Compressor Manual

ZR 160, ZR 200, ZR 250, ZR 275, ZT 160, ZT 200, ZT 250, ZT 275
Instruction book
Atlas Copco
ZR 160, ZR 200, ZR 250, ZR 275, ZT 160, ZT 200, ZT 250,

ZT 275
Instruction book
Original instructions
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
2013 - 01
No. 9095 0502 84
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions ........................................................................................................... 6
1.1 SAFETY ICONS................................................................................................................................. 6
1.2 SAFETY PRECAUTIONS, GENERAL......................................................................................................... 6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION ........................................................................................ 7
1.4 SAFETY PRECAUTIONS DURING OPERATION............................................................................................ 8
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ......................................................................... 9
2 General description ..................................................................................................... 11
2.1 INTRODUCTION .............................................................................................................................. 11
2.2 AIR SYSTEM .................................................................................................................................. 14
2.3 COOLING AND CONDENSATE SYSTEM.................................................................................................. 19
2.4 ELEKTRONIKON REGULATED DRAIN (ERD) ............................................................................................ 21
2.5 OIL SYSTEM .................................................................................................................................. 24
2.6 REGULATING SYSTEM ..................................................................................................................... 26
3 Elektronikon regulator type overview ........................................................................ 29
3.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW ................................................................................... 29
4 Elektronikon regulator ................................................................................................. 30
4.1 ELEKTRONIKON® REGULATOR ........................................................................................................... 30
4.2 CONTROL PANEL ............................................................................................................................ 32
4.3 FUNCTION KEYS ............................................................................................................................. 33
4.4 SCROLL KEYS................................................................................................................................ 34
4.5 EMERGENCY STOP BUTTON .............................................................................................................. 34
4.6 EXTERNAL COMPRESSOR STATUS INDICATION ...................................................................................... 35
4.7 CONTROL PROGRAMS ..................................................................................................................... 35
4.8 CONTROL PROGRAMS ..................................................................................................................... 37
4.9 CALLING UP MENUS ........................................................................................................................ 39
4.10 CALLING UP MENUS ........................................................................................................................ 40
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4.11 MAIN SCREEN MENU ....................................................................................................................... 41
4.12 MAIN SCREEN MENU ....................................................................................................................... 42
4.13 STATUS DATA MENU ....................................................................................................................... 43
4.14 MEASURED DATA MENu ................................................................................................................... 46
4.15 COUNTERS MENU ........................................................................................................................... 47
4.16 TEST MENU ................................................................................................................................... 48
4.17 MODIFY PARAMETERS MENU............................................................................................................. 49
4.18 MODIFYING PARAMETERS ................................................................................................................ 49
4.19 MODIFYING PROTECTION SETTINGS .................................................................................................... 50
4.20 MODIFYING SERVICE PLANS.............................................................................................................. 51
4.21 PROGRAMMING CLOCK FUNCTION ...................................................................................................... 52
4.22 MODIFYING CONFIGURATION SETTINGS ............................................................................................... 57
4.23 SERVICE MENU .............................................................................................................................. 58
4.24 SAVED DATA MENU ......................................................................................................................... 60
4.25 PROGRAMMABLE SETTINGS .............................................................................................................. 61
5 Elektronikon® GraphicPlus controller ....................................................................... 69
5.1 ELEKTRONIKON® GRAPHICPLUS CONTROLLER ...................................................................................... 69
5.2 CONTROL PANEL ............................................................................................................................ 71
5.3 DIGITAL OUTPUT CONTACTS ............................................................................................................. 72
5.4 ICONS USED .................................................................................................................................. 73
5.5 MAIN SCREEN ............................................................................................................................... 77
5.6 CALLING UP MENUS ........................................................................................................................ 81
5.7 SERVICE MENU .............................................................................................................................. 83
5.8 PROTECTIONS MENU....................................................................................................................... 88
5.9 WEEK TIMER MENU ......................................................................................................................... 90
5.10 INFO MENU ................................................................................................................................. 100
5.11 TEST MENU ................................................................................................................................. 101
5.12 COUNTERS ................................................................................................................................. 102
5.13 MODIFYING THE PRESSURE BAND .................................................................................................... 104
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5.14 INPUTS MENU .............................................................................................................................. 106
5.15 OUTPUTS MENU ........................................................................................................................... 111
5.16 EVENT HISTORY MENU .................................................................................................................. 113
5.17 MODIFYING SETTINGS ................................................................................................................... 114
5.18 PROGRAMMABLE SETTINGS ............................................................................................................ 120
5.19 WEB SERVER .............................................................................................................................. 121
6 Installation .................................................................................................................. 130
6.1 DIMENSION DRAWING .................................................................................................................... 130
6.2 INSTALLATION PROPOSAL ............................................................................................................... 137
6.3 ELECTRIC CABLE SIZE ................................................................................................................... 142
6.4 ELECTRIC CONNECTION ................................................................................................................. 143
6.5 QUALITY OF SAFETY COMPONENTS .................................................................................................. 145
6.6 COOLING WATER REQUIREMENTS .................................................................................................... 145
6.7 GENERAL PICTOGRAPHS ................................................................................................................ 148
6.8 PICTOGRAPHS, ELEKTRONIKON CONTROL SYSTEM ............................................................................... 149
7 Operating instructions............................................................................................... 151
7.1 INITIAL START-uP ......................................................................................................................... 151
7.2 BEFORE STARTING ....................................................................................................................... 161
7.3 ROUTINE STARTING ...................................................................................................................... 165
7.4 STARTING .................................................................................................................................. 167
7.5 STARTING AFTER EMERGENCY STOP OR SHUTDOWN ............................................................................ 167
7.6 DURING OPERATION ..................................................................................................................... 169
7.7 CHECKING THE DISPLAY ................................................................................................................ 171
7.8 MANUAL LOADING/UNLOADING ........................................................................................................ 172
7.9 STOPPING .................................................................................................................................. 174
7.10 TAKING OUT OF OPERATION ............................................................................................................ 178
8 Maintenance ............................................................................................................... 179
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8.1 PREVENTIVE MAINTENANCE SCHEDULE ............................................................................................. 179
8.2 MAINTENANCE INSTRUCTIONS ......................................................................................................... 181
8.3 MOTOR GREASING ....................................................................................................................... 182
8.4 OIL SPECIFICATIONS ..................................................................................................................... 182
8.5 STORAGE AFTER INSTALLATION ....................................................................................................... 182
8.6 SERVICE KITS .............................................................................................................................. 182
9 Servicing procedures ................................................................................................ 183
9.1 AIR FILTERS ................................................................................................................................ 183
9.2 OIL AND OIL FILTER CHANGE ........................................................................................................... 184
9.3 SAFETY VALVES ........................................................................................................................... 185
10 Problem solving ......................................................................................................... 186
10.1 PROBLEM SOLVING ....................................................................................................................... 186
11 Technical data ............................................................................................................ 188
11.1 READINGS .................................................................................................................................. 188
11.2 SETTINGS OF SAFETY VALVES ......................................................................................................... 189
11.3 SETTINGS FOR OVERLOAD RELAY AND FUSES ..................................................................................... 189
11.4 REFERENCE CONDITIONS ............................................................................................................... 191
11.5 LIMITATIONS ............................................................................................................................... 191
11.6 COMPRESSOR DATA ..................................................................................................................... 192
11.7 DRYER DATA ............................................................................................................................... 196
12 Storage instructions ................................................................................................. 200
12.1 OBJECTIVE ................................................................................................................................. 200
12.2 SHIPPING PRECAUTIONS ................................................................................................................ 200
12.3 PRE-STORAGE PRECAUTIONS ......................................................................................................... 200
12.4 STORAGE PRECAUTIONS ............................................................................................................... 200
13.1 Drive locate document............................................................................................... 202
13.1 PROTECTION FOR ZR / ZT COMPRESSORS .......................................................................................... 202
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1 Safety precautions
1.1 Safety icons
Explanation
Danger for life
Warning
Important note
1.2 Safety precautions, general
General precautions
1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the voltage and depressurize the compressor.
In addition, the power isolating switch must be opened and locked.
On units powered by a frequency converter, wait six minutes before starting any electrical repair.
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the unit or on its components.
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1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from neglecting these precautions,
or non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during installation

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

1. Never touch any piping or components of the compressor during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the
remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g.
to carry out routine checks. Wear ear protectors when opening a door.
On compressors without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair,
free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken
to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
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11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
1.5 Safety precautions during maintenance or repair
manufacturer.
Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the
remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or
disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated,
the machine shall be stopped but no inspection covers shall be opened before sufficient cooling
time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is
admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
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16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft has
been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required,
use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water.
If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek
medical first aid.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
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2 General description
2.1 Introduction
General views
General view of ZR 160 up to ZR 275 FF with Elektronikon controller
General view of ZR 160 up to ZR 275 FF with Elektronikon GraphicPlus controller
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General view of ZT 160 up to ZT 275 FF with Elektronikon controller
General view of ZT 160 up to ZT 275 FF with Elektronikon GraphicPlus controller
Ref. Name
AO Compressed air outlet
DRa Condensate drain receiver, aftercooler
DRi Condensate drain receiver, intercooler
MK4 Elektronikon regulator
MK5 Elektronikon GraphicPlus regulator
SVh Safety valve, high pressure
SVl Safety valve, low pressure
S2 Emergency stop button
WI Cooling water inlet
WO Cooling water outlet
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These units are two-stage, electric motor driven screw compressors which deliver oil-free, pulsation-free air.
ZR compressors are water-cooled.
ZT compressors are air-cooled.
The compressor is enclosed in a sound-insulated bodywork and includes mainly:
• Air filter
• Low-pressure compressor element
• Intercooler
• High-pressure compressor element
• Aftercooler
• Water separators
• Electric motor
• Drive coupling
• Gear casing
• Elektronikon® control system
• Safety valves
Drive arrangement
On ARR E, the motor is flanged to the gear casing by means of a coupling housing. The motor/gear casing
unit is supported on the frame by vibration dampers.
On ARR 1, the motor is mounted on a separate subframe. The subframe and gear casing are supported on the
frame by vibration dampers.
Elektronikon control system

The compressor is controlled by an electronic regulator which:
• Controls the operation of the compressor
• Reduces the power consumption
• Warns the operator in case of an abnormal operating condition
• Protects the compressor
• Monitors components subject to service
• If activated, the regulator can automatically restart the compressor after voltage failure
Optional equipment
Following equipment is available as an option:
Full-Feature
The compressor is additionally provided with an IMD adsoption dryer. The dryer is integrated in the bodywork
and removes moisture from the compressed air.
Kit for purge of dry air during standstill

When frequent and long standstills occur, it is recommended to install a kit for purge of dry air to guarantee
the life time of the oil-free screw elements. During standstill, condensation (which triggers corrosion) might
occur. This results in an expected element lifetime reduction or even a compressor stage blocking during
standstill. Condensation is prevented by blowing a small amount of dry air through the small gap between
rotor-rotor and rotor-housing once the compressor is stopped. To avoid long standstills, regular starting can
be programmed in the Elektronikon controller or by a central Atlas Copco ES controller.
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2.2 Air system
Flow diagram
Flow diagram of ZR 160 up to ZR 275
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Flow diagram of ZR 160 up to ZR 275 Full-Feature compressors
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Flow diagram of ZT 160 up to ZT 275 compressors
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Flow diagram of ZT 160 up to ZT 275 Full-Feature compressors
Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca1 Pre-aftercooler
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Reference Name
Ca Aftercooler
Ci1 Pre-intercooler
Ci Intercooler
Co Oil cooler
Cr Regeneration air cooler
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
FN Fan
MTa Moisture trap, aftercooler
MTi Moisture trap, intercooler
Nz Ejector nozzle
OF Oil filter
OP Oil pump
Ws Water separator
1 Demister
2 Rotor
3 Throttle valve, regeneration air inlet
4 Strainer
Description
Air drawn through filter (AF) is compressed in low-pressure compressor element (El). On ZR compressors,
the compressed air is discharged to intercooler (Ci).
On ZT compressors, the compressed air is discharged to silencer, pre-intercooler (Ci1) and intercooler (Ci).
The cooled air is further compressed in high-pressure compressor element (Eh) and discharged through
silencer (AS) and aftercooler (Ca).
On ZR/ZT 160 up to ZR/ZT 275, a check valve (CV) is fitted downstream of the silencer.
The wet air from the aftercooler enters water separator (Ws) via ejector nozzle (Nz). In demister (1), the water
droplets are removed from the air. The air is then led through rotor (2), which adsorbs the water vapour.
The compressed air leaves the compressor via the air outlet (AO).
Regenerating circuit of the dryer

Hot regeneration air is branched off from the aftercooler. The regeneration air passes through throttle valve
(3) and strainer (4), and is blown through the wet rotor channels.
The hot saturated air is then cooled down in regeneration air cooler (Cr). The regeneration air is then mixed
with the wet compressed air from the compressor aftercooler.
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2.3 Cooling and condensate system
Flow diagram
Flow diagram of ZR 160 up to ZR 275 compressors
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Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca1 Pre-aftercooler
Ca Aftercooler
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Reference Name
Ci1 Pre-intercooler
Ci Intercooler
Co Oil cooler
CV Check valve
FN Fan
OF Oil filter
OP Oil pump
Cooling system for ZR compressors

The cooling water flows through oil cooler (Co), the cooling jackets of high-pressure compressor element
(Eh) and low-pressure compressor element (El), as well as through intercooler (Ci) and aftercooler (Ca).
Cooling system for ZT compressors

The compressors are fitted with an oil cooler (Co), intercoolers (Ci1 and Ci) and aftercoolers (Ca1 and
Ca). The coolers are air-cooled, the cooling air is generated by fan (FN).
Condensate drain
Two moisture traps are installed: one downstream of the intercooler (MTi) to prevent condensate from
entering compressor element (Eh) and one downstream of the aftercooler (MTa) to prevent condensate
from entering the air outlet pipe.
On ZR/ZT 160 up to ZR/ZT 275, the moisture traps are connected to an ERD, see section Elektronikon
Regulated Drain.
2.4 Elektronikon regulated drain (ERD)
Description
The drain consists of a capacitive sensor which is incorporated in the drain collector and of a pilot valve
which is placed outside the drain collector. A drain opening delay timer is started when the collector is
filled up to the level of the capacitive sensor. As long as the delay timer is running, extra condensate will
be collected and the level will rise even higher than the position of the sensor. As soon as the delay timer
has expired, the pilot valve (normally open) is deactivated and the diaphragm opens the outlet,
discharging the condensate. From the moment that the sensor is not detecting any condensate anymore, a
drain closing delay timer is started. The pilot valve will still drain the condensate during the run of this
timer to make sure that the remaining amount of condensate is drained. The pilot valve is activated when
the timer has expired, the outlet closes quickly without wasting compressed air.
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Reference Description
1 Solenoid valve
2 Connector
3 Sensor
4 Bushing
5 Drain receiver
If the controller registers water in the intercooler or aftercooler drain receiver for too long a period, a shutdown
is generated. If water is detected on the integrated dryer for too long a period, a warning is generated.
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The level switch is a capacitive sensor which generates a high signal when no water is present. The
solenoid valves of the intercooler and aftercooler/integrated dryer are different. The solenoid valve of the
intercooler has a high flow but cannot handle high pressures. The solenoid valve on the aftercooler has less
flow but can handle higher pressures. It is not allowed to open the valves as they can loose their set point.
Special attention must be paid to the correct wiring of the different level switches and solenoid valves.
The output of the level switch can be called up on the screen of the Elektronikon regulator. The reading does
not indicate whether the solenoid valve is open or closed, but indicates whether the level switch is detecting
water in the collector. Since there is a drain opening delay timer, the display on the Elektronikon can show
"Condensate Drain IC Open", while the solenoid valve is still closed. Changes to the Elektronikon settings
are not allowed. The "Always pressurized" bit must be activated on aftercooler and integrated dryer drains.
On the intercooler it is not allowed to activate this bit.
A functionality test is possible through the Elektronikon regulator. By performing this test, all solenoid valves
will be opened for a short time (e.g. 15 seconds). The test can be performed by pressing the Menu key (F1),
scrolling down to "Test" and select with the tabulator key and then scrolling down to "Drain test" and selecting
again.
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2.5 Oil system
Flow diagram
Flow diagram of ZR 160 up to ZR 275 compressors
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Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca1 Pre-aftercooler
Ca Aftercooler
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Reference Name
Ci1 Pre-intercooler
Ci Intercooler
Co Oil cooler
CV Check valve
FN Fan
OF Oil filter
OP Oil pump
Description
Oil is circulated by pump (OP) from the sump of the gear casing through cooler (Co).
On ZT compressors, the oil flows through the cooling jackets of the compressor elements (El and
Eh). The oil passes through oil filters (OF) towards the bearings and timing gears.
Valve (BV) opens if the oil pressure should rise above a given value.
2.6 Regulating system
General
The regulator keeps the net pressure within programmable pressure limits by automatically loading and
unloading the compressor depending on the air consumption.
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During unloading
If the air consumption is less than the air delivery of the compressor, the net pressure increases. When the
net pressure reaches the upper limit of the working pressure (unloading pressure), solenoid valve (Y1) is
de- energised. The plunger of solenoid valve (Y1) moves by spring force shutting off the control air
supply to unloader (UA).
Phase Description
1 Control pressure is vented from chamber (1) of unloader (UA) through solenoid valve (Y1)
and chamber (3) towards the inlet of compressor element (El).
2 As there is no longer any pressure difference between chambers (1 and 3), plunger (2)
returns by spring force keeping full-load/no-load valve (TV) closed and unloading valve
(UV) open.
3 Compressed air between check valve (CV) and valve (UV) is blown off through silencer
(US). Check valve (CV) closes.
4 As vacuum prevails in intercooler (Ci), diaphragm (4) switches to the left.
Air delivery is stopped (0%), the compressor runs unloaded.
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During loading
When the net pressure decreases to the lower limit of the working pressure (loading pressure), solenoid
valve (Y1) is energised. The plunger of solenoid valve (Y1) moves against the spring force opening the
control air supply port to unloader (UA).
Phase Description
1 Atmospheric pressure is allowed through solenoid valve (Y1) to chamber (1) of unloader
(UA). As this pressure is higher than the pressure in chamber (3), full-load/no-load valve
(TV) starts opening.
2 Intercooler pressure is building up causing diaphragm (4) to switch to the right. As the
pressure difference between chambers (1 and 3) increases, plunger (2) moves further
against the spring force until full-load/no-load valve (TV) is fully open and unloading valve
(UV) closed.
Air delivery is resumed (100%), the compressor runs loaded.
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3 Elektronikon regulator type overview
3.1 Elektronikon® controller type overview

Type overview
Depending on the manufacturing date the compressor is equipped with the Elektronikon controller or the
Elektronikon controller GraphicPlus.
Elektronikon controller
Elektronikon GraphicPlus controller for fixed speed compressors
Please check the respective section in the following sections for user instructions.
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4 Elektronikon regulator
4.1 Elektronikon® regulator
Control panel
Introduction
In general, the Elektronikon regulator has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (made inactive)
Automatic control of compressor operation

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

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

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

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

1 Start button Button to start the compressor. LED (8) lights up
indicating that the Elektronikon regulator is operative.
2 Display Shows messages about the compressor operating
condition, a service need or a fault.
3 Scroll keys Keys to scroll upwards or downwards through the
display.
4 Tabulator key Key to select the parameter indicated by the horizontal
arrow. Only the parameters followed by an arrow
pointing to the right can be modified.
5 Function keys Keys to control and program the compressor.
6 Voltage on LED Indicates that the voltage is switched on.
7 General alarm LED Is lit if a shut-down warning condition exists or
maintenance is required.
7 General alarm LED Flashes if a shut-down condition exists, if an important
sensor is out of order or after an emergency stop.
8 Automatic operation LED Indicates that the regulator is automatically controlling
the compressor.
9 Stop button Button to stop the compressor. LED (8) goes out.
S2 Emergency stop button Push button to stop the compressor immediately in the
event of an emergency. After remedying the trouble,
unlock the button by pulling it out.
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4.3 Function keys
Control panel
Function keys
The keys (1) are used:
• To manually load/unload the compressor
• To call up or to program settings
• To reset a motor overload, shut-down or service message, or an emergency stop
• To access all data collected by the regulator
The functions of the keys vary depending on the displayed menu. The actual function is indicated just
above the relevant key. The most common functions are listed below:
Designation Function
“Add” To add compressor start/stop commands (day/hour)
“Back” To return to a previously shown option or menu
“Cancel” To cancel a programmed setting when programming parameters
“Delete” To delete compressor start/stop commands
“Help” To find the Atlas Copco internet address
“Limits” To show limits for a programmable setting
“Load” To load the compressor manually
“Mainscreen” To return from a menu to the main screen
“Menu” Starting from the main screen, to have access to the submenus
“Menu” Starting from a submenu, to return to a previous menu
“Modify” To modify programmable settings
“Program” To program modified settings
“Reset” To reset a timer or message
“Return” To return to a previously shown option or menu
“Unload” To unload the compressor manually
“Extra” To find the module configuration of the regulator
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4.4 Scroll keys
Control panel
The keys (1) allow the operator to scroll through the display.
As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll
key with the same symbol can be used to see the next item.
As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key
with the same symbol can be used to see the previous item.
When the scroll key is kept pressed, the scrolling is continued.
4.5 Emergency stop button
Control panel
In case of emergency, press button (S2) to stop the compressor immediately.

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

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

Automatic operation K07 11-12 10 A / 230 V AC
Warning K08 13-14 10 A / 230 V AC
Shut-down K09 15-16 10 A / 230 V AC
Compressor loaded K11 19-20 10 A / 230 V AC
Compressor running K21 17-18 10 A / 230 V AC
4.7 Control programs
Description
In order to facilitate programming and controlling, menu-driven control programs have been implemented in
the regulator.
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Menu flow for ZR/ZT 160 up to ZR/ZT 275 (simplified)
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Main menu
Program Function
Main screen Shows in short the operation status of the compressor. Is the gateway to all
functions.
“Status data” Calls up the status of the compressor protection functions (shut-down, shut-down
warning, service warning and warning). Resets a shut-down, motor overload and
service condition.
“Measured data” Calls up the data currently measured and the status of a number of inputs.
“Counters” Calls up the running hours, regulator (module) hours and number of motor starts.
“Test” Display test.
“Modify parameters” Modifies the settings for:
• Parameters (e.g. loading and unloading pressures)
• Protections (e.g. temperature shut-down level)
• Service plans (timers for service plans)
• Clock functions (automatic compressor start/stop/pressure band commands)
• Configuration (time, date, display language,...)
“Service” Calls up service plans and resets the timers after carrying out the service actions
belonging to a plan.
“Saved data” Calls up the saved data: last shut-down, last emergency stop data.
“Unload/Load” Loads and unloads the compressor manually.
4.8 Control programs
Function
In order to facilitate programming and controlling, menu-driven control programs have been implemented
in the regulator.
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Menu flow
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Program Function
„Main‟ Shows in brief the operational status of the pre-cooler. Is the gateway to all functions.
„Status Data‟ Calls up the status of the pre-cooler protection functions (shut-down, shut-down
warning and warning). Resets a shut-down and motor overload.
„Measured Data‟ Calls up the data currently measured and the status of a number of inputs.
„Counters‟ Calls up:
• Running hours
• Regulator (module) hours
• Number of motor starts
„Test‟ Allows:
• A display test
• A test of the electronic water drains
„Modify Params‟ Modifying the settings for:
• Dryer motor settings
• Parameters (not accessible)
• Protections (e.g. high pressure)
• Service plans (no service plans are programmed ex-factory)
• Clock functions (automatic start/stop commands)
• Configuration (time, date, display language,...)
„Service‟ No service plans are programmed ex-factory.
„Saved Data‟ Calls up the saved data: maximum five last shut-down data, last emergency stop
data.
4.9 Calling up menus
Description
Control panel
When the voltage is switched on, the Main screen is shown automatically. Example of Main screen of ZR
160 up to ZR 275
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“Compressor Outlet” 7.5 bar

.
“Automatically Loaded”
“Menu” “Unload”
F1 F2 F3
Example of Main screen of ZT 160 up to ZT 275

.
F1 F2 F3
After pressing the “Menu” (F1) key, the option “Status Data” will be followed by a horizontal arrow:
• Either press the tabulator key (2) to select this menu,
• or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then
press the tabulator key (2) to select this menu.
The arrow down key (1) can be used for a quick look at the actual compressor status.
Description
Control panel
When the voltage is switched on, the Main screen is shown automatically.
Main screen
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„Dryer PDP‟
˚C 5.5 ˚C
„Dryer Off‟
„Menu‟
F1 F2 F3
After pressing the „Menu‟ (F1) key, the option „Status Data‟ will be followed by a horizontal arrow:
• Either press the tabulator key (2) to select this menu,
• or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then
press the tabulator key (2) to select this menu.
The arrow down key (1) can be used for a quick look at the actual compressor status.
It is possible to go directly to the Configuration menu by pushing the arrow up key (1) for 2 seconds.
4.11 Main screen menu
Function
Control panel
The Main screen menu shows the status of the compressor operation and is the gateway to all
functions implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will automatically
return to the Main screen.
Whenever displayed on a submenu screen, press the “Mainscreen” (F1) key to return to the Main
screen. Example of Main screen of ZR 160 up to ZR 275
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.
F1 F2 F3
Example of Main screen of ZT 160 up to ZT 275

.
F1 F2 F3
The display indicates:

• The name of the sensor and its actual reading
• Messages regarding the compressor operating condition
• Just above the function keys (3), the actual functions of these keys
4.12 Main screen menu
Function
Control panel
The Main screen menu shows the status of the dryer operation and is the gateway to all functions
implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
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If the function or arrow keys (1, 2 and 3) are not used for some minutes, the regulator will automatically
return to the Main screen.
Whenever displayed on a submenu screen, press the „Main‟ (F1) key to return to the Main screen. Main
screen
„Dryer PDP‟
˚C 5.5 ˚C
„Dryer Off‟
„Menu‟
F1 F2 F3
The display indicates:

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

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

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

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

A shut-down warning level is a programmable level below the shut-down level.
• If a shut-down warning exists, LED (1) is alight. The Main screen will change into a screen similar to
the one below:
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.
*** “Shutdown Warning” ***
“Menu”*** ***”Unload”
F1 F2 F3
• The message “Shutdown Warning” appears.

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

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

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

.
“*Service Required*”
“Menu”*** ***”Unload”
F1 F2 F3
• The indicators (***) are blinking and the service warning message appears.
• Press the key Menu (F1) and the tabulator key (2) to select the “Status data” menu: the option “Service”
is blinking.
• Scroll to this option and select it by pressing the tabulator key (2); two options may blink:
• “Inputs”: if the programmed service level of a component is exceeded (e.g. the maximum
pressure drop of the air filter).
• “Plan”: if a service plan interval is exceeded.
• Stop the compressor and switch off the voltage.
• In case the service message was referring to “Inputs” (air filter): replace the filter, switch on the
voltage, scroll in the “Status Data” menu to “Inputs” and press the “Reset” key to reset the service
message.
• In case the service message was referring to “Plan”: carry out the service actions related to the
indicated plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See
Service menu.
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4.14 Measured data menu
Control panel
Function
To call up information regarding the actually measured data and the status of some inputs such as the motor
overload protection. Consult the menu flow in section Control programs.
Procedure
• Press the key “Menu” (F1).
• Press the arrow down key (1) until “Measured Data” is followed by a horizontal arrow.
• Activate the menu by pressing the tabulator key (2).
• By pressing the scroll keys (1), a number of actually measured data can be found.
• If one of the sensors is linked to a shut-down, service or warning function, both the actually measured
value as well as the corresponding shut-down, warning or service level can be called up by pressing key
(2).
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4.15 Counters menu
Control panel
Function
To call up:
• The running hours
• The loaded hours
• The number of motor starts
• The number of hours the regulator (module) has been under tension
• The number of load cycles
Procedure
• Press the arrow down key (1) until “Counters” is followed by a horizontal arrow.
• Press the tabulator key (2) to activate the menu.
• By pressing the arrow key (1), the above-mentioned data can be found.
Example of a Counters screen
.
“Running Hours” 2455 “hrs”
“Loaded Hours” 1973 “hrs”
“Motor Starts” 945
“Menu”
F1 F2 F3
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4.16 Test menu
Control panel
Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.
To test the Electronic Water Drains (EWD)
Procedure
• Starting from the Main screen (see Main screen menu), press the “Menu” (F1) key.
• Press arrow down key (1) until “Test” is followed by a horizontal arrow.
• Activate the menu by pressing the key (2).
To perform a display test:
• If necessary, scroll through the menu until “Display Test” is followed by a horizontal arrow.
• Press the key (2).
• During testing, the regulator will generate a series of patterns on the display which enable the operator to
check that each pixel still functions normally; the LEDs are lit at the same time.
• Press the “Menu” key (F1) to return to the submenu.
To test the Electronic Water Drains (on compressors designed for an ambient temperature of 40 ˚C
(104 ˚F):
• Press the arrow down key until the option “Outputs” is followed by a horizontal arrow.
• Press the “Start” key.
• Check that the valve opens for condensate discharge.
• Release the “Start” key after testing.
• Press the “Back” key to return to the previous menu.
To test the Electronic Water Drains (on compressors designed for an ambient temperature of 50 ˚C
(122 ˚F):
• Press the arrow down key until the option “Drain Test” is followed by a horizontal arrow.
• Press the “Start” key.
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• Check that the valve opens for condensate discharge.

• Press the “Stop” key after testing.
• Press the “Back” key to return to the previous menu.
4.17 Modify parameters menu
Function
To modify a number of programmable settings:
• Parameters (see section Modifying parameters).
• Protections (see section Modifying protections).
• Service plan settings (see section Modifying service plan settings).
• Clock function settings (see section Modifying clock function settings).
• Configuration settings (see section Modifying configuration settings).
4.18 Modifying parameters
Control panel
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
• Press the arrow down key (1) until “Modify Parameters” is followed by a horizontal arrow.
• The first item “Parameters” will be followed by a horizontal arrow.
• Press the tabulator key (2): the first items and their settings will appear.
• Press the arrow down key (1) until the parameter to be modified is followed by a horizontal arrow.
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Modifying the loading pressure setpoint

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

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

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

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

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

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

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

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

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

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

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

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

Service plan A 4000 running hours
Service plan A and B 8000 running hours
Service plan A 12000 running hours
Service plan A, B and C 16000 running hours
... ...
Procedure
• Press the arrow down key (1) until “Service” is followed by a horizontal arrow.
• A screen similar to the one below appears:
“Service Timer”
“Running Hours”
7971 “hrs”
“Menu” “Reset”
F1 F2 F3
• The screen shows that the total compressor running time is 7971 hours.
“Next Timer”
“Level” AB
8000 “hrs”
“Back” “Reset”
F1 F2 F3
• The screen shows that the next service plans to be carried out are plans A and B and that these plans
are to be carried out every 8000 running hours.
• Press the arrow down key (1) to find out which service plans were carried out previously, following
screen appears:
“Previous Timer”
“Level” A
4008 “hrs”
“Back”
F1 F2 F3
• The screen shows that plan A was carried out at 4008 running hours.
• Stop the compressor, switch off the voltage and carry out the service operations related to the
indicated service plans, see section Preventive maintenance schedule.
• Switch on the voltage and scroll to the “Next Timer” service screen.
• Press the “Reset” button (F3). Confirm the question for resetting.
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The “Reset” button only appears when the “Next Timer” level is almost reached.
After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours are
shown, i.e. the number of hours elapsed since initial programming ex-factory. This timer is
not taken into account.
4.24 Saved data menu

Control panel
Function
To call up some data saved by the regulator. These data are:
• Last shut-down data
• Last emergency stop data
Procedure
• Press the arrow down key (1) until “Saved Data” is followed by a horizontal arrow.
• The first option is shown “Last shutdown 1”.
• Press the tabulator key (2) to find out the date, time and other data reflecting the status of the
compressor at the last shut-down.
• If desired, scroll through the other items.
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4.25 Programmable settings
Parameters
Minimum Factory Maximum

setting setting setting
Motor running time in star, ZR/ZT 160 up to sec 15 15 30
ZR/ZT 275 (star-delta)
Load delay time (star-delta) sec 3 10 30
Load delay time (no star-delta) sec 13 20 30
Number of motor starts (star-delta) starts/day 0 72 120
Number of motor starts (no star-delta) starts/day 0 3 5
Minimum stop time sec 20 20 99
Programmed stop time sec 0 3 20
Power recovery time (ARAVF) sec 15 15 3600
Restart delay sec 0 3 255
Communication time-out sec 10 20 60
Permissive start function failure sec 0 30 255
Unloading pressure (7 bar Pack bar(e) 4.0 6.5 7.0
compressors)
Unloading pressure (100 psi Pack psig 58 94 101.5
compressors)
Unloading pressure (7 bar Full-Feature bar(e) 5.0 6.5 7.0
compressors)
Unloading pressure (100 psi Full-Feature psig 73 94 101.5
compressors)
Unloading pressure (7.5 bar Pack bar(e) 4.0 7.0 7.5
compressors)
Unloading pressure (110 psi Pack psig 58 101.5 108.8
compressors)
Unloading pressure (7.5 bar Full-Feature bar(e) 5.5 7.0 7.5
compressors)
Unloading pressure (110 psi Full-Feature psig 80 101.5 108.8
compressors)
Unloading pressure (8.6 bar compressors) bar(e) 4.0 7.0 8.6
Unloading pressure (125 psi compressors) psig 58 101.5 124.7
compressors)
Unloading pressure (145 psi Pack psig 58 130.5 145
compressors)
compressors)
Unloading pressure (145 psi Full-Feature psig 109 130.5 145
compressors)
Unloading pressure (10.4 bar Pack bar(e) 4.0 9.0 10.4
compressors)
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compressors)
Unloading pressure (10.4 bar Full-Feature bar(e) 7.5 9.0 10.4
compressors)
compressors)
compressors)
Unloading pressure (190 psi Pack psig 58 174 188.5
compressors)
compressors)
Unloading pressure (190 psi Full-Feature psig 138 174 188.5
compressors)
Loading pressure (7 bar Pack compressors) bar(e) 4.0 6.0 7.0
Loading pressure (100 psi Pack psig 58 87 101.5
compressors)
Loading pressure (7 bar Full-Feature bar(e) 5.0 6.0 7.0
compressors)
Loading pressure (100 psi Full-Feature psig 73 87 101.5
compressors)
Loading pressure (7.5 bar Pack bar(e) 4.0 6.0 7.5
compressors)
compressors)
Loading pressure (7.5 bar Full-Feature bar(e) 5.5 6.0 7.5
compressors)
compressors)
compressors)
compressors)
compressors)
compressors)
Loading pressure (10 bar Pack bar(e) 4.0 8.0 10.0
compressors)
Loading pressure (145 psi Pack psig 58 116 145
compressors)
compressors)
Loading pressure (145 psi Full-Feature psig 109 116 145
compressors)
compressors)
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compressors)
compressors)
compressors)
Loading pressure (13 bar Pack bar(e) 7.0 10.5 13.0
compressors)
Loading pressure (190 psi Pack psig 101.5 152 188.5
compressors)
compressors)
compressors)
Protections
ZR/ZT 160 up to ZR/ZT 275

Compressor outlet pressure (warning) bar(e) 0 14.0 17.0
Compressor outlet pressure (warning) psig 0 203 246.5
Compressor outlet pressure (shut-down) bar(e) 0 15.0 17.0
Compressor outlet pressure (shut-down) psig 0 217.5 246.5
Oil pressure (shut-down warning level) bar(e) 1.0 1.3 2.0
Oil pressure (shut-down warning level) psig 14.5 19 29
Oil pressure (shut-down level) bar(e) 1.0 1.2 2.0
Oil pressure, ZR/ZT 160 up to ZR/ZT 275 psig 14.5 17.4 29
(shut-down level)
Delay at start, oil pressure sec 15 15 20
Delay at signal, oil pressure sec 0 1 3
Compressor element 1 outlet temperature
(shut-down warning level) (7.0, 7.5 and 8.6
bar or 100, 110 and 115 psi compressors)
Compressors designed for a maximum inlet ˚C 100 210 220
temperature of 40 ˚C
Compressors designed for a maximum inlet ˚F 212 410 428
temperature of 104 ˚F
(shut-down level) (7.0, 7.5 and 8.6 bar or
100, 110 and 115 psi compressors)
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(shut-down warning level) (10.0, 10.4 and
12.0 bar (175 psi) compressors)
(shut-down level) (10.0, 10.4 and 12.0 bar
(175 psi) compressors)
Compressor element 1 outlet temperature ˚C 100 255 260
(shut-down warning level) (13.0 bar (190
psi) compressors)
Compressor element 1 outlet temperature ˚F 212 491 500
(shut-down warning level) (13.0 bar (190
psi) compressors)
Compressor element 1 outlet temperature ˚C 256 260 260
(shut-down level) (13.0 bar (190 psi)
compressors)
Compressor element 1 outlet temperature ˚F 493 500 500
(shut-down level) (13.0 bar (190 psi)
compressors)
(shut-down warning level) (7.0, 7.5 and 8.6
bar or 100, 110 and 115 psi compressors)
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(shut-down level) (7.0, 7.5 and 8.6 bar or
100, 110 and 115 psi compressors)
(shut-down warning level) (10.0, 10.4 and
12.0 bar compressors)
ZR Compressors designed for a maximum ˚C 100 225 235
inlet temperature of 50 ˚C
ZR Compressors designed for a maximum ˚F 212 437 455
inlet temperature of 122 ˚F
ZT Compressors designed for a maximum ˚C 100 255 260
ZT Compressors designed for a maximum ˚F 212 491 500
(shut-down warning level) (13.0 bar
compressors)
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(shut-down level) (10.0, 10.4 and 12.0 bar
compressors)
(shut-down level) (13.0 bar compressors)
Delay at signal (all compressor element sec 0 1 3
temperatures)
Oil temperature (shut-down warning level) ˚C 40 65 80
Oil temperature (shut-down warning level) ˚F 104 149 176
Oil temperature (shut-down level) ˚C 40 70 80
On ZT compressors designed for an inlet
temperature of 50 ˚C, the maximum setting
is increased to 85 ˚C
Oil temperature (shut-down level) ˚F 104 158 176
On ZT compressors designed for an inlet
temperature of 122 ˚F, the maximum setting
is increased to 185 ˚F
Delay at start, oil temperature sec 50 70 100
Delay at start, starter feed-back contact sec 0 18 33
(shut-down)
Delay at signal, starter feed-back contact sec 0 2 3
(shut-down)
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Delay at start, compressor electronic sec 0 15 60
condensate drain (warning)
Delay at signal, compresor electronic sec 5 5 5
condensate drain (warning)
Delay at start, dryer electronic condensate sec 0 15 60
drain (warning)
Delay at signal, dryer electronic condensate sec 5 5 5
drain (warning)
Service warning level for DP of air filter mbar 50 44 44
Service warning level for DP of air filter psi 0.73 0.6 0.6
Delay at signal, DP of air filter sec 0 60 255
Service plans

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

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

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

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

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

The Elektronikon Mk5 always comes with expansion module IO2 that has a number of digital output
contacts which can be used to connect external equipment.
Expansion Module IO2 for Elektronikon Mk5 GraphicPlus
The digital output contacts have following specifications:
Relay Connector Maximum load

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

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

Stopped / Running When the compressor is running, the icon rotates.
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Compressor status Motor stopped
Local start / stop
Machine control mode Remote start / stop
Network control
Automatic restart after voltage

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

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

(2) Loaded hours
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(3) Text varies upon the compressor's actual condition

(4) Menu
(5) Running hours
(6) Element outlet
(6) Compressor outlet
(7) Load
• Section A displays information regarding the compressor operation (e.g. outlet pressure (1),
temperature at compressor outlet (2)).
• Section B displays Status icons. Following icon types are shown in this field:
• Fixed icons
These icons are always shown in the main screen and cannot be selected by the cursor (e.g.
Compressor stopped or running)
• Shortcut icons
These icons are always shown in the main screen. If the icon is selected and the Enter key is
pushed, the screen will jump to the corresponding menu (e.g. if the icon for Motor stopped or
Running Loaded is selected, the screen will jump directly to the regulation menu after pressing
the enter key).
• Control mode icons
These icons are always shown in the main screen. If the icon is selected and the Enter key is
pushed, the screen jumps to the control mode menu. Following control modes are available:
Local control
Remote control
Network control
• Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer, automatic
restart after voltage failure, etc.)
• Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To show more information about displayed icons, select the icon using the scroll keys and push the Enter
key.
• Section C is called the Status bar
This bar shows the text that corresponds to the selected icon.
• Section D shows the Action buttons. These buttons are used:
• to call-up or program settings
• to reset a shutdown, service message or emergency stop
• to have access to all data collected by the controller
The function of the buttons depends on the displayed menu. The most common functions are:
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Designation Function
Menu To go to the menu
Modify To modify programmable settings
Reset To reset a timer or message
To enable an action button, highlight this button by using the Scroll keys and push the Enter
key. To go back to the previous menu, push the Escape key.
Chart views
When the Chart (High Resolution) display is selected, a chart with an X-axis covering 4 minutes is
displayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chart
dot represents 1 second.
When the Chart (Medium Resolution) display is selected, a chart with an X-axis covering 4 hours is
dot represents a 1 minute average value.
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When the Chart (Low Resolution) display is selected, a chart with an X-axis covering 10 days is
dot represents a 1 hour average value.
Control panel
Control panel
(1) Enter key

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

(2) Escape key
(3) Scroll keys
Menu icon, Service
Function
If the controller should indicate another time interval for the service plans than the one
stated in the instruction book, see section Preventive maintenance; the most strict
should be carried out. The compressor owner is responsible to carry out maintenance
at the given time intervals of the spare parts
• To reset the service plans that have been carried out.

• To check when the next service plans should be carried out.
• To check which service plans were carried out in the past.
• To modify the programmed service intervals.
Procedure
Starting from the Main screen (see Main screen),
• Move the cursor to the Menu action key and push the Enter key. Following screen appears:
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• Use the Scroll keys to move the cursor to the Service icon.
• Push the Enter key and following screen appears:
Text on figure
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
• Scroll through the items and select the desired item. Push the Enter key to display the details as
explained below.
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Overview
Text on figure
(1) Overview
(2) Running Hours
(3) Real Time Hours
(4) Reset
Running hours are the clocked times during which the compressor stage motor has been running. Real Time
Hours are programmable timers which keep counting even when the compressor isn't running. E.g. when a
customer would like to change a part yearly or every 4000 running hours, service level A can be put on Running
Hours 4000 hours and Real Time Hours 8800 (8760 hours = 1 year). A service warning will be displayed
after one year or sooner (after 4000 running hours ) if the compressor has been running a lot.
The figures at the left of the progress bars are the programmed service interval Running or Real Time
Hours. Those at the right count down and show the number of hours that need to be covered to reach the
next service intervention.
Colored letters indicate the next upcoming service level.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level represents a number
of service actions to be carried out at the time intervals programmed in the Elektronikon controller.
When a service plan interval is reached, a message will be displayed.
After carrying out the service actions related to the indicated levels, the timers must be reset manually. From
the Service menu above, select Service plan (3) and press Enter. Following screen appears:
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Text on figure
(1) Service plan

(2) Level
(3) Running hours
(4) Real time hours
(5) Modify
Modifying a service plan

Depending on the operating conditions, it might be necessary to modify the service intervals. To do so,
use the Scroll keys to select the value to be modified. A screen similar to the one below appears:
Push the Enter key. Following screen appears:
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Modify the value as required using the ↑ or ↓ scroll key and push the Enter key to confirm.
Note: Running hours and real time hours can be modified in steps of 100 hours.
Next Service
Text on figure
(1) Next service

(2) Level
(3) Running hours
(4) Actual
In the example above, the I Service level is programmed at 2000 running hours, of which 0 hours have passed.
History
The History screen shows a list of all service actions carried out in the past, sorted by date. The date at the
top is the most recent service action. To see the details of a completed service action (e.g. Service level,
Running hours or Real time hours), use the Scroll keys to select the desired action and push the Enter key.
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5.8 Protections menu
Control panel
Menu icon, Protections
Function
• To display and reset the protections.
Before resetting a warning or shutdown message, always solve the problem. Frequently
resetting these messages without remedying may damage the compressor.
Procedure
Starting from the Main screen (see Main screen):
• Move the cursor to the Menu action button and push the enter key (2). Following screen appears:
• Using the Scroll keys (1), move the cursor to the protections icon.
• Push the Enter key (2). Following screen appears:
A number of icons is shown, allowing to display and reset following protections:

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

• Warning/shutdown level of element 1 outlet temperature
• Warning/shutdown level of element 2 inlet temperature
• Warning/shutdown level of element 2 outlet temperature
•
Fan:
• Overload Fan Motor: Triggered if the overload of the fan motor trips.
•
Drain(s):
• Condensate Drain IC not ok (IC= Intercooler)
• Condensate Drain AC not ok (AC= Aftercooler)
•
Filters
• Warning/shutdown level (Low) of DP air filter (DP: delta pressure or pressure drop)
• DP air filter service level (Low)
•
Main Motor
• Overload Motor
• Starter Feedback Contact Open: monitors position of the delta contactor
• Starter Feedback Contact Close: monitors position of the delta contactor
•
Expansion Module Communication

• Not triggered: if Triggered the communication between the Elektronikon and the expansion
module failed.
•
.
Cooler
• Low level warning alarm of intercooler pressure
• High level warning alarm of cooling air inlet
•
Oil circuit
• Warning/shutdown level (Low) of oil pressure
• Warning/shutdown level (High) of oil temperature
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5.9 Week timer menu
Control panel
(1) Enter key

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

(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week 1
(6) Remaining Running Time
The selected item is highlighted in grey. Select the desired item and push the Enter key on the
controller to modify.
Programming week schemes

• Select Week Action Schemes and push Enter. A new window opens. The first item in the list is
highlighted in grey. Push the Enter key on the controller to modify Week Action Scheme 1.
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(2) Week Action Scheme 1
• When entering a Week Action Scheme, the corresponding week is displayed. The selected day
is highlighted in grey and the desired action can be set by pushing Enter.

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday
• A new window opens. The Modify action button is selected. Push the Enter key on the controller
twice to create the first action.
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(1) Monday
(2) Modify
• A new window appears. Select an action from the displayed list by using the Scroll keys on the controller.
Push the Enter key to insert e.g. a first startup time.
(1) Monday
(2) Actions
(3) Remove
(4) Start
(5) Stop
(6) Modify
• A new window opens. The startup action is now visible on Monday of Week Action Scheme 1/4.
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(1) Monday
(2) Start
(3) Save
(4) Modify
• To adjust the startup time, use the Scroll keys on the controller and push the Enter key to confirm.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A window appears. Use the ↑ or ↓ scroll keys to modify the hour values. Use the ← or → Scroll keys
to select the minutes and modify the values using the ↑ or ↓ scroll keys.
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(1) Monday
(2) Time
(3) Save
(4) Modify
• Push the Escape key on the controller. The Modify action button is selected. Use the Scroll keys to
select the action Save.
(1) Monday
(2) Start
(3) Save
(4) Modify
• A new window appears. Use the Scroll keys on the controller to select the correct actions. Press the
Enter key to confirm.
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(1) Monday
(2) Are you sure?
(3) No
(4) Yes
(5) Save
(6) Modify
Press the Escape key to leave this window.

• The actions are displayed below their respective day.

(2) Monday
(3) Start
(4) Tuesday
(5) Wednesday
(6) Thursday
(7) Friday
(8) Saturday
(9) Sunday
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Push the Escape key on the controller to leave this screen.
Programming the week cycle

A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed Week Action
Schemes can be chosen.
• Select Week Cycle from the main Week Timer menu list.
(1) Week Timer

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

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

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

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

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

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(3) Week Cycle

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

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

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

(2) Enter key
(3) Escape key
Menu icon, Info
Function
To show the Atlas Copco internet address.
Procedure
• Move the cursor to the Menu action button and push the Enter key. Following screen appears:
• Scroll the cursor to the Info icon (see above, section Menu icon).
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• Push the Enter key. The Atlas Copco internet address appears on the screen. At the bottom of the screen,
the More button is displayed. Push the button to display following additional info:
• MAC address
• Expansion modules
• Boot software
• Operating system
• Application software
• PEG software
• Licence ESi
5.11 Test menu

Control panel
Menu icon, Test
Function
• To perform a safety valve test and a drain test. Both actions can only be performed by authorized personnel
and are protected by a security code.
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5.12 Counters
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Counters
Function
To display:
• The running hours
• The loaded hours (air delivery)
• The number of motor starts
• The number of load cycles
• The number of hours that the controller has been powered (module hours)
Procedure
• Move the cursor to the Menu action button and press the Enter key. Following screen appears:
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Text on figure
(1) Menu
(2) Regulation
• Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon)
• Press the Enter key. Following screen appears:
Text on figure
(1) Counters
(2) Running hours
(3) Loaded Hours
(4) Motor starts
(5) Load relay
The screen shows a list of all counters and their current values.
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5.13 Modifying the pressure band

Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Regulation
Function
The regulation menu allows tuning of 2 pressure bands and the selection of the current pressure band.
Procedure
• The regulation menu is accessible in two ways:
a. select Menu action key using the Scroll keys and push the Enter key. Following screen appears:
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Text on figure
(1) Menu
(2) Regulation
Enter the Regulation menu by pushing Enter once again while the Regulation menu icon is highlighted.
b. Select following shortcut icon in the Main Screen and push enter
.
• Following screen appears:
Text on figure
(1) Regulation
(2) Unloading pressure 1
(3) Loading pressure 1
(4) Unloading pressure 2
(5) Loading pressure 2
(6) Modify
• The screen shows the current settings.

To modify the settings, move the cursor to the action button Modify and push the Enter key.
Following screen appears:
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• Unloading Pressure 1 is highlighted in grey. Use the Scroll keys (3) to highlight the setting to be
modified and push the Enter key (1). Following screen appears:
The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑
or ↓ key of the Scroll keys to modify the settings as required and push the Enter key to accept. If
necessary, change the other settings as required in the same way as described above.
5.14 Inputs menu
Control panel
(1) Enter key

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

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

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

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

To remove the input as main chart, proceed as follows:
• Using the arrow keys, scroll to the input with the small chart icon.
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(2) Remove from main chart

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

Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Outputs
Function
To display information regarding the current status of the digital outputs.
Procedure
Text on figure
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(1) Menu
(2) Regulation
• Move the cursor to the Outputs icon (see above, section Menu icon), using the Scroll keys.
• Push the Enter key.
Depending on the installed optional equipment less or more icons may appear.
• The outputs are categorized under a number of representative icons. Push the Enter key to show the
actual outputs.
General
• Load/Unload
• Automatic operation
• General warning
• General shutdown
•
Drain(s)
• Condensate drain IC
• Condensate drain AC
•
Main Motor
• Line contactor
• Star contactor
• Delta contactor
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5.16 Event history menu

Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Event History
Function
To display a list of all shutdowns, their causes and the status of counters and in/outputs at the moment
of shutdown.
Procedure
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• Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu icon).
• A chronological shutdown list is displayed.
• Select the moment of your interest and push Enter.
• The type of event and the status data of counters and in/outputs will be displayed.
5.17 Modifying settings
Control panel
(1) Enter key

(2) Escape key
(3) Scroll keys
Menu icon, Settings
Function
To display and modify a number of settings (e.g. Time, Date, Date format, Language, units ...)
Procedure
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• Using the Scroll keys, move the cursor to the Settings icon (see above, section menu icon).
• Push the Enter key. Following screen appears:
Depending on the installed optional equipment less or more icons may appear.
• The screen displays following icons:
Icon Function
Network settings
Regulation settings
General settings
Automatic restart after voltage failure settings
Access key
User password
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Icon Function
Main chart
• Move the cursor to the icon of the function that needs to be modified and push the Enter key.
Modifying network settings

• Select the network settings icon as described above and push the Enter key (1). Following screen appears:
Text on figure
(1) Network
(2) CAN
(3) Ethernet
• Scroll to the desired network and push the Enter key. Following screen appears:
Screen for CAN settings
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Screen for Ethernet settings
.
• Push the Enter key once again to modify a parameter. A network parameter can only be modified
when the network is disabled (Off).
Regulation settings
This menu allows to view and modify the regulation settings; see section Modifying the pressure band
General settings
• Select the General settings icon as described above and push the Enter key (1). Following screen appears:
Text on figure
(1) General
(2) Language in use
(3) Time
(4) Date
(5) Date format
• The screen displays the first 4 items of a list of all settings. Scroll through the list to display all other items.
• Push the Enter key, use the Scroll keys to select the setting to be modified and push the Enter key again.
• A screen appears. Use the ↑ or ↓ key to select the required parameter and push the Enter key to confirm.
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Automatic restart
• Select the Automatic restart settings icon as described above and push the Enter key (2). Following
screen appears:
Text on figure
(1) Automatic restart

(2) Maximum power down time
(3) Restart delay
(4) Modify
• The screen displays 3 adjustable settings.

• Push the Enter key (1), scroll to the setting to be modified and push the Enter Key once again.
• A screen appears; the required parameter is adjustable and confirmed by pushing the Enter Key once more.
Access key
A number of security levels are set in the controller (e.g. user, service technician, etc.). The Access key
menu item is used to change the security level.
• Scroll to the correct icon using the scroll key and push the Enter key.
• Push the Enter key twice to modify the security level code and push Enter to confirm.
User password
If the password option is enabled, it is impossible for unauthorized personnel to modify any setting.
• Using the Scroll keys, move the cursor to the Password icon.
• Push the Enter key twice to select and activate.
• Pick a 4 digit password using the Scroll keys and push the Enter key to confirm.
Main chart settings
Chart ranges and bands can be modified. This can cause the current value to be out
of range and can thus cause the absence of a visible curve in the graph.
The main chart settings menu allows to adjust the scale and curves on the graph. To modify these
settings, proceed as follows:
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• Select the Main chart settings icon as described above and push the Enter button (1). Following
screen appears:
Text on figure
(1) Main chart

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

Unit (Pack Feature Max.
version) version)
Pressure regulation (UN)LOAD level

mbar
7.5 bar (50 Hz) 4000 5500 7505
8.6 bar (50 Hz) 4000 6500 8605
10 bar (50 Hz) 7000 7500 10005
13 bar (50 Hz) 7000 9500 13005
=>converted (m)bar-psi values psi
* 108.7 psi (50 Hz) 58.0 79.8 108.9
* 125 psi (50 Hz) 58.0 94.3 124.8
* 145 psi (50 Hz) 101.5 108.8 145.1
* 188.5 psi (50 Hz) 101.5 137.8 188.6
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Min. Min. (Full

Unit (Pack Feature Max.
version) version)
Control timers
s
Unload time 3 3 20
Minimum stop time 20 20 99
Y-D starter
s
Y-D time 10 10 30
Y-D time with motor voltage > or = 2.3 kV 0 0 30
Load delay 3 3 30
Load delay with motor voltage > or = 2.3 kV 13 13 30
Automatic Restart After Voltage Failure - ARAVF

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

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

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

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

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

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

• The banner shows the compressor type and the language selector. In this example, three languages are
available on the controller.
• On the left side of the interface you can find the navigation menu (see picture below).
If a license for ESi is foreseen, the menu contains 3 buttons.
• Compressor (or machine): shows all compressor settings.
• Es: shows the ESi status (if a license is provided).
• Preferences: allows to change temperature and pressure units.
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Compressor settings
All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and it
will be displayed. Only the machine status is fixed and can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference button from
the navigation menu.
Counters
Lists all current counter values from controller and compressor.
Info status
Machine status is always shown on the web interface.
Digital inputs
Lists all Digital inputs and their status.
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Digital outputs
Lists all Digital outputs and their status.
Special protections
Lists all special protections of the compressor.
Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows the running
hours. It is also possible to show the current status of the service interval.
ES screen controller
If an ESi license is provided, the ES button is displayed in the navigation menu. At the left all compressors
in the ES are shown. At the right the ES status is shown.
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A possible ESi screen
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6 Installation
6.1 Dimension drawing

Dimensions
Dimension drawing of ZR 160 up to ZR 275
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Dimension drawing of ZR 160 up to ZR 275 page 1
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Dimension drawing of ZR 160 up to ZR 275 page 2
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Dimension drawing of ZT 160 up to ZT 275
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Dimension drawing of ZT 160 up to ZT 275, page 1
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Dimension drawing of ZT 160 up to ZT 275 Full-Feature compressors, page 2
Reference Name
1 Right side view
2 Front view
3 Motor cooling air outlet
4 Motor cooling + compressor air inlet
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5 Hot air version

7 Centre of gravity
8 Left side view of energy recovery version
9 Left side view
10 Cooling water out
11 Compressed air outlet
12 Cooling water inlet
15 Automatic drain, aftercooler
16 Automatic drain, intercooler
17 Rear side view
18 Top view
19 Type
20 Net mass (approx.) of units (kg)
23 Opening for transportation
24 4 slotted holes for pulling out of container
25 Water in/out
28 Automatic drain, dryer outlet
29 Automatic drain, regeneration outlet
34 Cooling air inlet
35 Standard version
36 Voltage supply entrance, possibility 2
37 Voltage supply entrance, possibility 1
38 Cooling air outlet
39 Voltage supply entrance, possibility 1 only for ZT 160 - 275
40 Hole M8
41 Voltage supply entrance, possibility 1 only for ZR 160 - 275
42 Left side view, Hot air
43 Electric cable for water shut-off valve
44 Voltage supply entrance,
45 Cold water circuit, cooling water in
46 Cold water circuit, cooling water out
47 Automatic drain, extra aftercooler
48 Energy recovery circuit, cooling water in
49 Energy recovery circuit, cooling water out
50 Automatic drain, dryer inlet
65 Low load option/blow off
66 Compressor air inlet
67 Motor cooling air inlet
68 Separated air intake
69 Standard unit
73 Grating, only separate air intake
74 Circuit A
75 Circuit B
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6.2 Installation proposal
Compressor room example
Installation proposal for ZR 160 up to ZR 275
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Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature
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Installation proposal for ZT 160 up to ZT 275,
(1) Minimum free area to be reserved.

(2) Ventilation proposal.
(3) Rear side view.
(4) Ventilation proposal (without option separate air intake).
(5) Ventilation proposal (with option separate air intake).
(6) Common ducting for multiple units is not allowed.
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(7) Reverse side view.

(8) If obstacles are present above container, minimum free area to be reserved.
Description
The compressor must only be moved or lifted as described in the section Initial start-up.
1. Install the compressor on a level floor suitable for taking its weight. The recommended minimum
distance between the top of the body and the ceiling is 1200 mm (47 in).
2. Remove the plastic plug (if provided) from the compressor air outlet pipe and install an air outlet valve.
Close the valve and connect it to the air net.
3. The pressure drop over the air outlet pipe can be calculated as follows:
dp = (L x 450 x Qc1.85) / (d5 x p)
Symbol Explanation
d Inner diameter of the outlet pipe in mm
dp Pressure drop (recommended maximum = 0.1 bar)
L Length of outlet pipe in m
p Absolute pressure at the compressor outlet in bar(a)
Qc Free air delivery of the compressor in l/s
It is strongly recommended to make the connection of the compressor air outlet pipe on top of the
main air net pipe in order to minimise carry-over of possible condensate residue.
As a rule of thumb, the following formula can be used to calculate the recommended volume of the
air net:
V = (30 x C x p x Q) / dp
Symbol Explanation
C Correction factor
dp Pressure difference between unloading and loading pressures in bar (recommended
minimum = 0.6)
p Compressor inlet pressure in bar absolute
Q Free air delivery of compressor in l/s
V Recommended air net volume in l
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Air consumption divided by compressor free air Correction factor C

delivery
0.9 0.10
0.8 0.15
0.7 0.20
0.5 0.25
0.3 0.20
0.2 0.15
0.1 0.10
4. The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air
to the compressor is avoided. The maximum air velocity through the grids is 5 m/s (16.5 ft/s).
The required ventilation capacity (per compressor installed) to limit the compressor room temperature
can be calculated as follows:
For ZR compressors: Qv = 0.1 N/dT
For ZT compressors: Qv = 0.92 N/dT
Symbol Explanation
dT Temperature increase in compressor room in ˚C
N Shaft input of compressor in kW
Qv Required ventilation capacity in m 3/s
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30 Pa (0.12
in wc). Common ducting for several compressors is not allowed.
5. Lay out the drain piping from the condensate outlets towards the condensate collector. The drain pipes
must not dip into the water in the collector. It is recommended to provide a funnel to allow visual
inspection of the condensate flow.
6. Elektronikon control system with control panel.
7. See Electric cable size for the recommended size of the supply cables.
Check that the electrical connections meet local codes. The installation must be earthed and protected
against short circuits by fuses in all phases. An isolating switch must be installed near the compressor.
8. Install a condensate drain valve in the lower part of the air net piping.
9. On ZR compressors, remove the plastic plugs (if fitted) from the compressor water pipes (WI and
WO) and connect the pipes to the cooling water circuit. Fit a valve in the compressor water inlet pipe
and outlet pipe.
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6.3 Electric cable size
General
Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 10 % of the nominal voltage. It may be necessary to
use cables with a larger size than those stated to comply with this requirement.
– Feeder cable selection should be sized by the customer with consideration of wiring length from
feeder point to ensure that the circuit is balanced & not influence by other electrical equipment.
As voltage drops can affect the performance of compressor.
– Applied voltage must be compatible with the Motor & Unit data plate ratings.
– Ensure that control voltage transformer tapping are set for specific voltage, prior to starting.
Cable size for 50 Hz compressors

Cable size for compressors designed to operate at an ambient temperature of up to 40 ˚C (104 ˚F)
Compressor Mains + earth cable Mains + earth cable Mains + earth cable Mains + earth cable
(mm2) (mm2) (mm2) (mm2)
380 V 400 V 500 V 690 V
ZR 160 2x (3x95 + 50) 2x (3x95 + 50) 2x (3x70 + 35)
ZT 160 2x (3x120 + 70) 4x (3x35 + 20) 2x (3x95 + 50)
ZR 200 2x (3x150 +95) 2x (3x150 +95) 2x (3x95 + 50)
ZT 200 2x (3x150 + 95) 2x (3x150 + 95) 4x (3x35 + 20)
ZR 250 4x (3x95 + 50) 4x (3x70 + 35) 2x (3x150 + 95)
ZT 250 4x (3x95 + 50) 4x (3x95 + 50) 2x (3x185 + 95)
ZR 275 7 bar (100 4x (3x70 + 35) 4x (3x70 + 35) 2x (3x150 + 95)
psi)
ZT 275 7 bar (100 4x (3x95 + 50) 4x (3x95 + 50) 2x (3x185 + 95)
psi)
ZR 275 others 4x (3x95 + 50) 4x (3x95 + 50) 2x (3x185 + 95)
ZT 275 others 4x (3x120 + 70) 4x (3x95 + 50) 4x (3x70 + 35)
Cable size for compressors designed to operate at an ambient temperature of up to 50 ˚C (122 ˚F)
(mm2) (mm2) (mm2) (mm2)
380 V 400 V 500 V 690 V
ZR 160 4x (3x70 + 35) 2x (3x185 + 95) 2x (3x150 + 95)
ZT 160 4x (3x70 + 35) 4x (3x70 + 35) 2x (3x150 + 95)
ZR 200 4x (3x120 + 70) 4x (3x95 + 50) 2x (3x185 + 95)
ZT 200 4x (3x120 + 70) 4x (3x95 + 50) 4x (3x70 + 35)
ZR 250 4x (3x150 + 95) 4x (3x120 + 70) 4x (3x95 + 50)
ZT 250 4x (3x150 + 95) 4x (3x150 + 95) 4x (3x95 + 50)
ZR 275 7 bar (100 4x (3x95 + 50) 4x (3x95 + 50) 2x (3x185 + 95)
psi)
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(mm2) 380 V (mm2) 400 V (mm2) 500 V (mm2) 690 V
ZT 275 7 bar (100 4x (3x120 + 70) 4x (3x120 + 70) 4x (3x70 + 35)
psi)
ZR 275 others 4x (3x120 + 70) 4x (3x95 + 50) 4x (3x70 + 35)
ZT 275 others 4x (3x150 + 95) 4x (3x120 + 70) 4x (3x95 + 50)
6.4 Electric connection
Attention
For the selection of the correct cables, refer to: Electric cable size .
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Electric connections
Electric connections for compressors with star-delta starter
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Text on figures
Reference Text on figure

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

When installing a remote emergency button or a motor contactor, the following B10d values are advised:
• Emergency stop button: 500 000
• Main contactor: 1 333 333
6.6 Cooling water requirements

Recommendations
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.
Only non-treated water must be used.
This recommendation is a general guide line for acceptable coolant quality.
Type of system
First, it is important to consider whether you are dealing with a closed system or an open system. In a
closed system, the same cooling water circulates through a system without contact with air.
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.
Ryznar stability index (RSI)

The Ryznar Stability Index (RSI) is a parameter for predicting whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling deposits and their effect are different 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).
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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
Symbol Explanation
pH Measured pH (at room temperature) of water sample
pHs pH at saturation
The pHs is calculated by using :

pHs = (9.3 + A + B) - (C + D)
Symbol Explanation
A Depends on the total solids concentration (mg/l)
B Depends on the highest cooling water temperature (˚C/˚F), (T=65 ˚C/149 ˚F)
C Depends on the calcium hardness (ppm CaCO3)
D Depends on the HCO3- concentration or M-alkalinity (mval/l)
The values of A, B, C and D can be found in the following table.
Total dissolved A Temperature B Ca-hardness (ppm C M-alkalinity (mval/l) D

solids (mg/l) (˚C) CaCO3)
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
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Interpretation of the value obtained
RSI Water condition Action

RSI<3.9 Very high scale formation Water cannot be used.
4.0<RSI<5.5 High boiler scale formation Regular inspection and descaling operation
necessary.
5.6<RSI<6.2 Slight boiler scale formation Water treatment not necessary.
Occasional inspection recommended.
6.3<RSI<6.8 Neutral water Water treatment not necessary.
Occasional inspection recommended.
6.9<RSI<7.5 Slight corrosion at higher Water treatment not necessary.
temperature Occasional inspection recommended.
7.6<RSI<9.0 Strong corrosion Regular inspection necessary, use of corrosion
inhibitor recommended.
9.1<RSI<11 Very strong corrosion Regular inspection necessary, use of corrosion
inhibitor required.
RSI>11 Very strong corrosion in Water should not be used.
complete water system
The table indicates that distilled or demineralized water should never be used, as their RSI is > 11.
The RSI only indicates the equilibrium of scaling - descaling. A 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 the 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 microS/cm) For an open system,
the following limits apply : TDS < 750 mg/l ( < 960 microS/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)

A level of 0.5 ppm should not be exceeded for long periods.
For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies.
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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
Iron and manganese

< 1 ppm
Organics
No algae
No oil
Suspended solids
Non-soluble particles, size < 1 mm.
< 10 ppm
6.7 General pictographs

Pictographs
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Reference Name
1 Condensate valve, intercooler
2 Automatic condensate outlet, intercooler
3 Automatic condensate outlet, aftercooler
4 Condensate valve, aftercooler
5 Warning: under tension
6 Read Instruction manual before starting the compressor
7 Switch off the voltage and depressurize the compressor before maintenance or repair
8 Before connecting the compressor electrically, consult the Instruction manual for the motor
rotation direction
9 Torques for steel (Fe) or brass (CuZn) bolts
10 Consult the Instruction manual before greasing
11 Switch off the voltage before removing the protecting cover inside the electric cabinet
12 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)
13 Consult the Instruction manual before maintenance or repair
14 Cooling water outlet
15 Cooling water inlet
6.8 Pictographs, Elektronikon control system
Control panel of Elektronikon Controller
Reference Name
1 Start
2 Stop
3 Automatic operation
4 Alarm
5 Voltage on
6 Emergency stop
7 Key to go to next field on display
8 Keys to scroll through display
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Control panel of Elektronikon GraphicPlus Controller
Reference Name
1 Alarm
2 Service
3 Automatic operation
4 Voltage on
5 Enter
6 Escape
7 Scroll keys
8 Stop
9 Start
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7 Operating instructions
7.1 Initial start-up
Safety precautions
The operator must apply all relevant Safety precautions.
Altitude operation
If the air inlet temperature can be below 0 ˚C/32 ˚F, precautions must be taken. If this is the case, or if the
compressor is being operated at high altitudes, consult the Atlas Copco Customer Centre.
Moving/lifting
In order not to damage the frame, the compressor must be moved either by a lift truck or by using lifting
equipment as described below.
When moving the compressor with a lift truck, use the slots in the frame. Make sure that the forks protrude
from the other side of the frame. When moving the compressor with a lifting device, insert beams in the slots.
Make sure that the beams cannot slide and that they protrude from the frame equally. The chains must be held
parallel to the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment
must be placed in such a way that the compressor is lifted perpendicularly. Lift gently and avoid twisting.
General preparation
Make sure that the compressor is installed correctly.
See Dimension drawing, Installation proposal and Electric cable size.
A sticker summarising the operating instructions is delivered with the compressor. Affix the sticker next to
the control panel.
Protection during transport
The compressor and motor are secured to the frame, immobilising the vibration dampers during transport. All
transport fixtures are painted red and must be removed.
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Transport fixtures on the motor side in ZR/ZT 160 up to ZR/ZT 275
On the motor side, the dampers are secured by means of bolts/spacers. Remove the bolts and spacers (1 and
2).
Transport fixtures on the gear casing side in ZR/ZT 160 up to ZR/ZT 275
On ZR/ZT 160 up to ZR/ZT 275, a transport support (1) is fitted to the gear casing. Remove the support.
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Silica gel bags
Position of silica gel bags on ZT 160 up to ZT 275
Position of silica gel bags on ZR 160 up to ZR 275
Remove flange (1) and take out the silica gel bags. Refit the flange.
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Tightening the tie rods on ZT compressors
Before initial start-up, the tie rods must be tightened. Proceed as follows:
• Check that all transport fixtures are removed
• Check that the compressor is pressureless
• Tighten the nuts of tie rods (1) by hand
• Tighten the check nuts
Water circuit of ZR compressors
Step Action
1 Check that the cooling water drain valves (customer's installation) in the inlet and outlet
lines are closed.
2 Open the water inlet valve and outlet valve (customer's installation).
3 Check for water flow.
Oil circuit
Position of oil level sight-glass on ZR 160 up to ZR 275
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Position of oil level sight-glass on ZT 160 up to ZT 275
Check that oil is visible in sight-glass (SG).
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Start-up
Electric cabinet of compressor with starter
1. Check that the voltage selecting wires on transformer T1 are connected correctly. An instruction label is
provided.
2. Check that the electrical installation meets local regulations.
3. On compressors with a starter, check the overload relay setting (F21) and check that the relay is set for
automatic resetting.
See Settings of overload relay and fuses.
Switch on the voltage.
4. Check that the gear casing is filled with oil.
5. Start the motor and stop it immediately.
6. Check that the direction of rotation is correct (as indicated by the arrow): anti-clockwise looking at the
motor drive shaft (there may also be an arrow on the coupling housing). A grating through which the
coupling can be observed is fitted. If the direction of rotation is wrong, switch off the voltage and
reverse two electric inlet connections.
7. Run the compressor for a few minutes.
8. Stop the compressor and check the oil level.
On ZR/ZT 160 up to ZR/ZT 275, the oil level after stopping must be in the middle of the sight-glass
(in the case of longer standstill, the oil level in the sight-glass may increase).
Top up, if necessary, with the correct type of oil.
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Adjustment of mix-air
Only for 13 bar (190 psi) Full-Feature compressors or 10 bar (145 psi) and 10.4 bar (150 psi)
Full-Feature compressors designed for an ambient temperature of up to 50 ˚C (122 ˚F)
If, due to changes of the ambient temperature, the Elektronikon regulator shows a warning
for the regeneration air temperature, the mix-air must be readjusted.
On ZT compressors, the shut-off valve (1) is located in the cooler compartment and the
regulating valve (2) is located in the compressor compartment. The safety grating must be
fitted again and the door of the cooler compartment must be closed before starting the
compressor.
Mix-air regulation valves, ZR compressors
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Mix-air regulation valves, ZT compressors
1. On ZR compressors, open shut-off valve (1) completely and close regulation valve (2).
2. On ZT compressors, remove the safety grating. Open shut-off valve (1) completely, mount the safety
grating again and close the door of the cooler compartment. Close regulation valve (2).
3. Start and load the compressor.
4. Adjust the pressure difference of the dryer compartments as described below.
5. Call up the regeneration air inlet temperature on the Elektronikon regulator, see section Control
programs. Open regulating valve (2) until the display of the Elektronikon regulator shows a value between
180 ˚C (356 ˚F) and 190 ˚C (374 ˚F).
6. Check the pressure difference between the dryer compartments again. If necessary, repeat the previous
steps.
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Adjustment of the pressure difference of the dryer compartments on Full-Feature compressors
Dryer components, ZR Full-Feature
Position of throttle valve on the regeneration air inlet of the dryer on ZT Full-Feature
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Position of dryer inlet, outlet and by-pass valves on ZT Full-Feature
Step Action
1 Close valves (1, Vd- and Vd+).
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Step Action
2 Close the dryer inlet and outlet valves (Vdi and Vdo) and open the dryer by-pass valve
(Vdb).
3 Start and load the compressor.
4 Open the dryer inlet valve (Vdi) slightly to pressurise the dryer.
5 Open the regeneration air valve (Vr) fully. Open the air outlet valve (Vdo) and close the
by-pass valve (Vdb).
6 Open valves (1 and Vd-). Open valve (Vd+) slightly, while monitoring the water levels in
the U-tube.
There are two possible conditions:
• The water level in the leg marked (+) rises. Close valve (Vd+) at once, decrease the
regeneration air inlet pressure (see step 7). Do this as often as necessary until the
water level drops.
• The water level in the leg marked (-) rises, which should normally be the case. If the
level in this leg rises 30 mm above the level in the leg marked (+), close valve (Vd+)
at once, as there is a risk that the water will escape the U-tube and disappear into the
pressure vessel. Increase the regeneration air inlet pressure (see step 7) and open
valve (Vd+) again.
7 Once the water column has stabilised, adjust the pressure differential as follows:
• Remove the protective cap from the adjusting screw of throttle valve (Rf).
• Loosen its check nut and turn the screw inwards to increase or outwards to decrease
the pressure differential.
• The water level in the leg marked (-) must be between 20 and 40 mm above that in
the leg marked (+).
• Monitor the water level for about 10 minutes.
• Tighten the check nut and reinstall the protective cap.
• Check that the moisture indicator is blue after approximately 30 minutes of operation.
If the moisture indicator is still pink after 2 hours of operation, the pressure dewpoint
is too high.
8 Stop the compressor.
7.2 Before starting

If the water system has been drained, close the drain valves and fit the drain plugs or pipe.
See section Stopping
The number of motor starts is programmed at maximum 3 per day.
To modify this setting, consult sections Modify parameters.
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Oil level
Oil system components, ZR 160 up to ZR 275
On ZR/ZT 160 up to ZR/ZT 275, the oil level must be in the middle of the sight-glass (SG) after stopping (in
the case of longer standstill, the oil level may increase in the sight-glass).
Top up, if necessary, with the correct type of oil.
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Condensate drains
Drain connections on ZR 160 up to ZR 275
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Drain connections on ZT 160 up to ZT 275
Reference Description
AO Compressed air outlet
Daa Automatic drain, aftercooler
Dad Automatic drain, dryer inlet
Dad1 Automatic drain, dryer outlet
Dad2 Automatic drain, dryer inlet
Dai Automatic drain, intercooler
Dar Automatic drain, regeneration outlet
Dmd Manual drain, dryer inlet
WI Water inlet
WO Water outlet
Open the water inlet valve and outlet valve (customer's installation).
On ZR compressors, opening of the water outlet valve can be overlooked if, after
previous operation, the setting of this valve has not been disturbed.
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7.3 Routine starting
Control panel
Control panel of Elektronikon controller
Procedure
Step Action
1 Open the air outlet valve (customer's installation).
2 Switch on the voltage and check that voltage on LED (6) lights up.
3 Press start button (1). The compressor starts running in unloaded condition and automatic
operation LED (8) lights up.
4 Approx. 25 seconds later (programmable), the compressor starts running loaded. The
message on display (2) changes from “Automatically unloaded” to “Automatically loaded”.
5 On ZR compressors, regulate the water flow with the compressor running loaded.
See section Readings for the cooling water temperature.

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

See section Compressor data for the cooling water consumption.
If the motor is stopped and automatic operation LED (7) is alight, the motor may start
automatically.
If the start/stop timer is active, the compressor can start automatically, even if it was
stopped manually.
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7.4 Starting
Control panel
Procedure
Step Action
1 Switch on the voltage 4 hours before starting in order to energise the crankcase heater.
Voltage on LED (4) is lit.
2 Press start button (11).
3 Start the compressor.
7.5 Starting after emergency stop or shutdown
Control panel
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Procedure
Step Action
1 Press the emergency stop button (S2) (if not yet done so).
2 Switch off the voltage and then depressurize the compressor.
3 Remedy the fault.
4 Unlock the emergency stop button by pulling it out.
5 Restart the compressor. See Routine starting.
If the automatic restart function after voltage failure is activated and the duration of repair
is shorter than the programmed power recovery time, reset the display after remedying
the fault. Press the key “Reset”; the message “All protection functions are OK” will appear,
whereupon the compressor can be restarted. Press the keys “Menu” and “Main Screen”
to return to the main display.
Control panel
Procedure
Step Action
1 Press the emergency stop button (if not yet done).
2 Switch off the voltage and then depressurize the compressor.
3 Remedy the fault.
4 Unlock the emergency stop button by pulling it back.
5 Reset the protection warning in the Elektronikon controller.
6 Restart the compressor. Check the section Routine starting.
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If the automatic restart function after voltage failure is activated and the duration of repair
is shorter than the programmed power recovery time, reset the display after remedying
the fault. Press the key “Reset”; the message “All protection functions are OK” will appear,
whereupon the compressor can be restarted. Press the keys “Menu” and “Main Screen”
to return to the main display.
Minimum stop time

The compressor will not be allowed to restart within a programmed time (20 s) after a stop for any reason
at all. A start command given during the minimum stop time will be memorized; automatic operation LED
(8) lights up. The compressor will start when the minimum stop time has run out.
Manual restart
In automatic operation, the regulator limits the number of motor starts.
On compressors with a low-voltage motor, observe a minimum interval of 20 minutes between two
manual starts.
On compressors with a medium-voltage or high-voltage motor, the number of motor starts is limited to 3
starts per day.
7.6 During operation
Control panel
Procedure
When automatic operation LED (8) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
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Step Action
1 Check the readings on display (2).
2 When reaching the preset unloading pressure, shown on display (2), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
3 To unload the compressor manually, press the key “Unload” (5).
To put the compressor back into automatic operation, press the key “Load” (5).
If the “Load” or “Unload” function is not indicated on the bottom line of the display (2),
press key “Menu” (5) until the function “Main Screen” appears above key (F1). Then
press the key “Main Screen”.
Control panel
Procedure
When automatic operation LED (7) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
Step Action
1 Check the readings on display (1).
2 When reaching the preset unloading pressure, shown on display (1), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
3 To unload the compressor manually, select Unload on the display using the cursor keys
and press the Enter key.
To put the compressor back into automatic operation, select Load on the display using the
cursor keys and press the Enter key.
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7.7 Checking the display
Control panel
Procedure
Before carrying out any maintenance, repair or adjustment work, stop the compressor,
press emergency stop button (S2), switch off the voltage and depressurize the
compressor.
Step Action
1 Regularly check the display for readings and messages. Normally, the main display is
shown, indicating the compressor outlet pressure, the status of the compressor and the
functions of the keys below the display.
2 Always check the display and remedy the trouble if alarm LED (7) is alight or flashing.
3 The display will show a service message if one of the monitored components is to be
serviced. Replace the component, change the oil or grease the drive motor as required.
Reset the relevant timer.
4 Check:
• The compressor control status (automatic or manual, local or remote)
• The status of the compressor start/stop timer (active or not). The compressor is
automatically started/stopped if these start/stop commands are programmed and
activated.
• The maximum working pressure
• The outlet pressure
• The pressure drop over the air filters
• The oil pressure
• The intercooler pressure
• The outlet temperature
• The temperatures of the compressor elements
• The cooling water temperatures
• The oil temperature
• The status of the drive motor overload protection (normal or not)
• The total running and loading hours
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Whenever a warning, service request, sensor error or motor overload message is

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

Control panel
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General
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and
restarts the compressor automatically. LED (8) is then alight.
If required, the compressor can be unloaded manually. In this case, the compressor is switched out of automatic
operation, i.e. the compressor remains running unloaded unless it is loaded again manually.
Manual unloading
Press the key “Unload” (5). LED (8) fades. The message “Manually Unloaded” appears on the display.
Manual loading
Press the key “Load” (5). LED (8) lights up. The “Load” command does not force the compressor in loaded
condition, but it will switch the compressor to automatic operation again, i.e. the compressor will be loaded
if the air net pressure drops below the programmed level.
If the “Load” or “Unload” function is not indicated on the bottom line of display (2), press
“Menu” (5) until “Main Screen” appears above key (F1), then press “Main Screen”.
Control panel
General
Normally, the compressor runs in automatic operation, i.e. the electronic regulator loads, unloads, stops and
restarts the compressor automatically. LED (7) is then alight.
If required, the compressor can be unloaded manually. In this case, the compressor is switched out of automatic
operation i.e. the compressor remains running unloaded unless it is loaded again manually.
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Manual unloading
Starting from the main screen, move the cursor so that Unload is highlighted in grey. When the Enter key
is pressed, the compressor starts running unloaded and LED (7) fades. The message Manual Unload
appears on the display.
Manual loading
Starting from the main screen, move the cursor so that Load is highlighted in grey. When the Enter key is
pressed, LED (7) lights up and the compressor starts running loaded in case the air net pressure drops
below the programmed level. The message Load appears on the display.
If the Load or Unload buttons are not displayed on the bottom line of the screen, make
sure to return to the Main screen first.
7.9 Stopping
Control panel
Procedure
Frequently stopping the compressor using the emergency stop button may damage the
compressor. Only use the emergency stop button in case of emergency.
Step Action
1 Close the air outlet valve.
2 Press stop button (9). The compressor will run unloaded for 3 seconds and then stop.
3 To stop the compressor in case of emergency, press the emergency stop button (S2).
Alarm LED (7) starts flashing. After remedying the trouble, unlock the emergency stop
button by pulling it out.
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Control panel
Procedure
Frequently stopping the compressor using the emergency stop button may damage the
compressor. Only use the emergency stop button in case of emergency.
Step Action
1 Close the air outlet valve.
2 Press stop button (13). The compressor will run unloaded for 3 seconds and then stop.
3 To stop the compressor in case of emergency, press the emergency stop button. Alarm
LED (4) starts flashing. After remedying the trouble, unlock the emergency stop button by
pulling it back.
Cooling water system on ZR compressors

Close the cooling water inlet valve after stopping.
If the compressor is installed in a room where freezing temperatures are expected, drain the
cooling system completely:
• By opening the main drain valves in the water inlet and outlet pipes (customer's installation)
• By removing the drain plugs. The following plugs (painted green) are provided:
• DP7 and DP8 underneath the cooler casing
• On ZR 160 up to ZR 275, drain plug (DP9) underneath the cooler casing
• DP2 and DP5 underneath the compressor elements
• DP6 on the oil cooler
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Cooler casing on ZR 160 up to ZR 275
Cooler casing on ZR 160 up to ZR 275
Drain plugs on high-pressure compressor element
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Drain plugs on low-pressure compressor element
Water drain plug on oil cooler on ZR 160 up to ZR 275
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7.10 Taking out of operation
Procedure
At the end of the service life of the compressor, proceed as follows:
Step Action
1 Close the air outlet valve and stop the compressor.
On compressors with an Elektronikon regulator, press the emergency stop button.
2 Switch off the voltage and disconnect the compressor from the mains.
3 Shut off and depressurise the part of the air net which is connected to the outlet valve.
4 Disconnect the compressor air outlet pipe from the air net.
5 Drain the oil and condensate circuits. Catch the oil in a receptacle.
6 Disconnect the compressor condensate piping from the condensate drain net.
7 On ZR compressors, drain the cooling water system and disconnect the cooling water
pipes from the compressor.
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8 Maintenance
8.1 Preventive maintenance schedule
Safety precautions
Before carrying out any maintenance, repair or adjustment work, stop the compressor.
On compressors with an Elektronikon regulator, press emergency stop button (S2).
Switch off the voltage and close the air outlet valve.
Push the test buttons on top of the Electronic Water Drains (EWD).
Open and lock the isolating switch.
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, minimise downtime and reduce the total life cycle costs and ensure that all warranties
are validated.
Warranty-Product Liability
Use only authorised parts at the correct intervals (check with your local Atlas Copco Service centre). Any
damage or malfunction caused by the use of unauthorised parts or unqualified personnel is not covered by
Warranty or Product Liability. In the event of any extended warranty, the end user must ensure that all
required maintenance actions are performed when indicated on the Elektronikon display (see table below)
or, alternatively, use an Atlas Copco Service agreement.
Service kits
Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service kits
comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts
while keeping the maintenance budget low.
Regular checks
The following checks should be carried out regularly to ensure safe operation and long service life.
Depending on the environmental and working conditions of the compressor, the local Atlas Copco Service
centre may overrule the standard maintenance schedule; always check if in doubt.
Period Running hours Operation

Daily 8 Check the Elektronikon display for warnings.
Daily 8 Check that condensate is discharged from the drain receivers during
loading.
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Period Running hours Operation

Daily -- Before stopping:
• drain the aftercooler drain receiver
• drain the intercooler drain receiver
• on Full-Feature compressors, drain the drain receivers of the
internal dryer
Weekly -- Check the oil level. See section Before starting.
Weekly -- Drain condensate from the air receiver, if installed.
Weekly -- Check for leaks.
When displayed -- Carry out service actions according to the displayed service warnings
or service plans as shown below.
Grease the motor bearings at the correct interval and with the correct grease type
and quantity as mentioned on the motor data plate. If in doubt, consult your Atlas
Copco Service centre.
Service plan
A number of service operations are grouped (called level A, level B, level C, ...). Each level stands for a
number of service actions to be carried out at the time intervals programmed in the Elektronikon
regulator.
When a level is reached, a message will appear on the screen. After carrying out all service actions, reset
the interval timers using the "Reset" key in the "Service" menu.
Activities Level A Level B Level C

Take service readings (air, oil, water temperature and X X X
pressure)
Check cooler functions (approach temperature) X X X
Change intercooler condensate check valve X X X
Service intercooler blowdown valve X
Check for air, water and oil leakage X X X
Check operation of safety valves X X
Check for presence of water in lube oil X X X
Change Roto Z oil (16000 hrs or 2-yearly) NA NA X
Change compressor oil filter (8000 hrs or annually) NA X X
Inspect/change air filter element(s) X X X
Replace filter element of gear case breather X X X
Check cycle of air intake throttle valve X X X
Replace diaphragm of air throttle valve X X
Replace bearing block (air intake valve) X X
Overhaul air intake valve X
Check functioning of check valve (8000 hrs or annually) X
On Z 160 up to ZR/ZT 275, overhaul check valve X
Check condition of balance piston diaphragm X
Change balance piston diaphragm X
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Activities Level A Level B Level C

Check/Service condensate drain(s) X X X
Clean fan cowl of electric motor X X X
Check rubber inserts of drive coupling (arr. E) X X
Replace inserts of drive coupling (arr. E) X
Take and record all S.P.M. readings. X X X
Inspect electrical contactors X X
Check all electrical connections X
8.2 Maintenance instructions
Important
• Repairs inside the speed regulation cabinet must only be carried out by Atlas Copco.
• Wait at least 6 minutes before starting any electrical repairs as hazardous high voltage
remains on the condensers of the speed regulation unit for 6 minutes after switching off
the voltage.
Safety precautions
When handling refrigerant R404a, all applicable safety precautions must be observed. The
following points are stressed:
• Contact of refrigerant with the skin will cause freezing. Special gloves must be worn and, if there is
contact with the skin, the skin should be rinsed with water. On no account may clothing be removed.
• Fluid refrigerant will also cause freezing of the eyes; therefore, safety glasses must be worn.
• Refrigerant R404a is poisonous. Do not inhale refrigerant vapours. Check that the working area
is adequately ventilated.
Before starting any maintenance or repairs, switch off the voltage and close the air inlet and outlet valves.
Local legislation
Local legislation may impose that:
• Work on the refrigerant circuit or on any equipment which influences its function must be carried out
by an authorised control body.
• The installation should be checked once a year by an authorised control body.
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General
The following remarks should be kept in mind:
• Keep the dryer clean.
• Regularly brush or blow off the finned surface of condenser.
• Regularly test electronic water drains (EWD).
8.3 Motor greasing
General
Stop the compressor before greasing.

Never mix greases of different brands or types.
Motor greasing
See the motor regreasing dataplate for the recommended grease type, the greasing quantity and interval for
the motor bearings.
8.4 Oil specifications
Roto-Z lubricating oil

Use Atlas Copco Roto-Z oil which is specially developed for oil-free rotary compressors. This oil has
a long service life and ensures optimum lubrication.
Atlas Copco Roto-Z oil can be ordered in following quantities:
Quantity (l) Quantity (US gal) Quantity (Imp gal) Quantity (cu.ft) Ordering number
5 l can 1.32 US gal can 1.10 Imp gal can 0.18 cu.ft can 2908 8503 00
20 l can 5.28 US gal can 4.40 Imp gal can 0.70 cu.ft can 2908 8501 01
209 l drum 55.18 US gal drum 45.98 Imp gal drum 7.32 cu.ft drum 2908 8500 00
8.5 Storage after installation
Run the compressor, e.g. twice a week, until warm.

If the compressor is going to be stored without running from time to time, protective measures must be
taken. Consult Atlas Copco.
8.6 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.
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9 Servicing procedures
9.1 Air filters
Location of the air filters
Air filter of ZR/ZT 160 up to ZR/ZT 275
Procedure
The filters must be serviced regularly; consult section Preventive maintenance schedule.
Never install damaged or clogged filters.
Procedure for ZR/ZT 160 up to ZR/ZT 275
Step Action
1 Stop the compressor and press the emergency stop button.
2 Switch off the voltage.
3 Remove nuts (1).
4 Loosen clamps (2).
5 Take out filter housing (3) with filter element (4).
6 Replace the dirty filter element with a new one.
7 Put the filter housing with the filter element back into place.
8 Tighten clamps (2) and nuts (1).
9 Switch on the voltage.
10 Unlock the emergency stop button and reset the air filter service warning.
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9.2 Oil and oil filter change

Oil system
Oil system components, ZR 160 up to ZR 275
Oil system components, ZT 160 up to ZT 275
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Procedure
Step Action
1 Run the compressor until warm.
On compressors equipped with an Elektronikon regulator, press the emergency stop
button.
3 Switch off the voltage.
4 The filler plug and drain points are painted yellow.
Remove filler plug (FC). Drain the compressor sump by opening drain valve (Dmo).
On ZR compressors, drain the oil cooler by openening drain valve (Dmc).
On ZT compressors, fit a proper flexible over the extension of drain plugs (Dmc). Drain the
oil system by loosening the drain plugs.
Close the drain valves and tighten the drain plugs after draining.
5 Remove the oil filters (OF). Clean the filter seats, oil the gaskets of the new filters and
screw the filters into place until the gaskets contact the seats. Then tighten by hand.
6 On ZR 160 up to ZR 275, fill the compressor sump to the middle of the oil level sight-glass
(SG).
See Oil specifications for the correct type of oil.
7 Reinstall the filler plug.
8 Switch on the voltage.
On compressors equipped with an Elektronikon regulator, unlock the emergency stop
button and reset the oil and oil filter service warnings.
9 Run the compressor for a few minutes.
11 On ZR 160 up to ZR 275 and ZT 160 up to ZT 275, check that the oil level is in the middle
of sight-glass (SG) after stopping (at longer standstill the level may rise in the sight-glass).
Top up, if necessary.
9.3 Safety valves
Testing
The valves can be tested on a separate compressed air line. If a valve does not open at the pressure
specified in Settings of safety valves, consult Atlas Copco.
Never run the compressor without safety valves.

No adjustments are allowed.
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10 Problem solving
10.1 Problem solving
Before carrying out any maintenance, repair or adjustment work, stop the compressor
and switch off the voltage. Close the air outlet valve and open the manual condensate
drain valves.
Press emergency stop button (S2).
Open and lock the isolating switch.
Control panel
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Faults and remedies
Condition Fault Remedy

Compressor starts running, but Pressure in air net is above Compressor will load when pressure in air
does not load after a delay time pre-set loading pressure net drops to pre-set loading pressure
Loading solenoid valve Check and, if necessary, replace the valve
inoperative
Full-load/no-load valve Have the valve inspected
malfunctioning
Compressor capacity or Air consumption exceeds Check pneumatic plant
working pressure lower than capacity of compressor
normal
Safety valves leaking Remove leaking valve and have it inspected
Oil pressure too low Oil level too low Top up level as described in section Before
starting.
Oil filters clogged Replace filters
Air temperature above normal Inlet temperature too high due Improve ventilation in compressor room and
to bad room ventilation or prevent recirculation of cooling air
recirculation of cooling air
On ZR compressors, Check water temperature and increase
insufficient cooling water flow cooling water flow
On ZR compressors, restriction Consult the Atlas Copco Customer Centre
in cooling water system due to
formation of scale or dirt
deposits
Unloading pressure incorrectly On compressors equipped with an
set Elektronikon regulator, see Modifying
parameters
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11 Technical data
11.1 Readings
Important
The readings below are valid when operating at reference conditions. Check the section
Reference conditions.
For the maximum working pressure and the outlet pressure, consult the section Compressor data. Pressure
readings
Item Reading Reading

dp of air filter Below 0.044 bar Below 0.64 psi
Intercooler pressure (loaded condition) 1.8-2.6 bar(e) 27.6-37.7 psig
Intercooler pressure (unloaded condition) (-0.65)-(-0.70) bar(e) (-9.43)-(-10.15) psig
Oil pressure (depends on climatic conditions) 2-2.5 bar(e) 29-36.3 psig
Temperature readings for ZR compressors

Oil temperature Approx. 40 ˚C Approx 104 ˚F
Air temperature, low-pressure element (element 1) out 160-180 ˚C 320-356 ˚F
Air temperature, high-pressure element (element 2) out 140-175 ˚C 284-347 ˚F
Air temperature, high-pressure element (element 2) in 25-30 ˚C 77-86 ˚F
Air outlet temperature Approx. 25 ˚C Approx. 77 ˚F
Cooling water inlet temperature Below 40 ˚C Below 104 ˚F
Cooling water outlet temperature Below 50 ˚C Below 122 ˚F
Temperature readings for ZT compressors

Oil temperature Approx. 50 ˚C Approx 122 ˚F
Air temperature, low-pressure element (element 1) out 160-185 ˚C 320-365 ˚F
Air temperature, high-pressure element (element 2) out 140-185 ˚C 284-365 ˚F
Air temperature, high-pressure element (element 2) in 25-30 ˚C 77-86 ˚F
Air outlet temperature Approx. 27 ˚C Approx. 81 ˚F
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11.2 Settings of safety valves
Item Opening Opening pressure

pressure
Low-pressure safety valve(s) for 7 up to 10.4 bar (101.5 up to 3.7 bar(e) 54 psig
151 psi) compressors
Low-pressure safety valve(s) for 13 bar (190 psi) compressors 4.5 bar(e) 65 psig
High-pressure safety valve(s) for 7 and 8.6 bar (101.5 and 125 9.3 bar(e) 135 psig
psi) compressors
High-pressure safety valve(s) for 10 and 10.4 bar (145 and 151 11 bar(e) 160 psig
psi) compressors
High-pressure safety valve(s) for 13 bar (190 psi) compressors 13.7 bar(e) 200 psig
11.3 Settings for overload relay and fuses

50 Hz compressors
ZT 160 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F
Supply voltage Maximum overload relay setting Maximum fuse ratings gL/gG
(V) (A) Type 2
(A)
380 178 2x (3x225)
400 172 2x (3x225)
500 138 2x (3x200)
ZR 160 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F
(V) (A) Type 2
(A)
380 178 2x (3x225)
400 172 2x (3x200)
500 138 2x (3x160)
(V) (A) Type 2
(A)
380 225 2x (3x315)
400 213 2x (3x315)
500 170 2x (3x225)
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(V) (A) Type 2
(A)
380 225 2x (3x315)
400 213 2x (3x250)
500 170 2x (3x200)
(V) (A) Type 2
(A)
380 308 2x (3x400)
400 282 2x (3x400)
500 225 2x (3x315)
(V) (A) Type 2
(A)
380 308 2x (3x400)
400 282 2x (3x400)
500 225 2x (3x315)
ZT 275 7 bar (100 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F
(V) (A) Type 2
(A)
380 294 2x (3x400)
400 282 2x (3x400)
500 221 2x (3x315)
ZR 275 7 bar (100 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F
(V) (A) Type 2
(A)
380 294 2x (3x400)
400 282 2x (3x400)
500 221 2x (3x315)
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ZT 275 7.5 up to 13 bar (110 up to 190 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F
(V) (A) Type 2
(A)
380 375 2x (3x500)
400 343 2x (3x400)
500 279 2x (3x400)
ZR 275 7.5 up to 13 bar (110 up to 190 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F
(V) (A) Type 2
(A)
380 375 2x (3x400)
400 343 2x (3x400)
500 279 2x (3x315)
11.4 Reference conditions
Item Condition
Absolute inlet pressure 1 bar(a)
14.5 psi
Relative air humidity 0%
Air inlet temperature 20 ˚C
68 ˚F
Nominal effective working pressure See Compressor data.
Cooling medium inlet temperature 20 ˚C
68 ˚F
11.5 Limitations
Pressure limitations
Item Limit Limit

Maximum effective working pressure See the section See the section
Compressor data. Compressor data.
Maximum cooling water inlet pressure 10 bar(e) 145 psig
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Temperature limitations
Item Limit Limit

Maximum air inlet temperature for compressors designed to 40 ˚C 104 ˚F
operate at ambient temperatures up to 40 °C (104 °F)
Maximum air inlet temperature for compressors designed to 50 ˚C 122 ˚F
operate at ambient temperatures up to 50 °C (122 °F)
Minimum ambient temperature 0 ˚C 32 ˚F
Maximum cooling water temperature at inlet on ZR compressors 40 ˚C 104 ˚F
Maximum cooling water temperature at outlet on ZR 50 ˚C 122 ˚F
compressors
11.6 Compressor data

Important note
The values below are valid at reference conditions. See Reference conditions.
The sound pressure level is measured according to ISO 2151: 2004 using ISO 9614-2.
ZR 7.5 bar - 50 Hz compressor
Unit ZR 160 ZR 200 ZR 250 ZR 275

Maximum working pressure bar(e) 7.5 7.5 7.5 7.5
Maximum working pressure psig 108.8 108.8 108.8 108.8
Nominal working pressure bar(e) 7 7 7 7
Nominal working pressure psig 101.5 101.5 101.5 101.5
Air temperature at outlet valve, approx., ˚C 25 25 26 26
Pack compressor
Air temperature at outlet valve, approx., ˚F 77 77 79 79
Pack compressor
Motor shaft speed r/min 1485 1485 1485 2980
Oil capacity l 60 60 60 60
Oil capacity US gal 15.84 15.84 15.84 15.84
Oil capacity Imp gal 13.2 13.2 13.2 13.2
Oil capacity cu.ft 2.1 2.1 2.1 2.1
Sound pressure level, Pack Arr. E dB(A) 67 67 67 67
compressor
Sound pressure level, Full-Feature Arr. E dB(A) 67 67 67 67
compressor
Cooling water consumption for Pack l/s 2.34 3.02 3.7 4.1
compressor at a temperature rise of 15 ˚C /
27 ˚F
Cooling water consumption for Pack cfm 4.95 6.39 7.83 8.68
27 ˚F
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Unit ZR 160 ZR 200 ZR 250 ZR 275

Cooling water consumption for Full-Feature l/s 3.86 5.05 6.11 6.76
18 ˚F
Cooling water consumption for Full-Feature cfm 8.18 10.7 12.95 14.32
18 ˚F
ZT 7.5 bar - 50 Hz compressor
Unit ZT 160 ZT 200 ZT 250 ZT 275

Maximum working pressure psig 108.8 108.8 108.8 108.8
Pack compressor
Pack compressor
compressor
compressor
ZR 8.6 bar - 50 Hz compressor
Unit ZR 160 ZR 200 ZR 250 ZR 275

Maximum working pressure psig 125 125 125 125
Pack compressor
Pack compressor
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Unit ZR 160 ZR 200 ZR 250 ZR 275

compressor
compressor
27 ˚F
27 ˚F
18 ˚F
18 ˚F
ZT 8.6 bar - 50 Hz compressor
Unit ZT 160 ZT 200 ZT 250 ZT 275

Pack compressor
Pack compressor
compressor
compressor
ZR 10 bar - 50 Hz compressor
Unit ZR 160 ZR 200 ZR 250 ZR 275

Maximum working pressure bar(e) 10 10 10 10
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Unit ZR 160 ZR 200 ZR 250 ZR 275

Pack compressor
Pack compressor
compressor
compressor
27 ˚F
27 ˚F
18 ˚F
18 ˚F
ZT 10 bar - 50 Hz compressor
Unit ZT 160 ZT 200 ZT 250 ZT 275

Maximum working pressure bar(e) 10 10 10 10
Pack compressor
Pack compressor
compressor
compressor
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ZR 13 bar - 50 Hz compressor
Unit ZR 250 ZR 275

Maximum working pressure bar(e) 13 13
Maximum working pressure psig 189 189
Nominal working pressure bar(e) 12 12
Nominal working pressure psig 174 174
Air temperature at outlet valve, approx., Pack compressor ˚C 22 23
Air temperature at outlet valve, approx., Pack compressor ˚F 72 73
Motor shaft speed r/min 1485 1485
Oil capacity l 60 60
Oil capacity US gal 15.84 15.84
Oil capacity Imp gal 13.2 13.2
Oil capacity cu.ft 2.1 2.1
Sound pressure level, Pack Arr. E compressor dB(A) 70 70
Sound pressure level, Full-Feature Arr. E compressor dB(A) 70 70
Cooling water consumption for Pack compressor at a temperature
l/s 3.44 3.74
rise of 15 ˚C / 27 ˚F
Cooling water consumption for Pack compressor at a temperature
cfm 7.28 7.92
rise of 15 ˚C / 27 ˚F
Cooling water consumption for Full-Feature compressor at a
l/s 5.66 6.16
temperature rise of 10 ˚C / 18 ˚F
Cooling water consumption for Full-Feature compressor at a
cfm 11.99 13.05
temperature rise of 10 ˚C / 18 ˚F
11.7 Dryer data
Reference conditions
Unit
Compressed air inlet pressure bar(e) 7 7 7 7
Compressed air inlet pressure psig 101.53 101.53 101.53 101.53
Ambient temperature ˚C 10 20 30 35
Ambient temperature ˚F 50 68 86 95
Compressed air inlet temperature ˚C 18 28 38 40
Compressed air inlet temperature ˚F 64.4 82.4 100.4 104.0
Inlet relative vapour pressure 1 1 1 1
Cooling air inlet temperature ˚C 10 20 30 35
Cooling air inlet temperature ˚F 50 68 86 95
Regeneration air temperature at ˚C 140 150 160 170
dryer inlet
Regeneration air temperature at ˚F 284 302 320 338
dryer inlet
Moisture content of regeneration gr/m3 6 10 10 10
air to dryer
196 9095 0502 84

Instruction book
Limits
Unit
Maximum compressed air inlet bar(e) 10.5 10.5 10.5 10.5
pressure
Maximum compressed air inlet psig 152.3 152.3 152.3 152.3
pressure
Minimum compressed air inlet bar(e) 4 4 4 4
pressure
Minimum compressed air inlet psig 58 58 58 58
pressure
Minimum ambient temperature ˚C 0 0 0 0
Minimum ambient temperature ˚F 32 32 32 32
Maximum compressed air inlet ˚C 50 50 50 50
temperature
Maximum compressed air inlet ˚F 122 122 122 122
temperature
Minimum regeneration air ˚C 110 120 130 135
temperature at dryer inlet
Minimum regeneration air ˚F 230 248 266 275
temperature at dryer inlet
Maximum temperature drop over ˚C 15 15 15 15
regeneration air piping
Maximum temperature drop over ˚F 27 27 27 27
regeneration air piping
50 Hz units
For ZR 160 and ZR 200 10/10.4/13 bar (145/150/189 psi)
Unit
Dewpoint of dried compressed air ˚C -30 -25 -20 -8
Dewpoint of dried compressed air ˚F -22 -13 -4 17.6
Volume flow at dryer inlet under l/s 470 470 470 470
nominal conditions
Volume flow at dryer inlet under cfm 995 995 995 995
nominal conditions
Temperature of dried compressed ˚C 30 40 55 70
air
Temperature of dried compressed ˚F 86 104 131 158
air
Pressure drop over pre-cooler bar 0.3 0.3 0.3 0.3
Pressure drop over pre-cooler psi 4.35 4.35 4.35 4.35
Cooling water consumption at a l/s 0.8 0.8 0.8 0.8
temperature rise of 5 ˚C
9095 0502 84 197

Instruction book
Unit
Cooling water consumption at a cfm 1.69 1.69 1.69 1.69
Cooling water pressure drop at a bar 0.12 0.12 0.12 0.12
Cooling water pressure drop at a psi 1.74 1.74 1.74 1.74
For ZT 160 and ZT 200 10/10.4/13 bar (145/150/189 psi)
Unit
Dewpoint of dried compressed air ˚C -35 -30 -20 -10
Dewpoint of dried compressed air ˚F -31 -22 -4 14
Volume flow at dryer inlet under l/s 460 460 460 460
nominal conditions
Volume flow at dryer inlet under cfm 974 974 974 974
nominal conditions
air
air
Pressure drop over pre-cooler bar 0.3 0.3 0.3 0.3
Pressure drop over pre-cooler psi 4.35 4.35 4.35 4.35
ZR 200 - 7/7.5/8.6 bar (102/109/125 psi) and ZR 250/275
Unit
Dewpoint of dried compressed air
- minimum flow ˚C -35 -25 -15 -5
- minimum flow ˚F -31 -13 5 23
- maximum flow ˚C -38 -30 -20 -10
- maximum flow ˚F -36 -22 -4 14
Volume flow at dryer inlet under
nominal conditions
- minimum l/s 607 607 607 607
- minimum cfm 1285 1285 1285 1285
- maximum l/s 780 780 780 780
- maximum cfm 1651 1651 1651 1651
air
air
Pressure drop over pre-cooler
198 9095 0502 84

Instruction book
Unit
- minimum bar 0.27 0.27 0.27 0.27
- minimum psi 3.92 3.92 3.92 3.92
- maximum bar 0.45 0.45 0.45 0.45
- maximum psi 6.53 6.53 6.53 6.53
Cooling water consumption at a l/s 2 2 2 2
Cooling water consumption at a cfm 4.23 4.23 4.23 4.23
Cooling water pressure drop at a bar 0.1 0.1 0.1 0.1
Cooling water pressure drop at a psi 1.45 1.45 1.45 1.45
ZT 200 - 7/7.5/8.6 bar (102/109/125 psi) and ZT 250/275
Unit
Dewpoint of dried compressed air
- minimum flow ˚C -35 -25 -15 -5
- minimum flow ˚F -31 -13 5 23
- maximum flow ˚C -38 -30 -20 -10
- maximum flow ˚F -36 -22 -4 14
Volume flow at dryer inlet under
nominal conditions
- minimum l/s 557 557 557 557
- minimum cfm 1179 1179 1179 1179
- maximum l/s 729 729 729 729
- maximum cfm 1543 1543 1543 1543
air
Temperature of dried compressed ˚F 86 104 127.4 140
air
Pressure drop over pre-cooler
- minimum bar 0.25 0.25 0.25 0.25
- minimum psi 3.63 3.63 3.63 3.63
- maximum bar 0.45 0.45 0.45 0.45
- maximum psi 6.53 6.53 6.53 6.53
9095 0502 84 199

Instruction book
12 Storage instructions
12.1 Objective
• The main objective of this presentation is to lay down the “Standard Storage Procedure” for the AIF
Product Range manufactured from Atlas Copco - Pune
• The same is necessary as it is seen that in certain cases the machine are stored for long periods prior to
commissioning.
• The responsibility of the units ( PC or CC) is as per the guidelines laid down elsewhere
• The present information relates to the Z-Range Oil Free Compressors
12. 2 Shipping Precautions

• Five Silica gel bags , tied together are placed inside the housing of the intercooler water separator of
the ZR Compressor. (One of the strings of the bags is made to stick out of the flange and a sticker is
glued to the flange to draw your attention to the presence of the silica gel bags)
• All drain plugs are removed from cooler and elements and collected in a bag. This bag is delivered
together with the unit
• The vent holes are closed off with moisture repellant adhesive tapes
• Unpainted surfaces are covered with a layer of highly adhesive grease
• Panel doors (except for the cubicle door ) are secured with a locking plate on one of the hinges and a
clamp on the bottom frame
• The Complete Compressor Unit is enclosed in a plastic cover
• The Complete unit is then placed on a wooden crate ( Made of Rubber Wood) . Lifting marks are
painted on the crates
12. 3 Pre-Storage Precautions

• The Unit is packed to be stored in a controlled environment ( No direct exposure to sunrays or rain)
• The place (warehouse ) where the unit is stored should be well ventilated. Stand the unit upright in its
crate. Be sure there is no source of vibrations nearby
• The Wooden Crate ( Made of Rubber Wood) has a life of 6 Months under a controlled environment.
• The Compressor Unit is now ready for storage for maximum 6 months. The storage period remains
valid provided that the ambient conditions remain normal (meaning no excesses of heat, cold or high
humidity)
• If the unit is to be stored for a period longer than 6 months than carry out the storage maintenance
procedure as stated in the next slide
12.4 Storage Precautions

• Renewing the silica gel bags
• Renewing the preservative oil film
• ZR units are normally delivered ex factory with Roto-Z oil as first fill. This also has preservative
qualities. The duration of the protective period is 6 months. Using Roto-Z precludes the need for
separate oil circulation procedures. On units , filled with Roto-Z oil ex-factory, turn the main
drive coupling by hand during a few minutes in order to re-distribute the oil film on bearing
balls, rollers and drive gears.
• When the unit does not contain oil , the following instructions apply
• Set up an oil circulation pump with a capacity of approx. 15 l/min and an effective working
pressure of 1.5 to 2.5 bar . Connect the pump to the compressor lubricating system.
200 9095 0502 84

Instruction book
• Fill up the compressor sump with 80 L of Roto-Z oil

• Circulate the oil throughout the compressor for approximately 15 minutes. Meanwhile , turn the
compressor coupling over hand , once every two or three minutes
• Drain the Roto-Z oil from the sump and disconnect the circulating pump. Re-install the original
pipes. Store the oil in a clean container for later use.
• Place the nominated quantity of dry silica gel bags inside the unit
• Close the main air inlet duct using the protective material (or similar) . Close the door of the unit
• Henceforth inspect the unit once a month. Turn the main coupling a few turns by hand , to change the
position of balls and roller in the bearings and re-distribute the oil film
9095 0502 84 201

Instruction book
13.1 Drive locate document
13.1 Protection for ZR / ZT compressors

While in Intermittent use - Subject
In humid environments, lifetime of oil free screw element can be influenced when the unit is
Standing still frequently and / or for a longer period of time.
During stand still period, condensation may occur and will be responsible for starting corrosion on
the inlet side of the rotors. As a result of this, the lifetime of the element may be influenced and it‟s
even possible that the element may be locked-up during stand still for a longer period of time.
Introduction of a protection dry-blow field kit w i l l a s s i s t to increase life time of the oil free screw
elements in applications were the unit is frequently standing still in environments with higher
humidity.
If the unit is stopped frequently and remain in stopped condition for longer period, the cultivation of
condensation can be prevented by blowing a small amount of air over the rotors. This will prevent any
possibility of starting corrosion on the element.
We now have a kit available to dry-blow and protect the elements from stand still corrosion. This kit
makes it possible to automatically dry the elements when unit is stopped.
If machine is stopped frequently and or remains in stopped condition for more than two days occasionally
we recommend installation of dry blow kit , which ensures dry air supply in interstage as well as in side
elements to avoid possible corrosion due to condensate in both LP & HP elements.
Two service kits are available for customer to order out Protection Dry-blow kit.
Kit Pn 2906 0891 00 for ZR/ZT 160-275 Kit Pn 2906 0892 00 for Other Z-units
In addition if the unit is not be used for a period of:
More than two days to three months following precautions to be carried out for improving element life:
1) Start the compressor at least twice a week until warm to have good film of oil on the bearings keeping
unit ready to start when required.
2) If power is isolated during this shut off duration, turn the drive coupling by 15 to 20 turns by hand in
correct rotation direction at least once in three days, to change the position of balls & rollers in bearings
to redistribute the oil film.
3) Open or Purge manual drains of intercooler, after cooler drain receivers or EWD‟s/ERD‟s, just before
stopping. Check if drain pipes are now free of water. Close the valves after condensate is completely
drained.
4) Ensure that cooling water supply is shut off by closing both inlet & outlet valves. Please ensure that
water from cooling circuit of compressor is completely drained out.
This is also important to avoid possible jamming of rotors.
If the unit is not going to be started for more than three months please ensure that Atlas Copco Service
representative is called well in advance for assisting to initiate secure storage instructions.
202 9095 0502 84

What sets Atlas Copco apart as a company is our conviction that
we can only excel in what we do if we provide the best possible
know-how and technology to really help our customers produce,
grow and succeed.
There is a unique way of achieving that - we simply call it the Atlas
Copco way. It builds on interaction, on long-term relationships
and involvement in the customers‟ process, needs and objectives.
It means having the flexibility to adapt to the diverse demands of
the people we cater for.
It‟s the commitment to our customers‟ business that drives our
effort towards increasing their productivity through better
solutions. It starts with fully supporting existing products and
continuously doing things better, but it goes much further, creating
advances in technology through innovation. Not for the sake of
technology, but for the sake of our customer‟s bottom line and
peace-of-mind.
That is how Atlas Copco will strive to remain the first choice, to
succeed in attracting new business and to maintain our position
as the industry leader.
No. 9095 0502 84 / 2013 - 01

Compressor Manual

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ZR 160, ZR 200, ZR 250, ZR 275, ZT 160, ZT 200, ZT 250, ZT 275

ZR 160, ZR 200, ZR 250, ZR 275, ZT 160, ZT 200, ZT 250,

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

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

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

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

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

2 General description ..................................................................................................... 11

2.1 INTRODUCTION .............................................................................................................................. 11

2.2 AIR SYSTEM .................................................................................................................................. 14

2.3 COOLING AND CONDENSATE SYSTEM.................................................................................................. 19

2.4 ELEKTRONIKON REGULATED DRAIN (ERD) ............................................................................................ 21

2.5 OIL SYSTEM .................................................................................................................................. 24

2.6 REGULATING SYSTEM ..................................................................................................................... 26

3 Elektronikon regulator type overview ........................................................................ 29

3.1 ELEKTRONIKON® CONTROLLER TYPE OVERVIEW ................................................................................... 29

4 Elektronikon regulator ................................................................................................. 30

4.1 ELEKTRONIKON® REGULATOR ........................................................................................................... 30

4.2 CONTROL PANEL ............................................................................................................................ 32

4.3 FUNCTION KEYS ............................................................................................................................. 33

4.4 SCROLL KEYS................................................................................................................................ 34

4.5 EMERGENCY STOP BUTTON .............................................................................................................. 34

4.6 EXTERNAL COMPRESSOR STATUS INDICATION ...................................................................................... 35

4.7 CONTROL PROGRAMS ..................................................................................................................... 35

4.8 CONTROL PROGRAMS ..................................................................................................................... 37

4.9 CALLING UP MENUS ........................................................................................................................ 39

4.10 CALLING UP MENUS ........................................................................................................................ 40

4.11 MAIN SCREEN MENU ....................................................................................................................... 41

4.12 MAIN SCREEN MENU ....................................................................................................................... 42

4.13 STATUS DATA MENU ....................................................................................................................... 43

4.14 MEASURED DATA MENu ................................................................................................................... 46

4.15 COUNTERS MENU ........................................................................................................................... 47

4.16 TEST MENU ................................................................................................................................... 48

4.17 MODIFY PARAMETERS MENU............................................................................................................. 49

4.18 MODIFYING PARAMETERS ................................................................................................................ 49

4.19 MODIFYING PROTECTION SETTINGS .................................................................................................... 50

4.20 MODIFYING SERVICE PLANS.............................................................................................................. 51

4.21 PROGRAMMING CLOCK FUNCTION ...................................................................................................... 52

4.22 MODIFYING CONFIGURATION SETTINGS ............................................................................................... 57

4.23 SERVICE MENU .............................................................................................................................. 58

4.24 SAVED DATA MENU ......................................................................................................................... 60

4.25 PROGRAMMABLE SETTINGS .............................................................................................................. 61

5 Elektronikon® GraphicPlus controller ....................................................................... 69

5.1 ELEKTRONIKON® GRAPHICPLUS CONTROLLER ...................................................................................... 69

5.2 CONTROL PANEL ............................................................................................................................ 71

5.3 DIGITAL OUTPUT CONTACTS ............................................................................................................. 72

5.4 ICONS USED .................................................................................................................................. 73

5.5 MAIN SCREEN ............................................................................................................................... 77

5.6 CALLING UP MENUS ........................................................................................................................ 81

5.7 SERVICE MENU .............................................................................................................................. 83

5.8 PROTECTIONS MENU....................................................................................................................... 88

5.9 WEEK TIMER MENU ......................................................................................................................... 90

5.10 INFO MENU ................................................................................................................................. 100

5.11 TEST MENU ................................................................................................................................. 101

5.12 COUNTERS ................................................................................................................................. 102

5.13 MODIFYING THE PRESSURE BAND .................................................................................................... 104

5.14 INPUTS MENU .............................................................................................................................. 106

5.15 OUTPUTS MENU ........................................................................................................................... 111

5.16 EVENT HISTORY MENU .................................................................................................................. 113

5.17 MODIFYING SETTINGS ................................................................................................................... 114

5.18 PROGRAMMABLE SETTINGS ............................................................................................................ 120

5.19 WEB SERVER .............................................................................................................................. 121

6 Installation .................................................................................................................. 130