions are normal:
All Conditions are OK
Menu Help
F1 F2 F3
Fig. 1.15 Status data screen, typical example
A shut-down message exists
LED (9) blinks and a shut-down message indicating the cause automatically appears on the display if
the compressor is shut down.
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Example of the indication in case of a shut-down:
Oil 1.9 bar
Shutdown Minimum 2.0 bar ↓

Menu *** *** Reset
F1 F2 F3
Fig. 1.16 Shut-down screen, typical example
1. The indicators (***) are blinking. The screen shows the sensor (Oil), the actual reading (1.9 bar),
that the compressor is shut down (Shutdown) and the shut-down setting (2.0 bar).
2. It remains possible to scroll through other menus, e.g. to check the values of other parameters.
When returning to the Status data menu, the option Shutdowns will blink. This option can be
selected by pressing the tabulator key (6) to return to the shut-down screen (Fig. 1.16).
Shut-down reset
1. Switch off the voltage and remedy the trouble. After remedying, switch on the voltage and press
the key Reset (F3).
2. Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor by
means of button I.
A shut-down warning message exists
A shut-down warning level is a programmable level below the shut-down level.
1. If a shut-down warning exists, LED (9) is alight. The Main screen will change into a screen similar
to the one below:

**** Shutdown warning **** ↓
Menu *** ***
F1 F2 F3
Fig. 1.17 Shut-down warning on Main screen, typical example
2. The message *Shutdown Warning* appears.

3. Press the key Menu (F1) and the tabulator key (6) to select the Status data menu, the option
Protection is blinking.
4. Scroll to this option and select it by pressing the tabulator key (6): option Warnings blinks; scroll to
this option and select it by pressing the tabulator key (6). A screen similar to the one in Fig. 1.18
appears:
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Oil 2.5 bar
Shutd Warn Minimum 2.6 bar ↓

Menu *** ***
F1 F2 F3
Fig. 1.18 Shut-down warning screen, typical example
The screen indicates that the gearbox oil pressure has dropped below the programmed shut-down
warning level.
5. The warning message will disappear automatically as soon as the warning condition disappears.
6. Remedy the trouble.
Warning
- Before starting any maintenance or repairs, press stop button (11), wait until the compressor
has stopped, press emergency stop button (7) and open the isolating switch (customer's
installation) to switch off the voltage to the compressor.
- Close the air outlet valve and depressurize the air system.
A service warning message exists
1. LED (9) is alight and the main screen will change into a screen similar to that shown in Fig. 1.19.

* Service Required * ↓
Menu *** ***
F1 F2 F3
Fig. 1.19 Example of a warning screen
2. The indicators (***) are blinking and the service warning message appears.
3. Press the key Menu (F1) and the tabulator key (6) to select the Status data menu: the option
Service is blinking.
4. Scroll to this option and select it by pressing the tabulator key (6); two options may blink:
<<Inputs>>: if the programmed service level of a component is exceeded (e.g. the maximum
pressure drop of the air filter).
<<Plan>>: if a service plan interval is exceeded.
5. Stop the compressor and switch off the voltage.
6. In case the service message was referring to <<Inputs>> (air filter): replace the filter, switch on the
voltage, scroll in the Status data menu to <<Inputs>> and press the Reset key (F3) to reset the
service message.
7. In case the service message was referring to <<Plan>>: carry out the service actions related to
the indicated plans. Reset the timers of the related plans as described in section 1.9.17.
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1.9.8 Measured data menu
Function
To call up information regarding the actually measured data and the status of a number of inputs, such
as the motor overload protection. See Fig. 1.11.
1.9.8.1 Procedure
1. Starting from the Main screen (see section 1.9.6):

- press key Menu (F1)
- press the ↓ key until the option Measured data is followed by a horizontal arrow
- activate the menu by pressing the tabulator key (6); a screen similar to the one in Fig. 1.20
appears.
Gearbox oil pressure 1.7 bar →

Dp Air filter -0.043 bar
Dp Oil filter 0.9 bar ↓
Menu Extra
F1 F2 F3
Fig. 1.20 Measured data display, typical example
2. By pressing the ↓ key, a number of actually measured data can be found (see Fig. 1.11).
3. If one of the sensors is linked to a shut-down, service or warning function, both the actually
measured value as well as the corresponding shut-down, warning or service level can be called up
by pressing the tabulator key (6).
1.9.9 Counters menu
Function
To allow the operator to call up the:

- running hours
- loaded hours
- number of motor starts
- regulator (module) hours (the hours the module has been under tension)
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1.9.9.1 Procedure

- press key Menu (F1)
- press ↓ key until the option Counters is followed by a horizontal arrow
- activate the menu by pressing the tabulator key (6); a screen similar to the one in Fig. 1.21
appears.
Running hours 1016 hrs

Loaded hours 980 hrs
Motor starts 945 ↓
Menu Change
F1 F2 F3
Fig. 1.21 Counters display, typical example
The display indicates that:

- the compressor has been in running condition for 1016 hours
- the compressor has been in loaded condition for 980 hours
- there have been 945 motor starts
2. By pressing the ↓ key, the item Module hours can be found (see also Fig. 1.11).
1.9.10 Test menu
Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.
Procedure
- press the key Menu (F1)
- press the ↓ key until the option Test is followed by a horizontal arrow
- press the tabulator key (6) to activate the menu
2. The option Display test will be followed by a horizontal arrow.
3. After pressing the tabulator key (6), the regulator will generate a series of patterns on the display,
which enable the operator to check that each pixel still functions normally; at the same time the
LEDs are lit.
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1.9.11 Modify parameters menu
Function
The menu allows the operator to program:
- Parameters
- Protections
- Service Plan
- Clock Function
- Configuration
1.9.12 Modifying parameters
Function
To modify a number of settings as mentioned in Fig. 1.11.
1.9.12.1 Procedure

- press the ↓ key until the option Modify parameters is followed by an horizontal arrow
2. The first option (Parameters) will be followed by a horizontal arrow.
3. Press the tabulator key (6): the first item (Pressure setpoint 1) and its setting will appear.
Pressure setpoint 1 10.4 bar ┤

Reg. Load Level Offset 1 0.6 bar
Reg. Unload Level Offset 1 0.6 bar ↓
Menu Modify
F1 F2 F3
Fig. 1.22 Modify parameters screen, typical example
4. Use the ↓ key to scroll until the parameter to be modified is followed by symbol ┤ on the screen.
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1.9.12.2 Modifying the pressure setpoint
If desired, the operator can program two pressure settings (Pressure setpoint1, Reg. Load level
Offset1, Reg. Unload Level Offset1, Pressure setpoint2, Reg. Load level Offset2 and Reg. Unload
Level Offset2).
1. Consult the steps above to select <<Pressure setpoint 1>>.

2. The screen shows that the current setting is 10.4 bar(e). To modify this setting, press the key
Modify (F2); the setting will blink.
3. Use the ↓ or ↑ key to change the value. The key Limits (F2) can be used to find out the limitations
for the parameter.
4. Press the key Program (F1) to program the new setting or the key Cancel (F3) to cancel the
modification operation.
5. If required, the procedure to modify <<Reg. Load Level Offset1>> or << Reg. Unload Level
Offset1>> is similar to the description above.
1.9.13 Modifying protections
Function
1. To modify protection settings:
- shut-down (<<Shutdown>>), e.g. for element outlet temperature
- shut-down warning (<<Shutdown warning>>), e.g. for element outlet temperature
- warning (<<Permissive start>>), e.g. gearbox oil pressure
- service warning (<<Service>>), e.g. Dp air filter (max. pressure drop)
2. To check some compressor conditions, e.g. the status of the emergency stop button. The list of
parameters is shown in Figs. 1.11.
Note
Some parameters cannot be modified.
1.9.13.1 Procedure

- press the ↓ key until the option Modify parameters is followed by a horizontal arrow
2. Use the ↓ key to scroll until the option Protections is followed by a horizontal arrow.
3. Press the tabulator key (6): the first item (e.g. Gearbox oil pressure) and its value will appear.
4. Use the ↓ key to scroll until the parameter to be modified is followed by a horizontal arrow and
press tabulator key (6).
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1.9.13.2 Modifying shut-down/warning settings for the gearbox oil pressure
1. Consult the section above to select the parameter Gearbox oil pressure:
Gearbox oil pressure 1.2 bar

→
Shutdown Minimum 1.0 bar
Back Modify
F1 F2 F3
2. The screen shows that the pressure is 1.2 bar and that the shut-down setting is 1.0 bar. To
modify this setting, press the key Modify (F2):
Shutdown Minimum 1.0 bar

Program Limits Cancel
F1 F2 F3
3. Use the ↓ or ↑ key to change the value. The key Limits (F2) can be used to find out the limitations
for the parameter.
4. Press the key Program (F1) to program the new setting or the key Cancel (F3) to cancel the
modification operation.
5. The screen shown in Fig. 1.23 shows an arrow pointing to the right to call up the screen to modify
the shut-down warning value:
Shutd. Warn. Minimum 1.6 bar

Back Modify
F1 F2 F3
Fig. 1.25 Shut-down warning screen, typical example
6. The screen shows that the current pressure is 1.2 bar and that the shut-down warning setting is
1.6 bar. The modifying procedure is similar to the description above.
Note:
The modifying procedure for other settings is similar. For some settings, a delay can be programmed.
See section 8.
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1.9.14 Modifying service plans
Function
To modify the hour intervals for the Service levels.
Service plans
The service operations to be carried out are grouped in plans called Service level A, C or E. When
reaching an interval, a message will appear on the screen indicating which Service plans are to be
carried out.
Important
Always consult Atlas Copco in case any timer setting should be changed. The intervals must not
exceed the programmed nominal values.
1.9.15 Programming Clock function
To program:
- time-based start/stop commands for the compressor
- time-based change-over commands for the net pressure settings (see also section 1.9.16)
1.9.15.1 Programming start/stop/pressure settings commands
In this example, the compressor will be programmed as follows:

- On Monday at 06:15 starting in pressure settings 1
- On Friday at 18:00 changing over to pressure settings 2
- On Saturday at 18:00 stopping

2. Use the ↓ key to scroll until the option Clock function is followed by a horizontal arrow. Press the
tabulator key (6); following screen appears:
Clock Function
Not activated →
Menu Modify Delete

F1 F2 F3
Fig. 1.26 Clock function screen, typical example
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3. Press the tabulator key (6); following screen appears:
Monday →
Tuesday
Wednesday ↓
Menu Delete
F1 F2 F3
Fig. 1.27 Week timer screen, typical example
4. Use the ↓ or ↑ keys until the day on which a command must be programmed is followed by a right
pointing arrow. Press the tabulator key (6); following screen appears:
--:-- -------------------------------------- ┤
--:-- --------------------------------------
--:-- -------------------------------------- ↓
Menu Modify Delete
F1 F2 F3
Fig. 1.28 Modifying screen (Week timer), typical example
5. Press the key Modify (F2). The first two digits will flash. Use the ↑ or ↓ key to enter <<06>>.
Press the tabulator key to jump to the following two dashes. Use the ↑ or ↓ key to enter <<15>>.
Press the tabulator key to jump to the row of dashes. Use the ↑ or ↓ key to enter the command
Start Compressor. Press the key Program to program the command: 06:15 Start Compressor.
6. Press the ↓ key: the symbol ┤ indicates that the second line is accessible. Press the key Modify
and modify this line in a similar way to the following command line: 06:15 Pressure settings 1.
7. Press the key Menu (F1) and scroll to <<Friday>>:
Thursday ↑
Friday →
Saturday ↓
Menu Delete
F1 F2 F3
8. Programming the command to change over to Pressure settings 2 at 18 o’clock is carried out in a
similar way as described above.
9. Press the key Menu (F1) and scroll to <<Saturday>>. Programming the command to Compressor
Stop at 18 o’clock is carried out in a similar way as described above.
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1.9.15.2 To activate/deactivate the timer

Clock Function
Not activated →
Menu Modify Delete

F1 F2 F3
3. Press the key Modify, <<Not activated>> starts blinking.

4. Press the ↓ key, <<Not activated>> changes into <<Activated>>.
5. Press the key Program.
Important:
1. It is necessary to program the start/stop/pressure settings commands in successive order time
wise, e.g.:
07.30 start
07.30 pressure settings 1
08.30 pressure settings 2
17.00 stop
etc.
2. Make sure that the clock function is activated (indicated as <<Activated>>). If not, the
programmed start/stop commands will not be executed.
1.9.15.3 To modify a command
Suppose the command to stop the compressor on Saturday 18:00 is to be modified: stopping at 17
o'clock instead of 18 o'clock:
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Clock Function
Not activated →
Menu Modify Delete

F1 F2 F3
Monday →
Tuesday
Wednesday ↓
Menu Delete
F1 F2 F3
4. Scroll through the display until <<Saturday>> is followed by a horizontal arrow. Press the
tabulator key (6). If necessary, scroll through the compressor start/stop/pressure setting
commands until the command to be modified is followed by symbol ┤ on the screen. Press the
key Modify, the first two digits of the command start blinking. Modify as required using the scroll
keys, i.e. in the example above change <<18>> into <<17>> using the ↓ key.
5. If necessary, press the tabulator key (6) to go to the next field to be modified, the minutes
indication and the start/stop/pressure setting indication.
6. Press the key Program to program the new command or the key Cancel to quit without
reprogramming.
1.9.15.4 To add a command
Adding a command at the end of an existing list

Clock Function
Not activated →
Menu Modify Delete

F1 F2 F3
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Suppose the command to stop the compressor at 18:00 must be added to the list of Monday:
- 06:15 start
- 06:15 pressure settings 1
Monday →
Tuesday
Wednesday ↓
Menu Delete
F1 F2 F3
4. Scroll through the display until <<Monday>> is followed by a horizontal arrow. Press the tabulator
key (6). Scroll through the compressor start/stop/pressure setting commands until the first empty
command line is indicated by symbol ┤ on the screen.
5. Press the key Modify; the first two digits of the command start blinking. Enter <<18:00 stop>>
using the scroll keys ↓ or ↑ to modify a field and the tabulator key (6) to jump from one field to
another.
6. Press the key Program to program the new command or the key Cancel to quit without
reprogramming.
Adding a command between two existing commands

1. Suppose the command 17:00 pressure settings 2 must be added to following list:
- 06:00 start
- 06:00 pressure settings 1
- 18:00 stop
2. The regulator does not allow to enter a new command which is situated before the last command
in the list time wise.
3. Scroll through the display until the command before which the new command must be entered is
followed by symbol ┤ (in the example above: 18:00 stop) and press the key Modify. Change this
command to the new command (in the example above: 17:00 pressure settings 2) and press the
key Program. Press the ↓ key, add the last command of the list (in the example above: 18:00
stop) and press the key Program.
1.9.15.5 To delete a command

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Clock Function
Not activated →
Menu Modify Delete

F1 F2 F3
Deleting all commands

Press the key Delete (F3) in the screen above. A question to confirm the deleting operation will
appear.
Deleting all commands related to a specific day

Scroll through the display until the desired day is followed by a horizontal arrow. Press the key Delete
(F3). A question to confirm the deleting operation will appear.
Deleting a specific start/stop/pressure settings command

Scroll through the display until the command line to be deleted is followed by symbol ┤. Press the key
Delete (F3). A question to confirm the deleting operation will appear.
1.9.16 Configuration menu
Function
To reprogram a number of parameters. See Fig. 1.11.
Procedure
2. Use the ↓ key to scroll until the option Configuration is followed by a horizontal arrow.
3. Press the tabulator key (6): The first option shown is Time. If another option is desired, scroll
through the display (using ↓ or ↑ keys) until the option is followed by symbol ┤ on the screen.
4. In case of option Time, the screen indicates the actual setting, e.g. 11:12.
5. If it is desired to modify the time, press key Modify. If not, press key Menu to return to the
submenu.
6. After pressing the key Modify, the first field (i.e. 11) will blink. Modify the hours using the ↓ or ↑
keys. Then press the tabulator key (6) to go to the next field (i.e. 12). The setting of this field can
now be modified with the ↓ or ↑ keys.
7. The bottom line of the display will show two options:
- Program to program the new setting
- Cancel to cancel the new setting
8. Proceed in a similar way for the other parameters to be modified.
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1.9.16.1 Programming compressor control modes
Compressor control modes

The compressor can be controlled locally, remotely or via a local area network (LAN - consult Atlas
Copco).
Procedure
2. Use the ↓ key to scroll until the option Configuration is followed by a horizontal arrow.
3. Press the tabulator key (6): The first option shown is Time. Scroll through the display (using ↓ or ↑
keys) until the option Central Control Mode is followed by symbol ┤ and press the key Modify.
Following screen is shown:
Central Control Mode Local Control
Program Cancel
F1 F2 F3
Fig. 1.36 Central control mode menu, typical example
4. <<Local Control>> is blinking; use the ↓ or ↑ keys to select the desired control mode. Press the
Program key to program or the Cancel key to cancel the modification.
1.9.17 Service menu
Function
- To reset the service plans which are carried out.
- To check for the next service plans to be carried out.
- To find out which service plans were carried out previously.
Service plans
- Contact your Atlas Copco customer centre for the service actions related to these plans.
- Consult section 1.9.14 if any modification to the intervals should be required.
When the service plan interval is reached, a message will appear on the screen. See section 1.9.7.
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Example
Programmed service plan intervals ex-factory:
Service plans Intervals

Service plan A Every 2000 running hours
Service plan C Every 8000 running hours
Service plan E Every 24000 running hours
Resulting service actions to be carried out:
Service actions according to At

Service plan A 2000 running hours
Service plan A and C 8000 running hours
Service plan A, C and E 24000 running hours
… …
Procedure
- press the ↓ key until the option Service is followed by a horizontal arrow
2. A screen similar to the one below appears:
Service Timer
Running Hours →
7971 hrs ↓
Menu
F1 F2 F3
Fig. 1.37 Service menu, typical example
The screen shows that the total compressor running time is 7971 hrs.
3. Press the tabulator key (6):
Next Timer
Level AC
8000 hrs ↓
Back Reset
F1 F2 F3
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The screen shows that the next service plans to be carried out are plans A and C and that these plans
are to be carried out every 8000 running hours.
4. Press the ↓ key to find out which service plans were carried out previously:
Previous Timer ↑
Level A
2008 hrs
Back
F1 F2 F3
The screen shows that service plan A was carried out at 2008 running hours.
5. Stop the compressor, switch off the voltage and carry out the service operations related to plans A
and C.
6. Switch on the voltage and scroll to the service screen shown in Fig. 1.38. Press the Reset button
(F3) to reset the timer. Confirm the question for resetting.
Notes
- The Reset button only appears when the Next Timer level is almost reached before elapsing
of the service plan interval.
- After pressing the ↓ key in Fig. 1.37, the Lifetime hours are shown (i.e. the number of hours
elapsed since initial programming ex-factory). This counter is not taken into account.
1.9.18 Saved data menu
Function
To call up some compressor data saved by the regulator. These data are:
- Last shut-down data
- Surge data
Procedure
- press the ↓ key until the option Saved data is followed by a horizontal arrow
2. The first option Shutdown data is followed by a horizontal arrow.
3. Press the tabulator key (6), the first item is shown (<<Last shutdown 1>>).
3. Press the tabulator key (6) to find out the date, time and other data reflecting the status of the
compressor at the last shut-down.
4. If desired, scroll through the other items.
2920 1498 00 43
Instruction book
2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 and 2.2)

(6)
(9)
(1) (4) (7)
(5) (8)
(10)
(2)
(3)
(32)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(22) (23) (24)
(20)
(21)
(22) (23) (24)
9823 2462 00/2

52962D
Fig. 2.1 Dimension drawing, compressor with bodywork
2920 1498 00 44
Instruction book
(25)
(26)
(27)
(28)
(29)
(31)
(30)
(22) (23) (24)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(22) (23) (24) (18)
(19)
(20)
9823 2462 00/2

52963D
Fig. 2.2 Dimension drawing, compressor without bodywork
2920 1498 00 45
Instruction book
Text on Figs 2.1 and 2.2
(1) Compressed air outlet

(2) Cooling water outlet
(3) Cooling water inlet
(4) Motor cooling air inlet for closed motor (IP55)
(5) Motor cooling air outlet for open motor (IP23)
(6) Motor cooling air outlet for closed motor (IP55)
(7) Motor cooling air inlet for open motor (IP23)
(8) Blow-off out
(9) Compressor air inlet
(10) For hot air only
(11) Condensate drains
(12) Automatic drain, blow-off silencer
(13) Manual drain, aftercooler, G ½"
(14) Automatic drain, aftercooler, G ½"
(15) Manual drain, intercooler, 2 G ½"
(16) Automatic drain, intercooler, 2 G ½"
(17) Manual drain, intercooler, 1 G ½"
(18) Automatic drain, intercooler, 1 G ½"
(19) Not for two-stage standard and three-stage hot air
(20) Not for two-stage hot air
(21) Air and water connections
(22) Compressed air outlet, three-stage
(23) Compressed air outlet, two-stage
(24) Water inlet and outlet
(25) Free space in canopy
(26) Cubicle
(27) For 10 kV motors only
(28) Main terminal box connection
(29) Ventilation, standard motors
(30) Open motor 1RA3 (IP23)
(31) Closed motor 1LA4 (IP55)
(32) With Elektronikon regulation (MK IV)
2920 1498 00 46
Instruction book
2.2 Installation proposal (Fig. 2.3)
(1)
(2)
(1)
(2)
(3)
(4)
(5) (6)
(7) (8)
9823 2494 00
52421D
(9)
Fig. 2.3 Installation proposal (typical example)
2920 1498 00 47
Instruction book
Text on Fig. 2.3
(1) Totally open zone

(2) Minimum free area
(3) Minimum corridor width
(4) Ventilation proposals
(5) Motor side
(6) Compressor side
(7) Closed motor IP55
(8) Open motor IP23
(9) No canopy
Ref. Description
1. Install the compressor on a level floor suitable for taking the weight of the compressor.
Recommended minimum distance between the top of the compressor and the ceiling is 150 cm for
ventilation and lifting.
2. Remove the cover from the air outlet pipe of the compressor and install the compressed air outlet
valve. The valve must be provided locally. Connect the valve to the air net. See also section
2.3 for alignment tolerances.
3. The pressure drop over the delivery pipe can be calculated as follows:
dp = (L x 450 x Qc1.85) / (d5 x P)
dp = pressure drop (recommended maximum = 0.1 bar)

L = length of delivery pipe in m
d = inner diameter of the delivery pipe in mm
P = absolute pressure at the compressor outlet in bar(a)
Qc = free air delivery of the compressor in l/s
4. The inlet grids and ventilation fan should be installed in such a way that any recirculation of
cooling air to the compressor is avoided. The air velocity through the grids should be limited to 5
m/s.
Consult section 7.4.2 for the compressor limitations.
The required ventilation capacity to limit the compressor room temperature can be calculated as
follows:
Qv = 0.1 N / dT
Qv = required ventilation capacity in m3/s

N = shaft input of the compressor in kW
dT = temperature rise over ambient in °C
5. Fit the manual condensate drain valves (5, 7 and 9-Fig. 3.1). Lay out the drain piping towards the
condensate collector. The drain pipes must not dip into the water of the collector. It is strongly
recommended to provide a funnel for each drain pipe to allow visual inspection of the condensate
flow.
6. Position of the control panel.
7a. Position of the medium voltage cable entry. Check that the electrical connections correspond to
the local codes. The installation must be earthed and protected against short circuits by fuses in
all phases. An isolating switch must be installed near the compressor.
7b. Position of the low-voltage cable entry.
2920 1498 00 48
Instruction book
8. Position of the condensate drain valves.
9. Remove the covers from the water inlet and outlet pipes. Install a water inlet and outlet valve, as
well as drain valves. The valves must be provided locally. It is recommended to provide a
strainer in the water inlet for filtering particles larger than 0.1 mm. The strainers have to be
suitable for the cooling water flow. It is also recommended to install a 1” nipple in the water inlet
and outlet pipes. Connect the inlet and outlet valves to the water net. See also section 2.3 for
alignment tolerances.
(1) (2)
(3)
(8)
(4)
(9)
(10)
(5) (6) (7)
9823 1514 51
52960D
F0/1 Fuses, control circuit F27 Overload relay, oil demister fan motor
F6 Undervoltage relay (customer's M27
installation) F29 Overload relay, oil heater R29
F11/12/13 Fuses, low-voltage supply F29a Overload relay, oil heater R29a (only for
F21 Overload relay, drive motor (customer's ZH9000/15000)
installation) K13 Auxiliary relay, motor starter control
F25 Overload relay, auxiliary oil pump motor K21 Starter, drive motor (customer's
M25 installation)
2920 1498 00 49
Instruction book
K25 Contactor, auxiliary oil pump motor M25 TT95b Spare, motor winding temperature U1-
K27 Contactor, oil demister fan motor M27 U2 (T1-T4) (optional)
K29 Contactor, oil heater R29 TT96a Motor winding temperature V1-V2 (T2-
L1/2/3Terminals, 3-phase low-voltage supply T5) (optional)
M1 Drive motor TT96b Spare, motor winding temperature V1-
M25 Motor, auxiliary oil pump V2 (T2-T5) (optional)
M27 Fan motor, oil demister TT97a Motor winding temperature W1-W2 (T3-
R29 Oil reservoir heater T6) (optional)
R29a Oil reservoir heater (only for TT97b Spare, motor winding temperature W1-
ZH9000/15000) W2 (T3-T6) (optional)
R96 Anti-condensation heater (optional) TT98 Motor bearing temperature, drive end
T1 Main transformer (optional)
T61 Motor current transformer/transmitter 4- TT99 Motor bearing temperature, non-drive
20mA (customer's installation) end (optional)
TT95a Motor winding temperature U1-U2 (T1- 1X0 Terminal strip, supply
T4) (optional) 1X3 Earth bolt, earth terminals
Fig. 2.4 Voltage supply connections, compressors without starter
Text on Fig. 2.4
(1) Customer's installation, medium-voltage supply

(2) Customer's installation, low-voltage supply
(3) Control voltage
(4) Compressor motor
(5) PT100 Protection in bearings (option)
(6) PT100 Protection in windings (option)
(7) Motor heater (option)
(8) To be installed by the customer
(9) PT100 motor windings
(10) PT100 motor bearings
2920 1498 00 50
Instruction book
2.3 Mounting of outlet piping
Atlas Copco ZH6000-10000 compressors with aftercooler are equipped with rubber compensators on
the air and water connections. These compensators can cope with some minor misalignment (Fig. 2.5)
when the customer pipe end is mounted. The allowable alignment tolerances for the different
compensators are listed in the table below. See section 2.3.1.
The piping system at customer side must be designed to fulfill the stated tolerances (both static and
during operation).
The compensators that are used are not suitable to carry the pressure thrust load. Make sure to
adequately support and anchor the piping system.
The compensator must not carry the weight of the customer pipe. Adequate supporting of the piping
system shall be provided to avoid weight load on the compensator.
For the design of piping and supporting structures, use an approved standard code (e.g. EN 13480 or
ASME 16.5/B31.3).
2.3.1 Rubber compensator types
EL (mm) minimum EL (mm) maximum

Compensator part number Diameter (in)
(Fig. 2.5) (Fig. 2.5)
DIN
1621 3098 00 3 115 140
1621 8073 00 6 115 140
ANSI
1621 8114 00 3 115 140
1621 8074 00 6 115 140
2.3.2 Alignment tolerances (Fig. 2.5)
Maximum allowed tolerance on lateral alignment: 0 ± 5 mm
The pipe ends must be mounted in such a way that they are in-line (no angular misalignment is
allowed).
Important
Design the piping and supporting structures in function to fulfill the requirements as stated.
2920 1498 00 51
Instruction book
Fig. 2.5 Mounting of outlet piping
Text on Fig. 2.5
(1) Pipe end, customer

(2) Pipe end, Atlas Copco
(3) Lateral alignment
(4) Angular alignment
(5) Atlas Copco side
(6) Customer side
(7) Customer air outlet pipe
(8) Compressor
2920 1498 00 52
Instruction book
2.4 Cooling water requirements
The cooling water quality must meet certain minimum requirements.
No general recommendation can encompass the effects of all combinations of the various compounds,
solids and gases typically found in cooling water in interaction with different materials.
This recommendation is a general guideline for acceptable coolant quality.
2.4.1 Type of the system
Closed system
In a closed system, the same cooling water is circulating through a system without contact with air.
Open system
An open system is a pass-through system, or a circulating system with a cooling tower. In the latter
case, the composition of the water that enters the cooler must be considered, and not the composition
of the make-up water. Due to the evaporative effect in the cooling tower, much higher concentrations
of ions can be obtained in the circulating water than in the make-up water.
2.4.2 Cooling water parameters
The Ryznar stability index (RSI)
The Ryznar Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitate
calcium carbonate. The adhesion of scaling depositions and their effect are different on different
materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH
value and by the saturation pH value (pHs).
The saturation pH value is determined by the relationship between the calcium hardness, the total
alkalinity, the total solids concentration and the temperature.
The Ryznar Index is calculated as follows:
RSI = 2*pHs - pH
Where: pH = measured pH (at room temperature) of water sample

pHs= pH at saturation
The pHs is calculated by using:
pHs = (9.3 + A + B) - (C + D)
A: depends on the total solids concentration (mg/l).
B: depends on the highest cooling water temperature (°C),

For ZH-units take: T = 65°C
C: depends on the calcium hardness (ppm CaCO3).

D: depends on the HCO3- concentration or M-alkalinity (mval/l).
2920 1498 00 53
Instruction book
The values from A, B, C and D are found in the table below.
Total
Temperature Ca-hardness M-Alkalinity
Dissolved A B C D
(°C) (ppm CaCO3) (mval/l)
solids (mg/l)
50 – 300 0.1 0-1 2.6 10 - 11 0.6 0.20 - 0.22 1.0

400 - 1000 0.2 2-6 2.5 12 - 13 0.7 0.24 - 0.26 1.1
7-9 2.4 14 - 17 0.8 0.28 - 0.34 1.2
10 - 13 2.3 18 - 22 0.9 0.36 - 0.44 1.3
14 - 17 2.2 23 - 27 1.0 0.46 - 0.54 1.4
18 - 21 2.1 28 - 34 1.1 0.56 - 0.70 1.5
22 - 27 2.0 35 - 43 1.2 0.72 - 0.88 1.6
28 - 31 1.9 44 - 55 1.3 0.90 - 1.10 1.7
32 - 37 1.8 56 - 69 1.4 1.12 - 1.38 1.8
38 - 44 1.7 70 - 87 1.5 1.40 - 1.76 1.9
45 - 50 1.6 88 - 110 1.6 1.78 - 2.20 2.0
51 - 56 1.5 111 - 138 1.7 2.22 - 2.78 2.1
57 - 63 1.4 138 - 174 1.8 2.80 - 3.54 2.2
64 - 71 1.3 175 - 220 1.9 3.54 - 4.40 2.3
72 - 80 1.2 230 - 270 2.0 4.6 - 5.4 2.4
280 - 340 2.1 5.6 - 7.0 2.5
350 - 430 2.2 7.2 - 8.8 2.6
440 - 550 2.3 9.0 - 11.0 2.7
560 - 690 2.4 11.2 - 13.8 2.8
700 - 870 2.5 14.0 - 17.6 2.9
880 - 1000 2.6 17.8 - 20.0 3.0
The interpretation of the values obtained is:
RSI < 6 boiler scale formation

RSI 6 - 7 neutral water
RSI > 7 corrosive water
A more detailed interpretation follows below:
RSI Tendency of the water Action
RSI < 3.9 Very high scale formation Water cannot be used
Regular control and descaling
4.0 < RSI < 5.5 High boiler scale formation
operation necessary
Water treatment not necessary
5.6 < RSI < 6.2 Slight boiler scale formation
Occasional inspection recommended
Water treatment not necessary
6.3 < RSI < 6.8 Neutral water
Occasional inspection recommended
Slight corrosion at higher Water treatment not necessary
6.9 < RSI < 7.5
temperature Occasional inspection recommended
Regular control necessary, use of
7.6 < RSI < 9.0 Strong corrosion
corrosion inhibitor recommended
Regular control necessary, use of
9.1 < RSI < 11 Very strong corrosion
corrosion inhibitor required
Very strong corrosion in
RSI > 11 Water should not be used
complete water system
This table indicates that distilled or demineralised water should never be used, as their RSI is >11.
2920 1498 00 54
Instruction book
The RSI only indicates the equilibrium of scaling – descaling. Cooling water showing good RSI
conditions can still be unsuitable due to other factors.
From the table above, the RSI index should be between 5.6 and 7.5, otherwise contact a specialist.
pH
The effect of pH is already calculated in the Ryznar index, but the pH itself has some additional
limitations:
6.8 < pH < 8.5
Total Dissolved solids (TDS)
This is the sum of all ions in the water. It can be derived from the dry residue after evaporation (but not
including suspended solids), or it can be estimated from the electrical conductivity.
In a closed system, the following limits apply:
TDS < 3000 mg/l (<3800 µS/cm)
For an open system, the following limits apply:
TDS < 750 mg/l (< 960 µS/cm)
Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited:
Closed cooling system: Chlorides < 500 ppm
Open cooling system: Chlorides < 150 ppm
However, if the water is scaling, lower limits should be used. (See The Ryznar stability index (RSI)).
Free chlorine (Cl2)
Continuously, a level of 0.5 ppm should not be exceeded.

For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies.
Sulphates (SO4--)
Closed cooling system: Sulphates < 400 ppm

Open cooling system: Sulphates < 150 ppm
Carbonate hardness
Closed cooling system: 50-1000 ppm CaCO3

Open cooling system: 50-500 ppm CaCO3
HCO3- / SO42- should be >1
Ammonia
< 0.5 ppm
Copper
< 1 ppm
2920 1498 00 55
Instruction book
Iron and manganese
< 1 ppm
Organics
No algae.
No oil.
Suspended solids
Non-soluble particles, size < 1mm.

< 10 ppm
Remark
- Chloride and sulphate are interactive. In open systems the sum of the squares of these values
must not exceed 85,000. For recirculating systems with proper controls and treatment, the
sum of the squares may be up to 520,000. Note that the sulphate value must include any
sulphite present.
2.5 Pictographs
1 Start
2 Function keys
3 Scrolling up/down
4 Tabulator key
5 Reset, emergency stop (if provided)
6 Emergency stop
7 Voltage on
8 General alarm
9 Automatic operation
10 Stop
Fig. 2.6 Pictographs, control panel
1 Condensate drain, blow-off silencer

2 Manual condensate drain, aftercooler
3 Automatic condensate drain, aftercooler
4 Manual condensate drain, second intercooler
5 Automatic condensate drain, second intercooler
6 Manual condensate drain, first intercooler
7 Automatic condensate drain, first intercooler
Fig. 2.7 Pictographs, condensate drains
2920 1498 00 56
Instruction book
1 Cooling water outlet

2 Cooling water inlet
Fig. 2.8 Pictographs, water
1 Warning, under tension

2 Heated surface
3 Consult the Instruction book
before greasing
4 Switch off the voltage and
depressurize the compressor
before maintenance or repair
5 Before connecting the
compressor electrically,
consult the Instruction book
for the motor rotation
direction
6 Torques for steel (Fe) or
brass (CuZn) bolts
7 Disconnect from electrical
supply before opening
8 Read Instruction book before
starting the compressor
Fig. 2.9 Pictographs, other locations
2920 1498 00 57
Instruction book
3 OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all related safety precautions, including those mentioned in this book.
Operating conditions
If the ambient or air inlet temperatures can be beyond the limitations stated in section 7.4, precautions
must be taken. In this case, and also if operating in other extreme conditions, consult Atlas Copco.
Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks
protrude from the other side of the frame. The compressor can also be lifted after inserting beams in
the slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The
chains must be held parallel to the bodywork by chain spreaders in order not to damage the
compressor. The lifting equipment must be placed in such a way that the compressor will be lifted
perpendicularly. Lift smoothly and avoid twisting.
3.1 Preparation for initial start-up
1. Consult section 2 for the dimension drawings, installation proposal and voltage supply
connections. Consult section 7.3 for the values of the overload relay and motor types.
2. If not provided, stick warning labels next to the control panel and also on both sides of the
compressor on an obvious place inside the bodywork indicating that the compressor is
automatically controlled (started and stopped) by the Elektronikon regulator.
3. A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect
the compressor against corrosion. Remove the plates.
4. Check the voltage selecting wires at transformer (T1-Fig. 1.9) for correct connection (a label is
stuck on the transformer). Check the setting of overload relays (F25/27/29-Fig. 1.9). See section
7.3.
5. Remove the centre part of the drive coupling (4-Fig. 1.1).
6. Have the drive motor alignment checked by an Atlas Copco representative.
7. Start the drive motor and stop it immediately. Check the rotation of drive motor (1-Fig. 1.1) while
the compressor is coasting to a stop: the correct rotation direction is counter-clockwise when
looking at the drive end shaft of the motor. If wrong, switch off the voltage and reverse two
incoming electric lines.
8. Fit the centre part of the drive coupling (4-Fig. 1.1) using new bolts.
9. Check that the oil reservoir is filled with oil to the full mark of sight-glass (3-Fig. 3.2). See section
4.3. For drive motors equipped with sleeve bearings, check that oil is visible in the bearing sight-
glasses.
10. The outlet of the demister may be ducted outside of the bodywork. The maximum pressure drop
over this pipe is 0.5 mbar. Never install valves in this pipe. Avoid any obstruction or liquid lock by
sagging of the pipe.
11. Check that the cooling water drain valves (customer's installation) in the inlet and outlet piping are
closed. Check that the drain valve (1-Fig. 3.4) in the water inlet pipe is closed and the drain plug
(2) is fitted.
12. Open the water inlet and outlet valves (customer's installation), as well as the flow regulating
valves (1, 2 and 4-Fig. 3.3). Check for water flow.
13. Close the condensate drain valves (5, 7 and 9-Fig. 3.1).
2920 1498 00 58
Instruction book
14. Switch on the voltage.
On compressors provided with a reset button (5): the control panel will indicate an emergency
stop. Press reset button (5), then press key Reset (F3).
Check the oil reservoir temperature: if below 38 °C, the oil heater will be activated (see section
1.9.4 to check the oil temperature and to find the message Oil heater on).
15. Check that the auxiliary oil pump (6-Fig. 3.3) starts running (see section 1.9.4 to find the message
Auxiliary oil pump on). The pump may start after a period of time, controlled by the Elektronikon
regulator.
Check the rotation direction of the motor (5-Fig. 3.3) of the oil pump: the correct rotation direction
is clockwise when looking at the drive end shaft of the motor; if wrong, switch off the voltage and
reverse two incoming electric lines at overload relay (F25-Fig. 1.9).
16. Check the rotation of fan motor (1-Fig. 5.5) of the demister: the correct rotation direction is
clockwise when looking at the drive end shaft of the motor. If wrong, switch off the voltage and
reverse two incoming electric lines at overload relay (F27-Fig. 1.9).
17. Have the tuning of inlet guide vanes (3-Fig. 3.3) and blow-off valve (9-Fig. 3.3) checked by an
Atlas Copco representative.
18. Have the settings programmed in the Elektronikon regulator checked by an Atlas Copco
representative.
3.2 Compressor control modes
The Elektronikon regulator allows the operator to select three control modes:
- Local control mode
- Remote control mode
- Local Area Network (LAN) control mode
1 Local control mode (remote control mode is made inactive):

The compressor can only be controlled by the buttons on the control panel.
The oil is kept on temperature and the oil pump is operative (started or stopped by the
Elektronikon regulator).
2 Remote control mode (local control is made inactive):

The compressor will only react to start/stop and manual load/unload commands by external
switches.
Emergency stop button (7) remains active.
The oil is kept on temperature and the oil pump is operative (started or stopped by the
Elektronikon regulator).
3 LAN control mode (local control is made inactive):

The compressor can be controlled by an ES controller.
Remark
When the electrical power to the compressor is switched off, the Elektronikon regulator will not
react to any start/stop command and the oil will not be heated and not circulated.
2920 1498 00 59
Instruction book
3.3 Before starting
Attention
Before starting the compressor, the oil temperature must exceed 25 °C; immediately after pressing the
start button, the oil pressure must exceed 0.2 bar(e). If these conditions are not fulfilled, the
compressor will not start and the alarm LED (9) will light up after the permissive start time (30
seconds).
It is recommended to keep the voltage to the compressor on in order to keep the oil heater energized
and the auxiliary oil pump operative (started and stopped by the Elektronikon regulator). See section
1.7.5.
1. Check the oil level (3-Fig. 3.2), which must be in the green range or above. Top up, if necessary,
with the correct type of oil. See section 4.3.
2. Close condensate drain valves (5, 7 and 9-Fig. 3.1).
3. Open the air outlet valve.
4. If the cooling water was drained (see section 3.7):
- close the drain valve (1-Fig. 3.4) in the water inlet pipe and fit the drain plug (2)
- fit the drain plugs (8-Fig. 3.3) underneath all coolers
5. Open the water inlet valve and outlet valve.
6. Open the water flow regulating valves (1, 2 and 4-Fig. 3.3). Opening of these valves can be
overlooked if, after previous operation, the settings have not been disturbed.
2920 1498 00 60
Instruction book
1 Air outlet
2 Water outlet
3 Water inlet
4 Automatic drain outlet, first intercooler
condensate drain
5 Condensate drain valve, first
intercooler condensate drain
6 Automatic drain outlet, second
7 Condensate drain valve, second
8 Automatic drain outlet, aftercooler
condensate drain
9 Condensate drain valve, aftercooler
condensate drain
10 Condensate drain, blow-off silencer
Fig. 3.1 Air, water and condensate drain connections
2920 1498 00 61
Instruction book
3.4 Starting
3.4.1 Routine starting
1. Switch on the voltage. Check that voltage on LED (8) lights up.
2. Normally, the main screen is shown. See section 1.9.6.
The menu shows:

- the compressor outlet pressure
- the compressor operation status
By pressing the ↓ key other conditions are shown (amongst others):

- the conditions of the auxiliary oil pump and oil heater
- whether the compressor is controlled locally (start/stop and manual load/unload commands
only possible by means of the buttons of the control panel), controlled remotely (start/stop and
manual load/unload commands only possible by means of external switches) or controlled by
Local Area Network (LAN)
- the status of the Week timer (if activated, the programmed time-based start and stop
commands will be executed; see section 1.9.15)
3. Press start button (1). The compressor starts running in unloaded condition. Automatic operation
LED (10) will light up. Auxiliary oil pump (6-Fig. 3.3) should automatically turn off after the
compressor has reached full operating speed.
4. After 20 seconds (programmable), the compressor starts running loaded.
5. If necessary, regulate the water flow with the compressor running loaded using valves (1, 2 and 4-
Fig. 3.3). Consult section 7.4 for the cooling water temperature and pressure, and for the cooling
water consumption.
3.4.2 Starting after emergency stopping or shut-down
Press emergency stop button (7) (if not yet done so), switch off the voltage and depressurize the
compressor. After remedying the fault, unlock the emergency stop button by pulling it out and push
reset button (5) if available. Push key Reset (F3) on the regulator. Restart the compressor as
described above.
2920 1498 00 62
Instruction book
3.4.3 Number of motor starts
In automatic operation, the Elektronikon regulator limits the number of motor starts. See section 8.
1 Oil filler cap

2 Oil strainer
4 Oil drain valve
5 Oil heater
6 Oil reservoir
1 Water regulating valve,

aftercooler circuit
second intercooler
circuit
3 Inlet guide vanes
first intercooler circuit
5 Motor, auxiliary oil
pump
6 Auxiliary oil pump
7 Vent plugs
8 Drain plugs
9 Blow-off valve
Fig. 3.3 View of coolers
2920 1498 00 63
Instruction book
3.5 During operation
1. When LED (10) is lit up, starting and stopping of the motor is automatically controlled: when the
motor is stopped, it may restart automatically.
2. Check the readings on display (2). See below.
3. To unload the compressor manually, press key Unload (F3). To put the compressor back into
automatic operation, press key Load (F3).
4. Check that condensate is drained through the automatic drain outlets (4, 6 and 8-Fig. 3.1) (the
amount depends on the ambient and operating conditions).
Important
1. If the motor is stopped and automatic operation LED (10) is lit up, starting and stopping of the
motors is automatically controlled by the Elektronikon regulator. See also:
- section 1.7.1 for automatic restart after idling
- section 1.7.7 for automatic restart after power failure
- section 1.9.15 for time-based start and stop commands.
2. After stopping, the motor is prevented from restarting within a programmable time period
which is set ex-factory at 240 seconds (called minimum stop time). A start command will be
executed after running out of this period.
3.5.1 Checking the display
1. Regularly check the display (2) for readings and messages. Normally, the compressor main
screen is shown. See section 1.9.6.
2. Always check the display and remedy the trouble if alarm LED (9) is blinking or lit up. Consult
section 1.9.7.
Warning
Before carrying out any maintenance, repair or adjustment, stop the compressor, press
emergency stop button (7), switch off the voltage and depressurize the compressor.
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3.6 Manual control of compressor operation
Normally, the compressor runs in automatic operation: the Elektronikon regulator controls the capacity
and operation of the compressor. LED (10) is lit up.
If required, the compressor can be unloaded manually by pressing the key Unload on the main screen
(Fig. 1.10): the compressor is switched out of automatic operation and remains running unloaded.
LED (10) goes out.
Press the key Load on the main screen (Fig. 1.10) to switch the compressor to automatic operation
again (automatic capacity regulation controlled by the Elektronikon regulator). LED (10) lights up.
3.7 Stopping
1. Press stop button (11). The compressor will follow a programmed stop sequence (run unloaded
for some seconds, after which it will stop).
2. Close the air outlet valve.
3. To stop the compressor immediately in case of emergency, press emergency stop button (7).
LED (9) starts blinking. After remedying the trouble, unlock the emergency stop button by pulling
it out and push reset button (5) if available. Push key Reset (F3) on the regulator.
4. Open condensate drain valves (5, 7 and 9-Fig. 3.1).
5. Close the cooling water inlet valve.
6. If the compressor is installed in a room where freezing temperatures are expected, drain the
cooling system:
- remove drain plug (2-Fig. 3.4) in the water inlet pipe and open the drain valve (1)
- remove the drain plugs (8-Fig. 3.3) underneath all coolers
Attention
It is recommended to keep the voltage to the compressor on to keep the oil heater energized and
the auxiliary oil pump operative (started and stopped by the Elektronikon regulator). See section
1.7.5.
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1 Water drain valve

2 Plug
Fig. 3.4 Water piping
3.8 Taking out of operation
At the end of the service life of the compressor, proceed as follows:
1. Close the air outlet valve and stop the compressor.

2. Switch off the voltage and disconnect the compressor from the mains.
3. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect
the compressor air outlet pipe from the air net.
4. Drain the water, oil and condensate circuits.
5. Disconnect the compressor condensate piping from the condensate drain net.
6. Disconnect the cooling water pipes from the compressor.
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Instruction book
4 MAINTENANCE
Warning
Before starting any maintenance or repair, press stop button (11), wait until the compressor has
stopped, press emergency stop button (7), switch off the voltage and depressurize the
compressor.
Safeguard against unintentional "switch-on". Apply all relevant safety precautions, including those
mentioned in this book.
4.1 Preventive maintenance schedule for the compressor 1)
4.1.1 Regular service operations
To ensure safe operation and long service life, carry out following operations at the interval (period or
running hours) which comes first. The "longer interval" checks must also include the "shorter interval"
checks. Read the related section before taking maintenance measures.
The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the
environmental and working conditions of the compressor.
In servicing, replace all removed gaskets, O-rings and washers.
Running See See notes

Period 2) Operation
hours 2) section below table
Check operation of inlet guide vanes and blow-
Daily 8 - -
off valve
" 8 1.7 - Check for warnings
" 8 3.3 1 Check oil level
" 24 7.1 - Check display readings
Check that condensate is discharged from
" 24 - 4
automatic drains
Manually drain condensate drain receivers after
" - 3.7 -
stopping
Weekly - 8 - Check programmed settings

" - - 2 Check for water, oil or air leaks
" - - - Check for abnormal noise
" - - - Drain condensate from air receiver, if installed
- - 4.2 3 Grease motor bearings
Check general condition of all flexible hoses

6-monthly 4000 - - and rubber compensators. Replace if
necessary.
Check pressure drop over oil demister pipe (if
- 3.1 -
ducted away)
A number of service operations are grouped. If

the programmed service interval is reached, a
- - - - message will appear on the display of the
regulator to carry out these service actions (see
section 4.1.4).
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Notes
1. Level should be in green range or above.
2. Any leak should be attended to immediately.
3. The interval depends on the ambient temperatures. Consult Atlas Copco if in any doubt.
4. The amount of condensate depends on the working and environmental conditions. The
amount discharged from the intercoolers is low in relation to the condensate flow from the
aftercooler.
4.1.2 Service kits
Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service
kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco
parts while keeping the maintenance budget low. See also section 4.5.
4.1.3 Service agreements
Atlas Copco Customer Centres have a range of service agreements to suit your needs:
- An Inspection plan
- A Preventive maintenance plan
- A Total responsibility plan
Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure optimum
operational efficiency, minimize downtime and reduce the total life cycle costs.
4.1.4 Service plan
A number of service operations are grouped (called Level A, Level C, Level E, ...). Each level stands
for a number of service actions to be carried out at the time intervals programmed in the Elektronikon
regulator.
When reaching a level, a message will appear on the screen. After carrying out all service actions, the
interval timers are to be reset using the key "Reset" in menu "Service". Consult your Atlas Copco
Customer Centre.
4.2 Motor greasing
For motors with roller bearings (section 7.3.2):
Type: Use Atlas Copco Roto-Glide grease.
Interval: The grease interval is 2000 operating hours or more. Consult the motor data plate.
Attention:
Never mix different greases.
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4.3 Lubricant specifications
Use Atlas Copco Roto-H Plus. This is special lubricant for ZH compressors ensuring optimum bearing
lubrication.
This lubricant can be ordered in following quantities:
All markets – except for USA and Canada
19-l can 2908 8507 00

208-l drum 2908 8508 00
For USA and Canada
5-gal can 2908 8509 00

55-gal drum 2908 8510 00
Attention:
Do not mix Roto-H Plus with Roto-H or other lubricants.
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Instruction book
4.4 Storage after installation
- Open condensate drain valves (5, 7 and 9-Fig. 3.1). Close the valves after draining.
- Keep the voltage to the compressor on to keep the oil warm and pumped around, preventing the
internal system from rusting.
- If the compressor is switched off; put the compressor back in operation, wait until the starting
conditions are fulfilled and run the compressor for about 15 minutes.
- Keep the compressor room well-ventilated and the compressor clean. Protect the compressor in
case the ambient temperature can be beyond the limitations (see section 7.4.2). If in any doubt,
consult Atlas Copco.
If the compressor is going to be stored without running from time to time, protective measures must be
taken. Consult Atlas Copco.
4.5 Service kits
Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas
Copco parts while keeping the maintenance budget low.
Footnotes chapter 4
1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts
is not covered by Warranty or Product Liability.
2) Whichever interval comes first. The local Atlas Copco Sales Company may overrule the
maintenance schedule, especially the service intervals, depending on the environmental and
working conditions of the compressor.
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5 SERVICING PROCEDURES
5.1 Air filters (Fig. 5.1)
1. In dusty operating conditions where it will be necessary to replace the filters too frequently, an
appropriate pre-filter of the dry type should be installed.
2. The filters must be serviced as soon as the service warning appears on the display or yearly.
4. Remove the cover (1) and clean the filter chamber.
5. Remove the filters (2). Take care that no dirt drops into the filter box.
6. Install the new filters (see section 4.5) and fit the cover. Never install damaged or clogged filters.
8. After carrying out the service actions of the related service plan, the service warning must be
reset. See also section 4.1.
1 Cover
2 Air filters
Fig. 5.1 Air filters
5.2 Oil and oil filter change (Figs. 5.2 and 5.3)
1. Run the compressor until warm. Stop the compressor and switch off the voltage.
2. Remove filler plug (1-Fig. 5.3). Drain the compressor sump by opening drain valve (4). Close the
valve after draining.
3. Remove the filter (Fig. 5.2) and fit a new one.
4. Remove inspection cover (7-Fig. 5.3) and check oil strainer (2). If necessary, clean the strainer.
Reinstall the cover.
5. Fill the compressor sump to the full mark of sight-glass (3) with oil as specified in section 4.3
(approx. 220 l).
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Filter change for optional dual oil filters (Fig. 5.4)
When handle (3) is switched to the left (and handle 1 perpendicular to handle 3), the right filter is in
operation and vice versa. Assume that the right filter is in operation and needs to be changed:
1. Loosen venting plugs (2) of the left filter until the venting holes are visible.
2. Switch handle (1) in line with handle (3) to fill the left filter with oil and to vent it.
3. When oil flows out of the venting holes, close the venting plugs. Switch handle (1) until it is
perpendicular to handle (3).
4. Switch handle (3) to the right, the left filter is in operation.
5. Remove the right filter and fit a new one (torque 35 Nm). Replace the seals on the venting plugs.
Fig. 5.2 Oil filter
1 Oil filler plug

2 Oil strainer
4 Oil drain valve
5 Oil heater
6 Oil reservoir
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1 Handle
2 Venting plugs
3 Handle
Fig. 5.4 Dual oil filters
5.3 Demister (Fig. 5.5)

2. Loosen the clamp ring and remove the upper part (2) of the demister.
3. Unscrew the bolt underneath the filter cartridge and take out the cartridge and gasket.
4. Fit the new gasket and filter cartridge into the upper part of the demister and screw in the bolt
underneath the cartridge to fix it.
5. Reinstall the upper part (2) of the demister and tighten the clamp ring.
Note:
A demister element kit can be ordered: part number 1621 8651 00.
1 Fan motor
2 Upper part of demister
Fig. 5.5 Oil demister
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Instruction book
6 PROBLEM SOLVING
Warning
Before starting any maintenance or repair, press stop button (11), wait until the compressor has
stopped, press emergency stop button (7), switch off the voltage and depressurize the
compressor.
Safeguard against unintentional "switch-on". Apply all relevant safety precautions, including those
mentioned in this book.
Faults and suggested remedies
1 The compressor does not start (LED 9 is lit up or blinks)

- Scroll to the status data menu (section 1.9.7) to check the protection functions.
a The number of programmed starts per day has been exceeded. See section 8
a Wait for the timer to expire
2 LED (9) is lit up or blinking

Consult sections 1.8 and 1.9.7
3 Air temperature above normal

a Inlet temperature too high due to bad room ventilation or recirculation of cooling air
a Improve ventilation of compressor room
b Insufficient cooling water flow
b Check and increase cooling water flow
c Insufficient cooling or restriction in cooling water system due to formation of scale or settling
down of dirt
c Consult Atlas Copco
4 Excessive vibration and noise

a Unstable operation of drive motor
a Have vibration level measured and motor inspected. Consult Atlas Copco
b Alignment altered
b Have compressor/motor re-aligned. Consult Atlas Copco
c Formation of coke on the bearings
c Have bearings inspected by Atlas Copco
5 Surge problems
Consult Atlas Copco
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7 PRINCIPAL DATA
7.1 Readings on display (2-Fig. 1.7) 1)
Outlet pressure see 7.4.4 up to 7.4.11

Setpoint pressure see 7.4.4 up to 7.4.11
Oil pressure, gearbox approx. 2.3 bar(e)
Outlet pressure, compressor element 3 slightly above outlet pressure
DP of air filter below 0.05 bar
DP of oil filter below 1 bar
Oil temperature, reservoir approx. 58 °C
Oil temperature, gearbox approx. 50 °C
Inlet temperature, compressor element 2 sum of cooling water inlet and cooler approach
temperatures
Inlet temperature, compressor element 3 sum of cooling water inlet and cooler approach
temperatures
Aftercooler outlet temperature sum of cooling water inlet and cooler approach
temperatures
Approach temperature, intercoolers below 20 °C
Approach temperature, aftercooler below 20 °C
Cooling water inlet temperature below 35 °C
Drive motor cooling air inlet temperature below 50 °C
Drive motor current depends on motor type
Vibration level, compressor element 1 5 to 15 micrometer
7.2 Programmable settings
A number of regulation settings and protection settings are programmable. See section 8.
7.3 Settings of overload relay - motor types
7.3.1 Settings of overload relay
Low voltage Auxiliary oil Oil demister Oil heater

Frequency Approval
supply pump F25 fan F27 F29
V Hz - A A A
230 50 IEC 4.7 1.0 3.8

400 50 IEC 2.7 0.6 2.2
500 50 IEC 2.2 0.4 1.8
220-230 60 CSA-UL 4.7 1.0 3.8

380 60 CSA-UL 2.7 0.6 2.1
440-460 60 CSA-UL 2.7 0.5 2.5
575 60 CSA-UL 2.2 0.4 2.0
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7.3.2 Motor types
Motor IP 55 Motor type Bearing type
Roller bearings (optional: sleeve

630 kW / 3-3.3-5-5.5-6-6.6 kV 1LA4 402-2
bearings)
630 kW / 10 kV 1LA4 450-2 Sleeve bearings
710 kW / 3-3.3-5-5.5-6-6.6 kV 1LA4 404-2
bearings)
800 kW / 3-3.3-5-5.5-6-6.6 kV 1LA4 450-2 Sleeve bearings
900 kW / 3-3.3-5-5.5-6-6.6 kV 1LA4 452-2 Sleeve bearings
1000 kW / 3-3.3-5-5.5-6-6.6-10kV 1LA4 454-2 Sleeve bearings
1120 kW / 3-3.3-5-5.5-6-6.6-10kV 1LA4 500-2 Sleeve bearings

800 hp / 2.3-3-3.3-4.16-6-6.6 kV 1LA4 400-2
bearings)
900 hp / 2.3-3-3.3-4.16-6-6.6 kV 1LA4 402-2
bearings)
1000 hp / 2.3-3-3.3-4.16-6-6.6 kV 1LA4 404-2
bearings)
1100 hp / 2.3-3-3.3-4.16-6-6.6 kV 1LA4 404-2
bearings)
1250 hp / 2.3-3-3.3-4.16-6-6.6 kV 1LA4 450-2 Sleeve bearings
1500 hp / 2.3-3-3.3-4.16-6-6.6 kV 1LA4 454-2 Sleeve bearings
Motor IP 23 Motor type Bearing type

630 kW / 3-3.3-5-5.5-6-6.6 kV 1RA3 354-2
bearings)
710 kW / 3-3.3-5-5.5-6-6.6 kV 1RA3 354-2
bearings)
800 kW / 3-3.3-5-5.5-6-6.6 kV 1RA3 400-2
bearings)
900 kW / 3-3.3-5-5.5-6-6.6 kV 1RA3 402-2
bearings)
1000 kW / 3-3.3-5-5.5-6-6.6 kV 1RA3 404-2
bearings)
1120 kW / 3-3.3-5-5.5-6-6.6 kV 1RA3 404-2
bearings)

800 hp / 2.3-3-3.3-4.16-6-6.6 kV 1RA3 350-2
bearings)
900 hp / 2.3-3-3.3-4.16-6-6.6 kV 1RA3 352-2
bearings)
1000 hp / 2.3-3-3.3-4.16-6-6.6 kV 1RA3 354-2
bearings)
1100 hp / 2.3-3-3.3-4.16-6-6.6 kV 1RA3 354-2
bearings)
1250 hp / 2.3-3-3.3-4.16-6-6.6 kV 1RA3 400-2 Sleeve bearings
1500 hp / 2.3-3-3.3-4.16-6-6.6 kV 1RA3 402-2 Sleeve bearings
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7.4 Compressor specifications
7.4.1 Design conditions
Absolute inlet pressure bar(a) 1

Relative air humidity % 60
Air inlet temperature °C 35
Nominal effective working pressure bar(e) see sections 7.4.4 up to 7.4.11
Cooling water inlet temperature °C 26.7
Motor shaft speed - 50 Hz versions r/min 2980
Motor shaft speed - 60 Hz versions r/min 3575
7.4.2 Limitations
Maximum setpoint pressure bar(e) see sections 7.4.4 up to 7.4.11

Maximum air inlet temperature °C 40
Minimum air inlet temperature °C -10
Maximum ambient temperature °C 40
Minimum ambient temperature °C 5
Maximum cooling water outlet temperature °C 50
Maximum cooling water inlet temperature °C 35
Maximum cooling water pressure bar(e) 5
Minimum cooling water pressure bar(e) 2
7.4.3 Sound pressure level 3)
Sound pressure level, with bodywork dB(A) 72

Sound pressure level, without bodywork dB(A) 83
7.4.4 Specific data of 7 bar - 50 Hz compressors 2)
Compressor ZH10000- ZH10000- ZH10000- ZH10000- ZH10000- ZH10000-

type 1 2 3 4 5 6
7 bar 7 bar 7 bar 7 bar 7 bar 7 bar
Maximum
setpoint bar(e) 7.7 7.7 7.7 7.7 7.7 7.7
pressure
Nominal working
bar(e) 7 7 7 7 7 7
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 6) kW 630 710 800 800 900 1000
Cooling water
m³/hr 60 64 71 75 83 95
consumption 4)
Corresponding
pressure drop
bar 0.6 0.7 0.8 0.9 1.0 1.2
over cooling
water system
Oil capacity l 220 220 220 220 220 220
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Instruction book

type 1 2 3 4 5 6
Maximum
setpoint bar(e) 8.8 8.8 8.8 8.8 8.8 8.8
pressure
Nominal working
bar(e) 8 8 8 8 8 8
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 6) kW 710 710 800 900 900 1120
Cooling water
m³/hr 62 67 74 79 84 101
consumption 4)
Corresponding
pressure drop
bar 0.7 0.7 0.8 0.9 1.0 1.3
over cooling
water system
Oil capacity l 220 220 220 220 220 220

type 1 2 3 4 5 6
Maximum
setpoint bar(e) 9.9 9.9 9.9 9.9 9.9 9.9
pressure
Nominal working
bar(e) 9 9 9 9 9 9
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 6) kW 710 800 800 900 1000 1120
Cooling water
m³/hr 66 71 75 82 90 102
consumption 4)
Corresponding
pressure drop
bar 0.7 0.8 0.9 1.0 1.1 1.3
over cooling
water system
Oil capacity l 220 220 220 220 220 220
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Instruction book
7.4.7 Specific data of 10.4 bar - 50 Hz compressors 2)

type 1 2 3 4 5 6
10.4 bar 10.4 bar 10.4 bar 10.4 bar 10.4 bar 10.4 bar
Maximum
setpoint bar(e) 11.4 11.4 11.4 11.4 11.4 11.4
pressure
Nominal working
bar(e) 10.4 10.4 10.4 10.4 10.4 10.4
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 6) kW 800 800 900 1000 1000 1120
Cooling water
m³/hr 72 74 82 86 95 104
consumption 4)
Corresponding
pressure drop
bar 0.8 0.8 1.0 1.0 1.2 1.4
over cooling
water system
Oil capacity l 220 220 220 220 220 220
7.4.8 Specific data of 100 psi - 60 Hz compressors 2)
Compressor
ZH6000-1 ZH6000-2 ZH6000-3 ZH6000-4 ZH6000-5 ZH6000-6
type
100 psi 100 psi 100 psi 100 psi 100 psi 100 psi
Maximum
setpoint bar(e) 7.7 7.7 7.7 7.7 7.7 7.7
pressure
Nominal working
bar(e) 7 7 7 7 7 7
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 7) hp 800 900 900 1000 1100 1250
Cooling water
m³/hr 60 64 71 76 83 95
consumption 4)
Corresponding
pressure drop
bar 0.6 0.7 0.8 0.9 1.0 1.2
over cooling
water system
Oil capacity l 220 220 220 220 220 220
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Instruction book
Compressor
ZH6000-1 ZH6000-2 ZH6000-3 ZH6000-4 ZH6000-5 ZH6000-6
type
Maximum
setpoint bar(e) 8.8 8.8 8.8 8.8 8.8 8.8
pressure
Nominal working
bar(e) 8 8 8 8 8 8
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 7) hp 800 900 1000 1100 1100 1500
Cooling water
m³/hr 62 68 74 80 84 101
consumption 4)
Corresponding
pressure drop
bar 0.7 0.7 0.8 0.9 1.0 1.3
over cooling
water system
Oil capacity l 220 220 220 220 220 220
Compressor
ZH6000-1 ZH6000-2 ZH6000-3 ZH6000-4 ZH6000-5 ZH6000-6
type
Maximum
setpoint bar(e) 9.9 9.9 9.9 9.9 9.9 9.9
pressure
Nominal working
bar(e) 9 9 9 9 9 9
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 7) hp 900 1000 1000 1100 1250 1500
Cooling water
m³/hr 67 71 76 83 90 103
consumption 4)
Corresponding
pressure drop
bar 0.7 0.8 0.9 1.0 1.1 1.4
over cooling
water system
Oil capacity l 220 220 220 220 220 220
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Instruction book
Compressor
ZH6000-1 ZH6000-2 ZH6000-3 ZH6000-4 ZH6000-5 ZH6000-6
type
Maximum
setpoint bar(e) 11.4 11.4 11.4 11.4 11.4 11.4
pressure
Nominal working
bar(e) 10.4 10.4 10.4 10.4 10.4 10.4
pressure
Air outlet
temperature, °C 34 34 35 36 37 38
approx.
Motor power 7) hp 1000 1000 1100 1250 1250 1500
Cooling water
m³/hr 72 75 83 86 96 104
consumption 4)
Corresponding
pressure drop
bar 0.8 0.9 1.0 1.0 1.2 1.4
over cooling
water system
Oil capacity l 220 220 220 220 220 220
7.5 Conversion list of SI units into British/American units
1 bar = 14.504 psi

1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 m = 3.281 ft
1 mm = 0.039 in
1 m3/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x °C = (32 + 1.8 x) °F 5)
Footnotes chapter 7
1) At nominal working pressure, 1 bar absolute inlet pressure, 20°C air inlet temperature and 20°C
water inlet temperature.
2) At design conditions.
3) According to PNEUROP PN8NTC2.2 under free field conditions at 1 m. With a tolerance of 3
dB.
4) At temperature rise of 10°C.
5) A temperature difference of 1°C= a temperature difference of 1.8°F.
6) Rated at 40°C and service factor 1.
7) Rated at 40°C and service factor 1.15.
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8 PROGRAMMABLE SETTINGS
8.1 Regulation settings - See section 1.9.12
Minimum Maximum
Factory setting
setting setting
Setpoint pressure (PT39)

50 Hz / 7.0 bar bar(e) 5 7 7.7
50 Hz / 8.0 bar bar(e) 5 8 8.8
50 Hz / 9.0 bar bar(e) 5 9 9.9
50 Hz / 10.4 bar bar(e) 5 10.4 11.4
60 Hz / 100 psi bar(e) 5 6.9 7.6
60 Hz / 115 psi bar(e) 5 7.9 8.7
60 Hz / 130 psi bar(e) 5 8.9 9.8
60 Hz / 150 psi bar(e) 5 10.3 11.3
Loading pressure setpoint Setpoint Setpoint Setpoint

bar(e)
(PT39) pressure - 0.2 pressure - 0.6 pressure - 1
Unloading pressure setpoint Setpoint Setpoint Setpoint
bar(e)
(PT39) pressure + 0.2 pressure + 0.6 pressure + 3
Y-time (DOL starter) s 0 0 40

Load delay time (DOL starter) s 20 20 99
Number of starts per day 1 24 24
Minimum stop time s 20 240 255
Required stop period s 5 5 60
Idling time 5) min 10 20 255
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8.2 Protection settings - See section 1.9.13
Minimum Factory Maximum

setting setting setting
Gearbox oil pressure (PT49)
-shut-down warning level bar(e) 1.1 1.6 1.6
-shut-down level bar(e) 1 1 1.5
-delay at start 1) s 6 10 25
-start failure 6) bar 0 0.2 0.5
Air outlet pressure, element 3 (PT32)

-shut-down warning level bar(e) 0 0.9 0.9
-shut-down level bar(e) 1 1 3
-signal delay 7) s 0 10 30
-start failure 6) bar(e) 0 1 3
Air inlet temperature, element 3 (TT29)

-shut-down warning level °C 50 52 65
-shut-down level °C 53 66 66
-signal delay 7) s -- 10 --
Air inlet temperature, element 2 (TT18)

-signal delay 7) s -- 10 --
Gearbox oil temperature (TT44)

-start failure 6) °C 20 25 40
Vibration, compressor element 1 (VP10)

-shut-down warning level micrometer 10 31 47
-shut-down level micrometer 32 48 48


Oil level (LT42)

-shut-down warning level l -- 179 --
-shut-down level l -- 150 --
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Instruction book
8.3 Service settings - See section 1.9.14
Minimum Maximum
Factory setting
setting setting
Service plans
Service plan A (running hours):

- Drive motor regreasing time (with hr 1 2000 4)
roller bearings) (KSH93)
Service plan C (running hours)

- Air filter lifetime (KSH02) hr 1 8000 2)
- Oil lifetime (KSH49) hr 1 8000 2)
- Oil filter lifetime (KSH48) hr 1 8000 2)
- Drive motor regreasing time (with
hr 1 8000 2)
sleeve bearings) (KSH93)
Service plan E (running hours)

- Oil demister lifetime (KSH41) hr 1 24000 3)
Analog signals
Approach temperature, cooler 1 (TT18/51) °C 15 20 100

Signal delay 7) s 15 30 255
Approach temperature, cooler 2 (TT29/51) °C 15 20 100
Approach temperature, aftercooler
°C 15 20 100
(TT36/51)
Air filter pressure drop (PDT02) bar -0.1 -0.05 -0.03

Oil filter pressure drop (PDT46) bar 0.7 1 1.5
Footnotes chapter 8
1) Is the time period after starting during which the signal is ignored.
2) Recommended interval: yearly or 8000 running hours.
3) Recommended interval: 3-yearly or 24000 running hours.
4) Recommended interval: 2000 running hours or more. Consult the motor data plate.
5) See section 1.7.1. The factory setting (infinite) means that the compressor remains running
unloaded unless the net pressure decreases to the loading pressure. Consult Atlas Copco if in
any doubt.
6) The compressor will not start if the oil temperature or oil pressure is below the setting, or when
the element 3 outlet pressure is above the setting at starting.
7) Is the time period during which the signal is ignored.
2920 1498 00 84
Instruction book
9 Options
ANSI FLANGES
The flanges on the air pipes and cooling water pipes can be provided with ANSI flanges instead of DIN
flanges.
HOT AIR VERSION

The compressors can be delivered without aftercooler for hot air delivery. In this case, the discharge
compensator is made of stainless steel and is delivered loose.
DUAL OIL FILTERS

Dual oil filters can be delivered to replace the oil filter during operation without stopping the
compressor.
NOISE INSULATING BODYWORK

For compressors with this option, a noise level of 72 dB(A) can be met.
AUTOMATIC WATER SHUT-OFF VALVE

An automatic water shut-off valve (175-Fig. 1.5) may be provided loose to shut off the system when
the compressor is not in operation.
COOLING WATER REVERSE FLOW VALVE

A cooling water reverse flow valve (174-Fig. 1.5) may be provided loose for reversing the water flow
through the intercoolers, aftercooler and oil cooler in order to clean the coolers without dismantling the
cooler bundles.
ELECTRONIC CONDENSATE DRAIN TRAPS

Electronic drain traps may be provided instead of float valve condensate drain traps (109b, 114b and
119b-Fig. 1.5). This option includes the electronic drain power supply and the high level condensate
detection in case of drain trap malfunction.
MOTOR WINDING TEMPERATURE PROTECTION

Temperature probes (PT100) can be embedded in the windings of the drive motor (TT95a, TT96a and
TT97a-Fig. 1.5). This option includes the wiring of the sensors from the auxiliary terminal box of the
main motor to the controller.
Temperature read-out on display is provided. Alarm and shut-down levels are handled by the control
system.
MOTOR BEARING TEMPERATURE PROTECTION

Temperature probes (PT100) can be embedded in the bearings of the drive motor (TT98 and TT99-
Fig. 1.5). This option includes the wiring of the sensors from the auxiliary terminal box of the main
motor to the controller.
Temperature read-out on display is provided. Alarm and shut-down levels are handled by the control
system.
MOTOR ANTI-CONDENSATION HEATER

An anti-condensation heater (R96-Fig. 1.5) can be mounted inside the main motor housing in order to
avoid condensation during motor standstill.
This option includes the anti-condensation power supply and its control.
MODBUS INTERFACE
A Modbus interface can be provided in order to communicate with external control systems.
This sales kit allows the operator to command the compressor remotely (start/stop, remote pressure
set point...) and allows access to operating parameter values (pressures, temperatures, vibrations…).
PROFIBUS DP INTERFACE
A Profibus DP interface can be provided in order to communicate with external control systems.
This sales kit allows the operator to command the compressor remotely (start/stop, remote pressure
set point...) and allows access to operating parameter values (pressures, temperatures, vibrations…).
2920 1498 00 85
Instruction book
MAIN DRIVE MOTOR WITH SLEEVE BEARINGS

This option includes the motor with sleeve bearings and the forced-feed lubrication from the
compressor oil system.
10 PED Instructions
This machine is a pressure assembly of cat III according to 97/23/EC.
The following pressure bearing parts are of category higher than I :
Intercooler I : Cat III

Design pressure 10 bar(e), content 299 l
Design code : ASME section VIII div. 1.
Intercooler II : Cat III

Design pressure 10 bar(e), content 261.5 l
Aftercooler : Cat III

Design pressure 16 bar(e), content 160 l
2920 1498 00 86
Instruction book
Notes:
2920 1498 00 87
Instruction book
Notes:
2920 1498 00 88
O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................
SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:
These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.
2920 1377 03 1/2 (continued on inside of cover)

SAFETY PRECA UTIONS (continued)
14. If the ground is not level or can be subject to variable inclination, 5. Never use flammable solvents or carbon tetrachloride for cleaning
consult Atlas Copco. parts. Take safety precautions against toxic vapours of cleaning
liquids.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses. 6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
Operation clean cloth, paper or tape.
1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
through a hose or air line, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.
2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:
8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.
1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.
2920 1377 03 2/2

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Instruction book

Atlas Copco Stationary Air Compressors

ZH6000 – ZH10000 - Three-stage

With Elektronikon regulator MK IV

Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium.

No. 2920 1498 00

Registration code: APC ZH≥4000 3-stage / 38 / 981

3.4.3 Number of motor starts ......................................................................................................... 63

1.1 General description

Six capacities are available for all pressure variants.

Example of compressor designation

Main components (Figs. 1.1, 1.2 and 1.3)

The compressor core comprises:

1 Drive motor 8 Compressed air outlet 14 Aftercooler

Fig. 1.1 Front view

Fig. 1.2 Rear view

1 Blow-off valve 9 Water regulating valve, 15 Auxiliary oil pump

Fig. 1.3 Core

1.2 Air flow

1.3 Condensate drain system

1 Oil filler cap

Fig. 1.4 Oil reservoir

1.4 Oil system

The system mainly includes:

100 Air filters 133 Manual condensate drain valve

ESHH91 Overload relay, drive motor PDT20 DP, element 2 pressure

Fig. 1.5 Instrument and piping diagram

Text on Fig. 1.5

(1) Ventilation line

A Air inlet 4 First compressor 13 Oil demister

Fig. 1.6 Air-oil-water flows

1.5 Cooling system (Fig. 1.3)

Following flow regulating valves are provided:

1.6 Electrical system

The system mainly includes:

1.7 Elektronikon regulator

In general, the Elektronikon regulator has following functions:

- Controlling the capacity of the compressor

1.7.1 Controlling the capacity of the compressor

The system includes:

AUTO-DUAL control system (standard)

Constant pressure control system (option)

The regulator will continuously regulate:

1.7.2 Protecting the compressor

1.7.2.1 Shut-down and shut-down warning

Check and remedy. See section 1.9.7.

Switch off the voltage and remedy. See section 1.9.7.

1.7.2.2 Surge control

1.7.3 Monitoring components - service warning

The Elektronikon regulator continuously monitors critical components subject to service:

1.7.4 Checking the start conditions

1.7.5 Controlling the lubricating oil system

- Energize the oil heater (5-Fig. 1.4)

1.7.6 Start commands during minimum stop time

Minimum stop time

1.7.7 Automatic restart after voltage failure

1.7.8 External compressor status indication

Auxiliary contacts are provided for external compressor status indication:

Indication Relay Terminals on strip 1X7 Max. load

Automatic operation K07 11-12 10 A / 230 V AC

1.7.9 BUS connection system

1.8 Control panel

2. The message Shutdown Warning appears.