Atlas Copco ZR 110 Instruction Book

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ZR 110, ZR 132, ZR 145, ZR 160, ZR 200, ZR 250, ZR 275, ZT 110,

ZT 132, ZT 145, ZT 160, ZT 200, ZT 250, ZT 275

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Questions and answers

Mohamed Djalel Boumediene

May 15, 2025

hello team, Is it possible to start ZT132 compressor without tank receiver? please advise, unloaded mode time could be extended? in case we don't have a tank receiver which test could be performed?

1 comments:

Mr. Anderson

May 22, 2025

Yes, the Atlas Copco ZT132 compressor can be started without a tank receiver. If a tank receiver is not available, the following tests can be performed:

1. Check that the transformer voltage selecting wires are correctly connected.
2. Ensure the electrical installation complies with local regulations.
3. Verify the gear casing is filled with oil.
4. Start the motor briefly and stop it to check the direction of rotation.
5. If the rotation is incorrect, reverse two electric inlet connections.
6. Run the compressor for a few minutes.
7. Stop the compressor and check the oil level in the sight-glass.

These steps help verify correct installation and operation without needing a tank receiver.

This answer is automatically generated

Summary of Contents for Atlas Copco ZR 110

Page 1 ZR 110, ZR 132, ZR 145, ZR 160, ZR 200, ZR 250, ZR 275, ZT 110, ZT 132, ZT 145, ZT 160, ZT 200, ZT 250, ZT 275 Instruction book...
Page 3 Atlas Copco ZR 110, ZR 132, ZR 145, ZR 160, ZR 200, ZR 250, ZR 275, ZT 110, ZT 132, ZT 145, 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.
Page 4: Table Of Contents
Instruction book Table of contents Safety precautions......................7 ........................... 7 AFETY ICONS ......................7 ENERAL SAFETY PRECAUTIONS ................... 8 AFETY PRECAUTIONS DURING INSTALLATION ....................9 AFETY PRECAUTIONS DURING OPERATION ................. 10 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description...................... 12 ..........................12 NTRODUCTION ............................
Page 5 Instruction book 3.10 .......................... 53 ALLING UP MENUS 3.11 ......................... 53 AIN SCREEN MENU 3.12 ..........................54 TATUS DATA MENU 3.13 ........................56 EASURED DATA MENU 3.14 ..........................56 OURS MENU 3.15 ..........................57 ERVICE MENU 3.16 ............................. 59 EST MENU 3.17 ........................60 ODIFY SETTINGS MENU...
Page 6 Instruction book ......................... 85 AIN SCREEN MENU 5.10 ..........................86 TATUS DATA MENU 5.11 ........................89 EASURED DATA MENU 5.12 ..........................90 OUNTERS MENU 5.13 ............................. 91 EST MENU 5.14 ....................... 92 ODIFY PARAMETERS MENU 5.15 ........................92 ODIFYING PARAMETERS 5.16 ......................
Page 7 Instruction book 6.15 ..........................155 UTPUTS MENU 6.16 ........................157 VENT HISTORY MENU 6.17 ........................158 ODIFYING SETTINGS 6.18 .......................164 ROGRAMMABLE SETTINGS 6.19 ..........................165 EB SERVER Installation........................174 ........................174 IMENSION DRAWING ......................190 ADAPTOR FLANGES ......................... 194 NSTALLATION PROPOSAL ..............206 NSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS ................
Page 8 Instruction book Maintenance........................ 282 ....................282 REVENTIVE MAINTENANCE SCHEDULE .......................... 285 OTOR GREASING ........................285 IL SPECIFICATIONS ......................285 TORAGE AFTER INSTALLATION Servicing procedures....................286 10.1 ..........................286 IR FILTERS 10.2 ......................287 IL AND OIL FILTER CHANGE 10.3 ..........................289 AFETY VALVES 10.4 .............................
Page 9: Safety Precautions
Instruction book Safety precautions Safety icons Explanation Danger to life Warning Important note General safety precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
Page 10: Safety Precautions During Installation
9. If compressed air is used in the food industry and more specifically for direct food contact, Atlas Copco recommends, for optimal safety, the use of certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your Atlas Copco Customer Center for advice on specific filtration.
Page 11: Safety Precautions During Operation
Instruction book 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.
Page 12: Safety Precautions During Maintenance Or Repair
Instruction book • 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 •...
Page 13 Instruction book 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.
Page 14: General Description
Instruction book General description Introduction General views General view of ZR 110, ZR 132 and ZR 145 FF with Elektronikon controller 2920 1815 04...
Page 15 Instruction book General view of ZR 110, ZR 132 and ZR 145 FF with Elektronikon GraphicPlus controller (Model year 2010) General view of ZR 110, ZR 132 and ZR 145 FF with Elektronikon GraphicPlus controller (Model year 2011) 2920 1815 04...
Page 16 Instruction book General view of ZR 160 up to ZR 275 FF with Elektronikon GraphicPlus controller General view of ZT 110, ZT 132 and ZT 145 FF with Elektronikon controller 2920 1815 04...
Page 17 Instruction book General view of ZT 110, ZT 132 and ZT 145 FF with Elektronikon GraphicPlus controller (Model year 2010) General view of ZT 110, ZT 132 and ZT 145 FF with Elektronikon GraphicPlus controller (Model year 2011) 2920 1815 04...
Page 18 Instruction book General view of ZT 160 up to ZT 275 FF with Elektronikon GraphicPlus controller Ref. Name Compressed air outlet Condensate drain receiver, aftercooler Condensate drain receiver, intercooler Elektronikon regulator Elektronikon GraphicPlus regulator Safety valve, high pressure Safety valve, low pressure Emergency stop button Cooling water inlet Cooling water outlet...
Page 19 Instruction book • 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.
Page 20 When the handle is turned to the right, the left cartridge is out of service and vice versa. Energy recovery The compressor is provided with an Atlas Copco energy recovery system to recover the major part of the compression heat in the form of hot water. SPM monitoring A number of vibration sensors are provided on the drive motor and compressor elements.
Page 21 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. Oversized motor The size of the motor is chosen in such a way that the Service Factor of the motor is never used.
Page 22: Air System
Instruction book Air system Flow diagram Flow diagram of ZR 110 up to ZR 275 and ZR 132 VSD up to ZR 315 VSD compressors 2920 1815 04...
Page 23 Instruction book Flow diagram of ZR 110 up to ZR 275 Full-Feature compressors and ZR 132 VSD up to ZR 315 VSD Full-Feature compressors 2920 1815 04...
Page 24 Instruction book Flow diagram of ZT 110 up to ZT 275 compressors and ZT 132 VSD up to ZT 315 VSD compressors 2920 1815 04...
Page 25 Instruction book Flow diagram of ZT 110 up to ZT 275 Full-Feature compressors and ZT 132 VSD up to ZT 315 VSD Full-Feature compressors Reference Name Air filter Air outlet Silencer By-pass valve 2920 1815 04...
Page 26 Instruction book Reference Name Pre-aftercooler Aftercooler Pre-intercooler Intercooler Oil cooler Regeneration air cooler Check valve High-pressure compressor element Low-pressure compressor element Moisture trap, aftercooler Moisture trap, intercooler Ejector nozzle Oil filter Oil pump Water separator Demister Rotor Regulation valve for the inlet of the regeneration air Strainer Description Air drawn through filter (AF) is compressed in low-pressure compressor element (El).
Page 27: Cooling And Condensate Drain System
Instruction book Cooling and condensate drain system Flow diagram Flow diagram of ZR 110 up to ZR 275 compressors 2920 1815 04...
Page 28 Instruction book Flow diagram of ZT 110 up to ZT 275 compressors Reference Name Air filter Air outlet Silencer By-pass valve Pre-aftercooler Aftercooler 2920 1815 04...
Page 29: Elektronikon Regulated Drain (Erd)
Instruction book Reference Name Pre-intercooler Intercooler Oil cooler Check valve High-pressure compressor element Low-pressure compressor element Moisture trap, aftercooler Moisture trap, intercooler Oil filter 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).
Page 30 Instruction book 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.
Page 31 Instruction book for ZT compressors (before model year 2014) for ZT compressors (from model year 2014) 2920 1815 04...
Page 32 Instruction book Reference Description Solenoid valve Connector Sensor Bushing Drain receiver If the controller detects water in the intercooler or aftercooler drain receiver for too long a period, a shutdown is generated. If water is detected on the integrated dryer drain receiver for too long a period, a warning is generated.
Page 33: Oil System
Instruction book Oil system Flow diagram Flow diagram of ZR 110 up to ZR 275 compressors and ZR 132 VSD up to ZR 315 VSD compressors 2920 1815 04...
Page 34 Instruction book Flow diagram of ZT 110 up to ZT 275 compressors and ZT 132 VSD up to ZT 315 VSD compressors Reference Name Air filter Air outlet Silencer By-pass valve Pre-aftercooler Aftercooler 2920 1815 04...
Page 35: Regulating System
Instruction book Reference Name Pre-intercooler Intercooler Oil cooler Check valve High-pressure compressor element Low-pressure compressor element Moisture trap, aftercooler Moisture trap, intercooler Oil filter 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).
Page 36 Instruction book 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).
Page 37 Instruction book 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 Atmospheric pressure is allowed through solenoid valve (Y1) to chamber (1) of unloader...
Page 38: Energy Recovery
Instruction book Energy recovery General The system recovers the major part of the compression heat. The percentage of shaft input power available for recovery is between 80 and 95, depending on the operating conditions. If an MD dryer is installed downstream of the compressor, this percentage is reduced to approx. 70 of the shaft input instead of approx.
Page 39 Instruction book Pump unit Atlas Copco supplies pump units to transfer the energy recovered from the compressor to the heat consumer (HC). The pump unit constitutes a closed water circuit with the compressor cooling system. Two water pumps (WP1/2) are fitted. One pump circulates the hot cooling water from the compressor through the heat consumer and back to the compressor.
Page 40 This aftercooler and the dryer (if water-cooled) need to be cooled separately by low-temperature water. Consult the Atlas Copco Customer Centre. The general temperature level of compressors with a modified cooling system for energy recovery is approx.
Page 41: Low Load Compensator For Imd Dryer
Instruction book Low load compensator for IMD dryer Description Flow diagram of a ZT compressor with Low Load compensator functionality (during unload) 2920 1815 04...
Page 42 Instruction book Flow diagram of a ZR compressor with Low Load compensator functionality (during unload) Reference Name Outlet of compressed air (air net) 2a, 2b Non-return valve Heater Rotor Motor Cooler 2920 1815 04...
Page 43: Smartbox And Smartlink
Instruction book Reference Name 7a, 7b, 7c, 7d Solenoid valve Nozzle of dryer inlet Water separator Silencer Safety valve Compressed air from compressor Regeneration air from compressor Symbol Explanation Air flow Air flow direction No air flow Drain Cooling water To allow low load operation (load rate <...
Page 44 Atlas Copco allows to request and quickly receive quotes for spare parts or additional services. This product level is free of charge and available for 3 years following the machine purchase.
Page 45 Instruction book • Use the data of the SMARTLINK–ready machine to register as a user. • You will receive an e-mail with login credentials. • Go to the SMARTLINK web site http://www.atlascopco.com/smartlink, log in with the user credentials. • Enjoy SMARTLINK! •...
Page 46: Elektronikon Regulator
Instruction book Elektronikon regulator ® 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) •...
Page 47 Automatic restart 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 and the...
Page 48: Control Panel
Instruction book Control panel Elektronikon regulator Parts and functions Reference Designation Function Automatic Operation LED Indicates that the electronic regulator is automatically controlling the compressor. Voltage on LED Indicates that the voltage is switched on. Display Indicates messages concerning: • The compressor operating condition •...
Page 49: Function Keys
Instruction book 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 •...
Page 50: Scroll Keys
Instruction book 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.
Page 51: Control Mode Switch
Instruction book In case of emergency, press button (S2) to stop the compressor immediately. 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.
Page 52: External Compressor Status Indication
External communication Description If it is desired to connect the compressor to an Atlas Copco ES system an optional communication module (COM1 or COM2) needs to be installed. If it is desired to connect the compressor to a profibus network, a profibus module in combination with a COM2 module must be installed.
Page 53 Connect the cable delivered with the communication module from connector (..X3) of the communication module to a free ..X2 connector on a module of the compressor regulator. Consult Atlas Copco to check the installation and to have the communication software loaded. Installation of Profibus module...
Page 54: Control Programs
(N and L1) on the profibus module. Connect an earth cable between the profibus module and the module of the compressor regulator. Consult Atlas Copco to check the installation and to have the communication software loaded. Control programs In order to facilitate programming and controlling, menu-driven control programs have been implemented in the regulator.
Page 55: Calling Up Menus
Instruction book 3.10 Calling up menus When the voltage is switched on, the Main screen is shown automatically. Calling up menus Starting from the Main screen: • Either use the key ”Menu” (F1) to scroll to the first submenu “Status data” and press the key “Select” (F2) to select this submenu.
Page 56: Status Data Menu
Instruction book Function The Main screen menu shows in short the compressor operation status 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 keys or arrow keys (1, 2 and 3) are not used for about 4 minutes, the regulator will automatically return to the Main screen.
Page 57 Instruction book Procedure Starting from the Main screen (see Main screen menu), press key “Menu” (F1). Following screen appears: Status data MainScreen Select No shut-down warning message or shut-down message exists • General alarm LED (1) is out. • After pressing key “Select” (F2), a message will appear indicating that all conditions are normal: All protection functions are OK Menu •...
Page 58: Measured Data Menu
Instruction book Shut-down reset • Switch off the voltage and remedy the trouble. • Switch on the voltage and start the compressor. It may be necessary to 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.
Page 59: Service Menu
• By using scroll keys (1), the other items can be called up. • The horizontal arrow shows the parameter which can be modified (if this should be required, consult the Atlas Copco Customer Centre). 3.15 Service menu Control panel Function To call up and reset service messages for the monitored components.
Page 60 Instruction book • Activate the menu by pressing key “Select” (F2). Calling up service messages • The display will show the name of the first component and the message whether service is needed or not. Dp Air Filter No service required Menu Select Reset...
Page 61: Test Menu
Instruction book Before starting any maintenance or repairs, apply all relevant Safety precautions. Service reset To reset the service timer: • Take the necessary service action. • Call up the service menu for the relevant component (see section “Procedure” above). •...
Page 62: Modify Settings Menu
Instruction book 3.17 Modify settings menu Function To modify a number of programmable settings: • Regulation settings (see section Modifying regulation settings). • Protection settings (see section Modifying protection settings). • Service settings (see section Modifying service settings). 3.18 Modifying regulation settings Control panel Function To modify a number of regulation settings.
Page 63: Modifying Protection Settings
Instruction book 3.19 Modifying protection settings Control panel Function To modify a number of protection settings. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press key “Menu” (F1). • Press key (1) until “Modify settings” is shown. •...
Page 64 Menu Modify • If it should be necessary to modify the nominal setting, consult the Atlas Copco Customer Centre. • Modify the value by means of scroll keys (1). • Press the key ”Program” to program the new value or the key “Cancel” to cancel the modification operation (the original value will be retained).
Page 65: Modifying Service Settings
Instruction book 3.20 Modifying service settings Control panel Function To modify a number of service settings. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press key “Menu” (F1). • Press key (1) until “Modify settings” is shown. •...
Page 66: Timers Menu
Instruction book The regulator will not accept new values beyond the limitations. It is possible to check the limitations which are valid for the parameter to be modified by selecting “Limits”. 3.21 Timers menu Control panel Function To program time-based start/stop commands for the compressor. Procedure Starting from the Main screen (see Main screen...
Page 67 Instruction book • Using scroll keys (1), modify this command as required, as described below in section “Modifying a command”. Add and delete commands as required, as described below in sections “Adding a command” and “Deleting a command”. • Activate the timer as described below. Activating/deactivating the timer •...
Page 68 Instruction book Modifying a command • Suppose the command “Monday 17:00 Stop Compressor” is to be modified, i.e. stopping at 18 o'clock instead of 17 o'clock. • Press the key “List” and scroll through the compressor start/stop commands until the command to be modified is indicated by the horizontal arrow on the screen.
Page 69: Configuration Menu
Control programs. Two languages are programmed. The function “Auto restart after voltage failure” can only be activated by an Atlas Copco Customer Centre. For the date format: “DD MM YY” stands for day/month/year - “MM DD YY” stands for month/day/year - “YY MM DD” stands for year/month/day.
Page 70: Saved Data Menu
Instruction book 3.23 Saved data menu Control panel Function To call up the compressor data saved by the electronic regulator: • The data of the five last shut-downs (indicated “Last shutdown 1”, “Last shutdown 2”, ...): cause of the shut-down, time, date and other data reflecting the condition of that moment. •...
Page 71: Show More Menu
“Local control” means that the start/stop buttons on the keyboard are activated. “Remote control” means that these functions are controlled remotely. Consult the Atlas Copco Customer Centre. • The third line indicates whether the timer which generates time-based start and stop commands is...
Page 72: Unload-Load Menu
Instruction book 3.25 Unload-load menu Control panel Function To load and unload the compressor manually. Normally, the compressor is running in automatic operation, i.e. loading, unloading, stopping and automatic restarting. LED (1) is then alight. If required, the compressor can be unloaded manually: the compressor will run unloaded unless it is loaded again manually.
Page 73 Instruction book Minimum Factory Maximum setting setting setting Load delay time (not star-delta) Number of motor starts (low-voltage motor) starts/hr Number of motor starts (high-voltage starts/day Consult motor motor) manufacturer Required stop period Power recovery time Elektronikon regulator Minimum stop time Unloading pressure bar(e) Unloading pressure...
Page 74 Instruction book Minimum Factory Maximum setting setting setting Compressor element 2 outlet temperature ˚C (shut-down level) Compressor element 2 outlet temperature ˚F (shut-down level) Protection settings Minimum Factory Maximum setting setting setting Compressor element 1 outlet temperature ˚C (shut-down warning level) Compressor element 1 outlet temperature ˚F (shut-down warning level)
Page 75 410 ˚F, the minimum limit for the shut-down level changes into 411 ˚F. The recommended difference between the warning level and shut-down level is 18 ˚F. Use Atlas Copco Roto-Z oil. The change interval for this oil is after 16000 running hours or 2-yearly.
Page 76 Instruction book Term Explanation Unloading/ The regulator does not accept illogical settings, e.g. if the unloading pressure is Loading pressure programmed at 7.5 bar(e), the maximum limit for the loading pressure changes into 7.4 bar(e). The recommended minimum pressure difference between loading and unloading is 1 bar.
Page 77: Elektronikon Regulator Type Overview
Instruction book Elektronikon regulator type overview ® Elektronikon controller type overview Type overview Depending on the manufacturing date or the ordered configuration, the compressor is equipped with • the Elektronikon controller • the Elektronikon Graphic controller • the Elektronikon GraphicPlus controller Elektronikon controller Elektronikon Graphic controller for fixed speed compressors 2920 1815 04...
Page 78 Instruction book Elektronikon Graphic controller for variable speed drive (VSD) compressors Elektronikon GraphicPlus controller for fixed speed compressors Elektronikon GraphicPlus controller for variable speed drive (VSD) compressors 2920 1815 04...
Page 79: Elektronikon Regulator
Instruction book Elektronikon regulator ® 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.
Page 80 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.
Page 81: Control Panel
Instruction book Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Start button Button to start the compressor. LED (8) lights up indicating that the Elektronikon regulator is operative. Display Shows messages about the compressor operating condition, a service need or a fault. Scroll keys Keys to scroll upwards or downwards through the display.
Page 82: Function Keys
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”...
Page 83: Scroll Keys
Instruction book 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.
Page 84: External Compressor Status Indication
Instruction book 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.
Page 85 Instruction book Menu flow for ZR/ZT 110 up to ZR/ZT 275 and ZR 300 up to ZR 750 (simplified) Main menu Program Function Main screen Shows in short the operation status of the compressor. Is the gateway to all functions. 2920 1815 04...
Page 86: Calling Up Menus
Loads and unloads the compressor manually. Calling up menus Description Control panel When the voltage is switched on, the Main screen is shown automatically. Example of Main screen of ZR 110 up to ZR 750 “Compressor Outlet” 7.5 bar “Automatically Loaded” “Menu”...
Page 87: Main Screen Menu
Instruction book Example of Main screen of ZT 110 up to ZT 275 “Compressor Outlet” 7.5 bar “Automatically Loaded” “Menu” “Unload” 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, •...
Page 88: Status Data Menu
Instruction book Example of Main screen of ZR 110 up to ZR 750 “Compressor Outlet” 7.5 bar “Automatically Loaded” “Menu” “Unload” Example of Main screen of ZT 110 up to ZT 275 “Compressor Outlet” 7.5 bar “Automatically Loaded” “Menu” “Unload”...
Page 89 Instruction book The Status data submenu gives information regarding the status of the compressor protection functions (shut-down, shut-down warning and service warning) and allows resetting of a shut-down, motor overload and service condition. Procedure Starting from the Main screen (see Main screen menu): •...
Page 90 Instruction book • If a shut-down warning exists, LED (1) is alight. The Main screen will change into a screen similar to the one below: “Compressor Outlet” 7.0 bar “Shutdown Warning” “Menu”*** ***”Unload” • The message “Shutdown Warning” appears. • Press the key “Menu” (F1) and the tabulator key (2) to select the “Status data” menu; the option “Protection”...
Page 91: Measured Data Menu
Instruction book • 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. 5.11 Measured data menu...
Page 92: Counters Menu
Instruction book 5.12 Counters menu Control panel Function To call up: • The running hours • The loaded hours • The number of motor starts • The number of hours the regulator (module) has been under tension • The number of load cycles Procedure Starting from the Main screen (see Main screen...
Page 93: Test Menu
Instruction book 5.13 Test menu Control panel Function To carry out a display test, i.e. to check whether the display and LEDs are still intact. To test the Electronic Water Drains (EWD) Procedure • Starting from the Main screen (see Main screen menu), press the “Menu”...
Page 94: Modify Parameters Menu
Instruction book 5.14 Modify parameters menu Function To modify a number of programmable settings: • Parameters (see section Modifying parameters). • Protections (see section Modifying protections). • Service plan settings (see section Modifying service plan settings). • Clock function settings (see section Modifying clock function settings).
Page 95: Modifying Protection Settings
Instruction book • 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. •...
Page 96: Modifying Service Plans
Service plans are to be carried out. Always consult your Atlas Copco Customer Centre in case any timer should be changed. The intervals must not exceed the programmed nominal values.
Page 97: Programming Clock Function
Instruction book 5.18 Programming clock function Control panel Function To program: • Time-based start/stop commands for the compressor • Time-based change-over commands for the net pressure band Programming start, stop and pressure band commands In this example, the compressor will be programmed as follows: •...
Page 98 Instruction book “Monday” “Tuesday” “Wednesday” “Menu” “Delete” • 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: --:-- ---------------------- --:-- ---------------------- --:-- ----------------------...
Page 99 Instruction book “Clock Function” “Not Activated” “Menu” “Modify” “Delete” • 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.: •...
Page 100 Instruction book 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.
Page 101: Modifying Configuration Settings
Instruction book 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 •...
Page 102 Instruction book Function To modify a number of parameters. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right. •...
Page 103: Service Menu
Instruction book 5.20 Service menu Control panel Function • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. • To find out which service plans were carried out previously. Service plans A number of service operations are grouped (called Level A, Level B, etc...).
Page 104 Instruction book Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Service” is followed by a horizontal arrow. • Activate the menu by pressing tabulator key (2). •...
Page 105: Saved Data Menu
Instruction book 5.21 Saved data menu Control panel Function To call up some data saved by the regulator. These data are: • Last shut-down data • Last emergency stop data Procedure Starting from the Main screen (see Main screen menu): •...
Page 106 Instruction book Minimum Factory Maximum setting setting setting Communication time-out Permissive start function failure Unloading pressure (7 bar Pack bar(e) compressors) Unloading pressure (100 psi Pack psig 101.5 compressors) Unloading pressure (7 bar Full-Feature bar(e) compressors) Unloading pressure (100 psi Full-Feature psig 101.5 compressors)
Page 107 Instruction book Minimum Factory Maximum setting setting setting Loading pressure (100 psi Pack psig 101.5 compressors) Loading pressure (7 bar Full-Feature bar(e) compressors) Loading pressure (100 psi Full-Feature psig 101.5 compressors) Loading pressure (7.5 bar Pack bar(e) compressors) Loading pressure (110 psi Pack psig 108.8 compressors)
Page 108 Instruction book Protections ZR/ZT 110 up to ZR/ZT 275 Minimum Factory Maximum setting setting setting Compressor outlet pressure (warning) bar(e) 14.0 17.0 Compressor outlet pressure (warning) psig 246.5 Compressor outlet pressure (shut-down) bar(e) 15.0 17.0 Compressor outlet pressure (shut-down) psig 217.5 246.5 Oil pressure (shut-down warning level)
Page 109 Instruction book Minimum Factory Maximum setting setting setting Compressors designed for a maximum ˚F inlet temperature of 122 ˚F Compressor element 1 outlet temperature (shut-down level) (10.0, 10.4 and 12.0 bar (175 psi) compressors) Compressors designed for a maximum ˚C inlet temperature of 40 ˚C Compressors designed for a maximum ˚F...
Page 110 Instruction book Minimum Factory Maximum setting setting setting Compressor element 2 outlet temperature (shut-down warning level) (10.0, 10.4 and 12.0 bar compressors) Compressors designed for a maximum ˚C inlet temperature of 40 ˚C Compressors designed for a maximum ˚F inlet temperature of 104 ˚F ZR Compressors designed for a maximum ˚C inlet temperature of 50 ˚C...
Page 111 Instruction book Minimum Factory Maximum setting setting setting Compressors designed for a maximum ˚C inlet temperature of 40 ˚C Compressors designed for a maximum ˚F inlet temperature of 104 ˚F ZR Compressors designed for a maximum ˚C inlet temperature of 50 ˚C ZR Compressors designed for a maximum ˚F inlet temperature of 122 ˚F...
Page 112 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...
Page 113 0.6 bar/9 psig. Delay at shut- Is the time for which the signal must exist before the compressor is shut down. If it down signal should be required to program this setting to another value, consult Atlas Copco. 2920 1815 04...
Page 114: Elektronikon® Graphicplus Controller
Instruction book Elektronikon® GraphicPlus controller ® 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.
Page 115 The controller allows automatic restart of the compressor unit if the supply is restored after voltage failure. For compressors leaving the factory, this function is disabled. If desired, this function can be enabled by your local Atlas Copco Customer Center. Assuming the controller was running in automatic operation, the compressor unit will restart when the supply voltage to the module is restored if ARAVF is enabled.
Page 116: Control Panel
Instruction book Control panel Elektronikon regulator Parts and functions Reference Designation Function Display Shows the compressor operating condition and a number of icons to navigate through the menu. Pictogram Automatic operation Pictogram General alarm General alarm LED Blinks when operating in shutdown warning condition.
Page 117: Digital Output Contacts
Instruction book 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.
Page 118: Icons Used
Instruction book Relay Connector Maximum load 3 X 31 15 A / 250 V AC 15 A / 30 V DC RC* protected 3 X 31 10 A / 250 V AC 10 A / 30 V DC resistive load 3 X 30 10 A / 250 V AC 10 A / 30 V DC...
Page 119 Instruction book When the compressor is stopped, the icon is motionless. Stopped / Running When the compressor is running, the icon rotates. Compressor status Motor stopped Local start / stop Machine control mode Remote start / stop Network control Automatic restart after voltage Automatic restart after voltage failure is enabled failure Week timer...
Page 120 Instruction book Menu icons Icon Description Service Alarms (warnings, shutdowns) Week timer Info Test Counters Regulation setpoints Inputs Outputs SPM readings Event history (saved data) Settings 2920 1815 04...
Page 121 Instruction book 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...
Page 122: Main Screen
Instruction book General alarm Oil circuit Regulation General settings Access key / User password Navigation arrows Icon Description Down Main screen Control panel Control panel 2920 1815 04...
Page 123 Instruction book Enter key Escape key Scroll keys Function The main screen shows the status of the compressor operation and is the gateway to all functions implemented in the controller. The main screen is shown automatically when the voltage is switched on and a key is pushed. The display switches to sleep mode when no keys are pushed for several minutes.
Page 124 Instruction book Typical Main screen (Four value lines) Text on figures Compressor Outlet Loaded hours Text varies upon the compressor's actual condition Menu Running hours Element outlet (when no aftercooler is mounted) Compressor outlet Load • Section A displays information regarding the compressor operation (e.g. outlet pressure (1), temperature at compressor outlet (2)).
Page 125 Instruction book Local control Remote control Network control • Optional icons These icons are only shown if their corresponding function is activated (e.g. week timer, automatic restart after voltage failure, etc.) • Pop up icons These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...) To show more information about displayed icons, select the icon using the scroll keys and push the Enter key.
Page 126 Instruction book When the Chart (High Resolution) display is selected, a chart with an X-axis covering 4 minutes is displayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chart dot represents 1 second. When the Chart (Medium Resolution) display is selected, a chart with an X-axis covering 4 hours is displayed.
Page 127: Calling Up Menus
Instruction book Calling up menus Control panel Control panel Enter key Escape key Scroll keys Description When the voltage is switched on, the main screen is shown automatically (see section Main screen): • To go to the Menu screen, highlight the Menu button (4), using the Scroll keys. •...
Page 128: Service Menu
Instruction book • 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. •...
Page 129 Instruction book 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 •...
Page 130 Instruction book Text on figure Service Overview Service plan Next service History • Scroll through the items and select the desired item. Push the Enter key to display the details as explained below. Overview Text on figure Overview Running Hours Real Time Hours Reset Running hours are the clocked times during which the compressor stage motor has been running.
Page 131 Instruction book After carrying out the service actions related to the indicated levels, the timers must be reset manually. From the Service menu above, select Service plan (3) and press Enter. Following screen appears: Text on figure Service plan Level Running hours Real time hours Modify...
Page 132 Instruction book 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 Next service Level Running hours...
Page 133: Protections Menu
Instruction book 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): •...
Page 134 Instruction book A number of icons is shown, allowing to display and reset protections Typical example of a general alarm screen Text on figure: General Compressor outlet Level high Shutdown warning Shutdown Reset Modify The screen shows that the actual reading for the compressor outlet is 2.53 bar. The screen shows also the settings for the shutdown warning (3.60 bar) and shutdown (3.70 bar).
Page 135 Instruction book The displayed and resettable protections are : • General: • Compressor outlet warning/shutdown level (High) • Compressor outlet warning level (Low) • Emergency stop status • No valid pressure control: Triggered if the compressor outlet pressure sensor fails. •...
Page 136: Week Timer Menu
Instruction book • 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 Week timer menu Control panel Enter key Escape key...
Page 137 Instruction book 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), •...
Page 138 Instruction book 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. Week Action Schemes Week Action Scheme 1 Week Action Scheme 2...
Page 139 Instruction book • A new window opens. The Modify action button is selected. Push the Enter key on the controller twice to create the first action. Monday Modify • A new window appears. Select an action from the displayed list by using the Scroll keys on the controller.
Page 140 Instruction book Monday Start Save Modify • To adjust the startup time, use the Scroll keys on the controller and push the Enter key to confirm. Monday Start Save 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 ↑...
Page 141 Instruction book Monday Time Save Modify • Push the Escape key on the controller. The Modify action button is selected. Use the Scroll keys to select the action Save. Monday Start Save Modify • A new window appears. Use the Scroll keys on the controller to select the correct actions. Press the Enter key to confirm.
Page 142 Instruction book Monday Are you sure? Save Modify Press the Escape key to leave this window. • The actions are displayed below their respective day. Week Action Scheme 1 Monday Start Tuesday Wednesday Thursday Friday Saturday 2920 1815 04...
Page 143 Instruction book Sunday Push the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed Week Action Schemes can be chosen. •...
Page 144 Instruction book Week Action Scheme 1 Week 3 Week Action Scheme 3 Modify Push the Enter key twice to modify the first week. • Following window appears. Select action e.g. Week Action Scheme 1. Week Cycle Week 1 Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Modify...
Page 145 Instruction book Week Cycle Status Week Timer Inactive Remaining Running Time • A new window appears. Select Week 1 and push the Enter key to enable the Week Timer. Week Timer Week Week Timer Inactive Week 1 • Press the Escape key to leave the pop up window. The status shows that week 1 is active. •...
Page 146: Info Menu
Enter key Escape key Scroll keys Menu icon, Info Function To show the Atlas Copco internet address. Procedure Starting from the Main screen (see Main screen), • Move the cursor to the Menu action button and push the Enter key. Following screen appears: •...
Page 147: Test Menu
Instruction book • 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 •...
Page 148: Counters
Instruction book 6.12 Counters Control panel Enter key Escape key 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 •...
Page 149 Instruction book Text on figure Menu 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 Counters Running hours Loaded Hours Motor starts Load relay The screen shows a list of all counters and their current values.
Page 150: Modifying The Pressure Band
Instruction book 6.13 Modifying the pressure band Control panel Enter key Escape key Scroll keys Menu icon, Regulation Function The regulation menu allows tuning of 2 pressure bands and the selection of the current pressure band. Procedure Starting from the Main screen (see Main screen), •...
Page 151 Instruction book Text on figure Menu 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 Regulation Unloading pressure 1 Loading pressure 1...
Page 152: Inputs Menu
Instruction book • 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 ↑...
Page 153 Instruction book Enter key Escape key Scroll keys Menu icon, Inputs Function To display the current values and the status of a number of digital and analogue inputs. Procedure Starting from the main screen (see Main screen), Move the cursor to the Menu action key and push the Enter key. Following screen appears: Text on figure Menu Regulation...
Page 154 Instruction book Depending on the installed optional equipment less or more icons may appear. Text on figure Inputs Cooler • The inputs are categorized under a number of representative icons. Push the Enter key to show the actual inputs. • If an input reaches a warning or shutdown level, the original icon is replaced by the warning or shutdown icon, respectively.
Page 155 Instruction book • 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: • Navigate to the input screen as described above. •...
Page 156 Instruction book Removing the main chart input To remove the input as main chart, proceed as follows: • Navigate to the input screen as described above. • Push the Enter key; the first input on the screen will be highlighted in grey. •...
Page 157: Outputs Menu
Instruction book 6.15 Outputs menu Control panel Enter key Escape key Scroll keys Menu icon, Outputs Function To display information regarding the current status of the digital outputs. Procedure Starting from the Main screen (see Main screen), • Move the cursor to the Menu action button and push the Enter key. Following screen appears: 2920 1815 04...
Page 158 Instruction book Text on figure Menu 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. •...
Page 159: Event History Menu
Instruction book 6.16 Event history menu Control panel Enter key Escape key 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 Starting from the Main screen (see Main...
Page 160: Modifying Settings
Instruction book • 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. 6.17 Modifying settings Control panel Enter key...
Page 161 Instruction book • Using the Scroll keys, move the cursor to the Settings icon (see above, section menu icon). • Push the Enter key. A screen similar to the one below appears: Depending on the installed optional equipment less or more icons may appear. •...
Page 162 Instruction book 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 Network...
Page 163 Instruction book Screen for Ethernet settings • Push the Enter key once again to modify a parameter. A network parameter can only be modified when the network is disabled (Off). Regulation settings This menu allows to view and modify the regulation settings. General settings •...
Page 164 Instruction book • 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.
Page 165 Instruction book 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: •...
Page 166: Programmable Settings
Remark A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of service operations to be carried out at the programmed intervals. Consult your Atlas Copco Service Center. Other programmable settings Min.
Page 167: Web Server
If both the web server functionality and SMARTBOX are required, please contact your local Atlas Copco Customer Center for support. Make sure you are logged in as administrator. • Use the internal network card from your computer or a USB to LAN adapter.
Page 168 Instruction book • Use a UTP cable (CAT 5e) to connect to the controller (see picture below). Configuration of the network card • Go to Network and Sharing Center (1). • Click on Change adapter settings (1). • Select the Local Area Connection, which is connected to the controller. •...
Page 169 Instruction book • Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid conflicts, uncheck other properties if they are checked. After selecting TCP/IPv4, click on the Properties button (2) to change the settings. • Use the following settings: •...
Page 170 Instruction book • Subnet mask = 255.255.254.0 • Connect your Elektronikon Mk5 to the company's network (LAN) by using a UTP cable (min. CAT 5e). • Adapt the network settings in the Elektronikon Mk5: • Go to Main Menu • Go to Settings (1) •...
Page 171 Instruction book • Go to Ethernet (1) • Switch Off (1) the Ethernet communication to allow editing the settings • Adapt IP Address (1) • Adapt Gateway IP (2) • Adapt Subnet Mask (3) • Switch On (4) the Ethernet communication 2920 1815 04...
Page 172 Instruction book • Wait a few minutes so the LAN network can connect to the Elektronikon Mk5 Configuration of the web server ® The internal web server is designed and tested for Microsoft Internet Explorer. Also "Opera", "Mozilla Firefox", "Safari"and "Chrome" should work. Viewing the controller data All screen shots are indicative.
Page 173 Instruction book Screen shot (example!) Navigation and options • The banner shows the unit type and the language selector. In this example, three languages are available on the controller. • On the left side of the interface, you can find the navigation menu. If a license for ESi is foreseen, the menu contains 3 buttons.
Page 174 Instruction book Unit settings All unit settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed. Only the machine status is fixed and can not be removed from the main screen. Analog inputs Lists all current analog input values.
Page 175 Instruction book Digital outputs Lists all digital outputs and their status. Special protections Lists all special protections of the unit. Service plan Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours.
Page 176: Installation
Instruction book Installation Dimension drawing Dimensions Dimension drawing of ZR 110 up to ZR 145 2920 1815 04...
Page 177 Instruction book Dimension drawing of ZR 110 up to ZR 145 Full-Feature, page 1 2920 1815 04...
Page 178 Instruction book Dimension drawing of ZR 110 up to ZR 145 Full-Feature, page 2 2920 1815 04...
Page 179 Instruction book Dimension drawing of ZT 110 up to ZT 145, page 1 2920 1815 04...
Page 180 Instruction book Dimension drawing of ZT 110 up to ZT 145, page 2 Reference Name Right side view Front view Motor cooling air outlet Motor cooling + compressor air inlet Hot air version Voltage supply entrance 2920 1815 04...
Page 181 Instruction book Reference Name Center of gravity Left side view of energy recovery version Left side view Cooling water out Compressed air outlet Cooling water inlet ANSI flanges, optional M8 for ducting on roofs; for position, see top view Automatic drain, aftercooler Automatic drain, intercooler Rear side view Top view...
Page 182 Instruction book Reference Name Energy recovery circuit, cooling water in Energy recovery circuit, cooling water out Automatic drain, dryer inlet Detail X Detail Y Cooling water From FD dryer: Tropicalized integrated dryer, see detail To FD dryer: Tropicalized integrated dryer, see detail Service cover for regeneration cooler of dryer Full-Feature with energy recovery.
Page 183 Instruction book Dimension drawing of ZR 160 up to ZR 275 Pack and ZR 250/315 VSD Pack compressors (in metric units) 2920 1815 04...
Page 184 Instruction book Dimension drawing of ZR 160 up to ZR 275 Pack and ZR 250/315 VSD Pack compressors (in imperial units) 2920 1815 04...
Page 185 Instruction book Dimension drawing of ZT 160 up to ZT 275 Pack and ZT 250/315 VSD Pack compressors (in metric units) 2920 1815 04...
Page 186 Instruction book Dimension drawing of ZT 160 up to ZT 275 Pack and ZT 250/315 VSD Pack compressors (in imperial units) 2920 1815 04...
Page 187 Instruction book Dimension drawing of ZR 160 up to ZR 275 Full-Feature and ZR 250/315 VSD Full-Feature compressors (in metric units) 2920 1815 04...
Page 188 Instruction book Dimension drawing of ZR 160 up to ZR 275 Full-Feature and ZR 250/315 VSD Full-Feature compressors (in imperial units) 2920 1815 04...
Page 189 Instruction book Dimension drawing of ZT 160 up to ZT 275 Full-Feature and ZT 250/315 VSD Full-Feature compressors (in metric units) 2920 1815 04...
Page 190 Instruction book Dimension drawing of ZT 160 up to ZT 275 Full-Feature and ZT 250/315 VSD Full-Feature compressors (in imperial units) Reference Description Right side view Front view Motor cooling air outlet Compressed air inlet Motor cooling air inlet (only for option: separate air intake) 2920 1815 04...
Page 191 Instruction book Reference Description Motor cooling air inlet + compressor air inlet (for standard unit) Left side view (for standard compressor) Center of gravity Cooling water in Cooling water out Circuit A Compressed air outlet for standard dryer or low load dryer Compressed air outlet for option: dryer bypass Automatic drain of dryer with Low Load option G 1/2"...
Page 192: Din To Jis Adaptor Flanges
Instruction book Reference Description Net mass of a compressor without a motor 700 kg should be added in case of an oversized motor or motor with supply voltage > 690 V 1540 lb should be added in case of an oversized motor or motor with supply voltage > 690 V Cooling air outlet Automatic drain of dryer inlet G 1/2"...
Page 193 Instruction book Drawings DIN to JIS adaptor flange with inner pipe diameter ranging from 32 to 65 mm 2920 1815 04...
Page 194 Instruction book DIN to JIS adaptor flange with inner pipe diameter ranging from 80 to 125 mm 2920 1815 04...
Page 195 Instruction book Reference Name Flange of compensator Mating flange Outlet pipe Section X-X Cooling water, quantity: 2 Applicable for range O.D. = Outer Diameter Bolt hole pitch I.D. = Inner Diameter Pipe size Hole for pipe Air outlet, quantity: 1 Applicable for range To be ordered through Systems Wilrijk 2920 1815 04...
Page 196: Installation Proposal
Instruction book Installation proposal Compressor room example Installation proposal for ZR 110 up to ZR 145 and ZR 132/160 VSD 2920 1815 04...
Page 197 Instruction book Installation proposal for ZR 110 Full-Feature up to ZR 145 Full-Feature and ZR 132/160 VSD Full-Feature 2920 1815 04...
Page 198 Instruction book Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full- Feature without Energy Recovery and without dryer by-pass option (in mm) 2920 1815 04...
Page 199 Instruction book Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full- Feature without Energy Recovery and without dryer by-pass option (in inch) 2920 1815 04...
Page 200 Instruction book Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full- Feature with Energy Recovery (in mm) 2920 1815 04...
Page 201 Instruction book Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full- Feature with Energy Recovery (in inch) 2920 1815 04...
Page 202 Instruction book Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full- Feature with dryer by-pass option (in mm) 2920 1815 04...
Page 203 Instruction book Installation proposal for ZR 160 Full-Feature up to ZR 275 Full-Feature, ZR 250 VSD Full-Feature and ZR 315 VSD Full- Feature with dryer by-pass (in inch) 2920 1815 04...
Page 204 Instruction book Installation proposal for ZT 110 up to ZT 145 and ZT 132/160 VSD 2920 1815 04...
Page 205 Instruction book Installation proposal for ZT 160 up to ZT 275, ZT 250 VSD and ZT 315 VSD Minimum free area to be reserved. Ventilation proposal. Rear side view. Ventilation proposal (without option separate air intake). Ventilation proposal (with option separate air intake). Common ducting for multiple units is not allowed.
Page 206 Instruction book Reverse side view. Description The compressor must only be moved or lifted as described in the section Initial start-up. 1. Install the compressor on a level floor suitable for taking its weight. The recommended minimum distance between the top of the body and the ceiling is 1200 mm (47 in). 2.
Page 207 Instruction book Air consumption divided by compressor free air Correction factor C delivery 0.10 0.15 0.20 0.25 0.20 0.15 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:...
Page 208: Installation Requirements For Rubber Compensators
Installation requirements for rubber compensators Types and sizes Atlas Copco oil-free air products with aftercooler are equipped with rubber compensators on the air outlet and water connections. Types of misalignments The supplied compensators can cope with 2 types of minor misalignments when the customer pipe end is mounted: •...
Page 209 Instruction book Drawing reference Description Atlas Copco compressor pipe end Customer installation pipe end Angular misalignments Δα are NOT allowed! 2920 1815 04...
Page 210 Instruction book Misalignment tolerances • Single direction misalignments Axial : ΔL Axial : ΔL Lateral: ΔR Lateral: ΔR Δα ° = stretch or compression = NO angular misalignment is tolerated! • Combined direction misalignments Drawing reference Description Compression Stretch Do NOT operate outside of the black polygon. Do NOT exceed the misalignment tolerances to avoid compensator damage! The piping system of the customer should be designed to fit the misalignment tolerances both during standstill and operation.
Page 211 Instruction book Temperature correction factors Medium temperature Medium temperature Correction factor for maximum working pressure of (°C) (°F) the compensator 0.92 0.83 0.75 0.67 0.54 Torque values Compensator bolts should be torqued in 3 successive steps • Step 1: Hand-tighten each bolt. •...
Page 212 Instruction book The compensator loads (F and F ) that are mentioned on the drawing are strictly forbidden: • Weight loads F • Thrust forces F For the design of piping and supporting structures, use an approved standard code (e.g. EN 13480 or ASME 16.5/B31.3).
Page 213 Instruction book Situation Description Flat DIN flanges prevent damage of the rubber sealings. Collared flanges prevent premature wear. Add a flat sealing or if necessary a metal disc with flat seal in case of damage risk. Avoid excessive torque to prevent damage to the bended pipes or the sealings. Rubber sealings will get damaged when the inner pipe diameter exceeds the inner sealing diameter.
Page 214 Instruction book • CORRECT installation! 2920 1815 04...
Page 215: Electric Cable Size, Fuses And Cable Length
Instruction book Drawing reference Description Larger than maximum allowed installation length. Less than or equal to maximum allowed installation length Minimum 1 mm of free space Do NOT: • Paint the rubber bellows of the expansion joint since: • Solvents can damage the rubber cover. •...
Page 216 Proposed Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 4 X (3 X35+16) 2 x(3 X 200) 315 50 kA ZT/ZR 132 4 X (3 X70+35) 2 x(3 X 250) 315 50 kA ZT/ZR 145...
Page 217 Proposed Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 4 X (3 X50+25) 2 x(3 X 200) 315 50 kA ZT/ZR 132 2 X (3 X150+95) 2 x(3 X 250) 400 50 kA ZT/ZR 145...
Page 218 Proposed Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 4 X (3 X50+25) 2 x(3 X 200) 315 50 kA ZT/ZR 132 2 X (3 X120+70) 2 x(3 X 200) 400 50 kA ZT/ZR 145...
Page 219 Proposed Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 2 X (3 X70+35) 2 x(3 X 160) 315 50 kA ZT/ZR 132 2 X (3 X70+35) 2 x(3 X 160) 315 50 kA ZT/ZR 145...
Page 220 Proposed Maximum (mm²) cable fuses (A) fuse(A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 2 X (3 X35+16) 2 x(3 X 100) 315 50 kA ZT/ZR 132 2 X (3 X50+25) 2 x(3 X 125) 315 50 kA ZT/ZR 145 2 X (3 X50+25)
Page 221 Proposed Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 2 X (3 X50+25) 2 x(3 X 125) 315 50 kA ZT/ZR 132 2 X (3 X50+25) 2 x(3 X 125) 315 50 kA ZT/ZR 145...
Page 222 Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 4 X (3 X 35+16) 2 x(3 X 200) 315 50 kA ZT/ZR 145 2 X (3 X 120+70) 2 x(3 X 250) 400 50 kA ZT/ZR 160...
Page 223 Proposed Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 2 X (3 X150+95) 2 x(3 X 250) 400 50 kA ZT/ZR 145 2X (3 X150+95) 2 x(3 X 250) 400 50 kA ZT/ZR 160 4 X (3 X 95+50)
Page 224 Maximum (mm²) cable fuses (A) fuse (A) length (m) (gL/gG) (gL/gG) ZT/ZR 110 4 X (3 X 50+25) 2 x(3 X 200) 315 50 kA ZT/ZR 145 4 X (3 X 50+25) 2 x(3 X 200) 315 50 kA ZT/ZR 160...
Page 225 Maximum SCCR (mm²) cable fuses (A) fuse (A) length (m) (LPJ) (LPJ) ZT/ZR 110 2 X (3 X250MCM 2 x(3 X 175) 600 65 kA +2AWG) ZT/ZR 145 2 X (3 X250MCM 2 x(3 X 175) 600 65 kA +2AWG)
Page 226 Maximum Proposed Maximum SCCR (mm²) cable fuses (A) fuse (A) length (m) (LPJ) (LPJ) ZT/ZR 110 2 X (3 X1AWG 2 x(3 X 65 kA +6AWG) 125) ZT/ZR 145 2 X (3 X000+4AWG) 2 x(3 X 65 kA 175) ZT/ZR 160...
Page 227 Maximum SCCR (mm²) cable fuses (A) fuse (A) length (m) (LPJ) (LPJ) ZT/ZR 110 4 X (3 X3AWG 2 x(3 X 150) 600 65 kA +8AWG) ZT/ZR 145 4 X (3 X3AWG 2 x(3 X 150) 600 65 kA +8AWG)
Page 228: Electric Connection
When the compressor is equipped with a medium- or high-voltage motor, the electrical cubicle should be supplied separately with cable sections mentioned below. • ZT-ZR 110-275 (except ZT 275 FF + Low Load option): 2.5 mm • ZT 275 FF with Low Load option: 4 mm For compressors with a medium-voltage or high-voltage motor, take into account the information on the motor data plate and the ambient temperature plus 5 K to select the cable size of the drive motor supply.
Page 229 Instruction book Electric connections Electric connections for compressors with star-delta starter (Model year 2003) 2920 1815 04...
Page 230 Instruction book Electric connections for compressors with star-delta starter (Model year 2014) 2920 1815 04...
Page 231 Instruction book Electric connections for compressors without a starter (Model year 2003) 2920 1815 04...
Page 232 Instruction book Electric connections for compressors without a starter (Model year 2014) Text on figures Reference Text on figure Customer’s installation K21, K23 larger than or equal to 56 with 6 type “2” fuses K21, K23 larger than or equal to 56 with 3 type “1” fuses K21, K23 smaller than 56 with 3 type “2”...
Page 233: Quality Of Safety Components
Instruction book Reference Text on figure (16) Extra set of fuses for CSA/UL certified compressors (17) Customer's motor starter (18) Separate low voltage supply or transformer (19) For compressors with motor supply voltage > 690 V Quality of safety components When installing a remote emergency button or a motor contactor, the following B10d values are advised: •...
Page 234 Instruction book Symbol Explanation Measured pH (at room temperature) of water sample pH at saturation The pH is calculated by using : = (9.3 + A + B) - (C + D) Symbol Explanation Depends on the total solids concentration (mg/l) Depends on the highest cooling water temperature (˚C/˚F), (T=65 ˚C/149 ˚F) Depends on the calcium hardness (ppm CaCO Depends on the HCO...
Page 235 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; if not, consult your local Atlas Copco Customer Centre.
Page 236: General Pictographs
Instruction book Sulphates (SO Closed cooling system : sulphates < 400 ppm Open cooling system : sulphates < 150 ppm Carbonate hardness Closed cooling system : 50-1000 ppm CaCO Open cooling system : 50-500 ppm CaCO / SO should be > 1 Ammonia <...
Page 237: Pictographs, Elektronikon Control System
Instruction book Reference Name Condensate valve, aftercooler Warning: under tension Read Instruction manual before starting the compressor Switch off the voltage and depressurize the compressor before maintenance or repair Before connecting the compressor electrically, consult the Instruction manual for the motor rotation direction Torques for steel (Fe) or brass (CuZn) bolts Consult the Instruction manual before greasing...
Page 238 Instruction book Control panel of Elektronikon GraphicPlus Controller Reference Name Alarm Service Automatic operation Voltage on Enter Escape Scroll keys Stop Start 2920 1815 04...
Page 239: Operating Instructions
Ambient conditions / altitude opeartion Refer to Limitations for the limits of ambient conditions and altitude operation. If the compressor is operated beyond these limits, precautions must be taken. If this is the case, consult your Atlas Copco Customer Center.
Page 240 Instruction book Transport fixtures on the motor side in ZR/ZT 110 up to ZR/ZT 275 On the motor side, the dampers are secured by means of bolts/spacers. Remove the bolts and spacers (1 and Transport fixtures on the gear casing side in ZR/ZT 110 up to ZR/ZT 275 On ZR/ZT 110 up to ZR/ZT 275, a transport support (1) is fitted to the gear casing.
Page 241 Instruction book Transport fixtures on subframe of Arr. 1 Transport fixtures on subframe of Arr. 1 The subframe (2) of Arr. 1 units is secured by means of bolts/spacers (1). These must be removed. 2920 1815 04...
Page 242 Instruction book Silica gel bags Position of silica gel bags on ZR 110 up to ZR 145 Position of silica gel bags on ZT 110 up to ZT 145 2920 1815 04...
Page 243 Instruction book 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. 2920 1815 04...
Page 244 • Check that the compressor is pressureless • Tighten the nuts of tie rods (1) by hand • Tighten the check nuts Water circuit of ZR compressors Water drain plug, HP element of ZR 110 up to 275 2920 1815 04...
Page 245 Instruction book Water drain plug, LP element of ZR 110 up to 275 Water drain plugs, coolers of ZR 110 up to 275 Water drain plugs, cooler block of ZR 110 up to 275 2920 1815 04...
Page 246 Check that the cooling water drain valves (customer's installation) in the inlet and outlet lines are closed. Open the water inlet valve and outlet valve (customer's installation) and check for water flow. Check the water flow. Oil circuit Position of oil level sight-glass on ZR 110 up to ZR 275 2920 1815 04...
Page 247 Instruction book Position of oil level sight-glass on ZT 110 up to ZT 275 Check that oil is visible in sight-glass (SG). 2920 1815 04...
Page 248 Instruction book Start-up Electric cabinet of compressor with starter (Model year 2003) 2920 1815 04...
Page 249 Instruction book Electric cabinet of compressor with starter (Model year 2014) 2920 1815 04...
Page 250 Instruction book Electric cabinet of compressor without starter(Model year 2003) 2920 1815 04...
Page 251 Instruction book Electric cabinet of compressor without starter(Model year 2014) 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.
Page 252 Instruction book Top up, if necessary, with the correct type of oil. Adjustment of mix-air (for ZR/ZT 110 up to ZR/ZT 145 Full-Feature compressors) 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.
Page 253 Instruction book 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.
Page 254 Instruction book Dryer components, ZR Full-Feature Position of throttle valve on the regeneration air inlet of the dryer on ZT Full-Feature 2920 1815 04...
Page 255 Instruction book Position of dryer inlet, outlet and by-pass valves on ZT Full-Feature Step Action Close valves (1, Vd- and Vd+). 2920 1815 04...
Page 256 Instruction book Step Action On compressors equipped with a PDP sensor, close the valve to this sensor. If the compressor runs with the dryer by-passed without closing the valve to the PDP sensor, the sensor will be damaged. Close the dryer inlet and outlet valves (Vdi and Vdo) and open the dryer by-pass valve (Vdb).
Page 257 Instruction book Regulation valves for ZR Full-Feature compressors without dryer by-pass 2920 1815 04...
Page 258 Instruction book Regulation valves for ZR Full-Feature compressors with dryer by-pass 2920 1815 04...
Page 259 Instruction book Regulation valves for ZR Full-Feature compressors without dryer by-pass 2920 1815 04...
Page 260 Instruction book Regulation valves for ZR Full-Feature compressors with dryer by-pass 2920 1815 04...
Page 261 Instruction book Regulation valves for ZT Full-Feature compressors without dryer by-pass 2920 1815 04...
Page 262 Instruction book Regulation valves for ZT Full-Feature compressors with dryer by-pass 1. On Full-Feature compressors without dryer by-pass, close regulation valve (1). On Full-Feature compressors with dryer by-pass, open shut-off valve (2) and close regulation valve (1). Open the dryer inlet and outlet valves (Vdi and Vdo) and close the dryer by-pass valve (Vdb). 2.
Page 263: 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. Oil level Oil system components, ZR 110 up to ZR 275 2920 1815 04...
Page 264 Instruction book Oil system components, ZT 110 up to ZT 275 On ZR/ZT 110 up to ZR/ZT 275, the oil level must be in the middle of the sight-glass (SG) after stopping (in the case of longer standstill, the oil level may increase in the sight-glass). Top up, if necessary, with the correct type of oil.
Page 265 Instruction book Condensate drains Drain connections on ZR 110 up to ZR 145 Drain connections on ZR 160 Pack up to ZR 275 Pack 2920 1815 04...
Page 266 Instruction book Drain connections on ZR 160 Full-Feature up to ZR 275 Full-Feature 2920 1815 04...
Page 267 Instruction book Drain connections on ZT 110 up to ZT 275 Reference Description Compressed air outlet Automatic drain, aftercooler Automatic drain, dryer inlet Daea Automatic drain, extra aftercooler (for Energy Recovery option only) Automatic drain, intercooler Dall Automatic drain, optional low load dryer Dar1 Automatic drain, regeneration outlet Dar2...
Page 268: Routine Starting
Instruction book Routine starting Control panel Control panel of Elektronikon controller Procedure Step Action Open the air outlet valve (customer's installation). Switch on the voltage and check that voltage on LED (6) lights up. Press start button (1). The compressor starts running in unloaded condition and automatic operation LED (8) lights up.
Page 269 Instruction book Control panel Control panel of Elektronikon GraphicPlus controller 2920 1815 04...
Page 270 Instruction book Procedure Step Action Open the air outlet valve (customer's installation). Switch on the voltage and check that voltage on LED (8) lights up. Press start button (14). The compressor starts running in unloaded condition and automatic operation LED (7) lights up. Approx.
Page 271: Starting After Emergency Stop Or Shutdown
Instruction book See section Readings for the cooling water temperature. See section Compressor data for the cooling water consumption. The operator must apply all relevant safety precautions. If the motor is stopped and automatic operation LED (7) is alight, the motor may start automatically.
Page 272 Instruction book Control panel Control panel of Elektronikon GraphicPlus controller Procedure The operator must apply all relevant safety precautions. Step Action Press the emergency stop button (if not yet done). Switch off the voltage and then depressurize the compressor. Remedy the fault. Unlock the emergency stop button by pulling it back.
Page 273: During Operation
Instruction book 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. During operation Control panel Control panel of Elektronikon controller Procedure...
Page 274 Instruction book Control panel Control panel of Elektronikon GraphicPlus controller Procedure The operator must apply all relevant safety precautions. 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 Check the readings on display (1).
Page 275: Checking The Display
Instruction book Checking the display Control panel Control panel of Elektronikon controller 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 Regularly check the display for readings and messages.
Page 276: Manual Loading/Unloading
Instruction book 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.
Page 277 Instruction book Control panel Control panel of Elektronikon controller 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.
Page 278 Instruction book Control panel Control panel of Elektronikon GraphicPlus controller 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.
Page 279: Stopping
Instruction book Stopping Control panel Control panel of Elektronikon controller 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 Close the air outlet valve. Press stop button (9).
Page 280 • By removing the drain plugs. The following plugs (painted green) are provided: • DP7 and DP8 underneath the cooler casing (for ZR 110 up to ZR 145) • On ZR 160 up to ZR 275, drain plug (DP9) underneath the cooler casing •...
Page 281 Instruction book Water drain plugs underneath cooler casing of ZR 110 up to ZR 145 Cooler casing on ZR 160 up to ZR 275 Cooler casing on ZR 160 up to ZR 275 2920 1815 04...
Page 282 Instruction book Drain plugs on high-pressure compressor element Drain plugs on low-pressure compressor element 2920 1815 04...
Page 283: Taking Out Of Operation
Instruction book Water drain plug on oil cooler on ZR 110 up to ZR 275 Taking out of operation Procedure At the end of the service life of the compressor, proceed as follows: Step Action Close the air outlet valve and stop the compressor.
Page 284: Maintenance
Warranty-Product Liability Use only authorized parts at the correct intervals (check with your local Atlas Copco Service center). Any damage or malfunction caused by the use of unauthorized parts or unqualified personnel is not covered by Warranty or Product Liability. In the event of any extended warranty, the end user must ensure that all required maintenance actions are performed when indicated on the Elektronikon display (see table below) or, alternatively, use an Atlas Copco Service agreement.
Page 285 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 center may overrule the standard maintenance schedule; always check if in doubt.
Page 286 Instruction book Activities Level A Level B Level C Take service readings (air, oil, water temperature and pressure) Check cooler functions (approach temperature) and clean if necessary Change intercooler condensate check valve Check intercooler blowdown valve Check for air, water and oil leakage Check critical bolt/coupling connections Check operation of safety valves Check for presence of water in lube oil...
Page 287: Motor Greasing
The bearings of the fan motor are greased for life. 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:...
Page 288: Servicing Procedures
Instruction book Servicing procedures 10.1 Air filters Location of the air filters Air filter of ZR/ZT 110 up to ZR/ZT 275 Procedure The filters must be serviced regularly; consult section Preventive maintenance schedule. Never install damaged or clogged filters. Procedure for ZR/ZT 110 up to ZR/ZT 275 and ZR/ZT 132 VSD up to ZR/ZT 315 VSD Step Action Stop the compressor and press the emergency stop button.
Page 289: Oil And Oil Filter Change
Instruction book 10.2 Oil and oil filter change Oil system Oil system components, ZR 110 up to ZR 275 2920 1815 04...
Page 290 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. On ZR 110 up to ZR 275, fill the compressor sump to the middle of the oil level sight- glass (SG).
Page 291: Safety Valves
Stop the compressor. On ZR 110 up to ZR 275 and ZT 110 up to ZT 275, check that the oil level is in the middle of sight-glass (SG) after stopping (at longer standstill the level may rise in the sight-glass).
Page 292 Instruction book Cooler block (CB) of air-cooled Full-Feature compressors Coolers of water-cooled Full-Feature compressors 2920 1815 04...
Page 293 Instruction book Drawing reference Description Aftercooler AC (ER) Extra aftercooler in case of the energy recovery option Intercooler Oil cooler Regeneration cooler (only on Full-Feature compressors) Keep the coolers clean to ensure cooling efficiency. On air-cooled compressors proceed as follows: Cooler block (CB) of air-cooled Full-Feature compressors Step Action...
Page 294 Instruction book Step Action If it is required to clean the coolers with a cleaning agent, consult your Atlas Copco Customer Center. Re-install the compressor roof. 2920 1815 04...
Page 295: Problem Solving
Instruction book Problem solving 11.1 Problem solving • Before starting any maintenance or repairs, stop the compressor. • Depressurize the air system as follows: • Close the air outlet valve. • On compressors equipped with Electronic Water Drains (EWD), press the test buttons on top of the electronic water drains.
Page 296 Check water temperature and increase insufficient cooling water flow cooling water flow On ZR compressors, restriction in cooling water Consult the Atlas Copco Customer Center system due to formation of scale or dirt deposits On ZT compressors, coolers Refer to the Coolers section.
Page 297 Do not operate the dryer at a pressure Operating pressure too low lower than the one specified in Compressor data Dryer rotor/motor does not Consult Atlas Copco Customer Center turn Rotor compartment sealing ring, sealing sectors and rotor Consult Atlas Copco Customer Center...
Page 298 • OK: Check all connections of the rotation sensor following the electrical diagram. Consult your Atlas Copco Customer Center. • NOK: Switch off the voltage and reverse two of the input line connections. Consult your Atlas Copco Customer Center.
Page 299 Action Check that the circuit breaker in the dryer control box is switched on. Check that the gear motor cable is correctly connected to the terminals of the dryer control box Consult your Atlas Copco Customer Center. 2920 1815 04...
Page 300: Technical Data
The readings below are indicative values when operating at reference conditions. Check the section Reference conditions. These values are no rejection limits. In case of doubt, consult your Atlas Copco Customer Center. For the maximum working pressure and the outlet pressure, consult the section Compressor data. Pressure readings Item...
Page 301: Settings Of Safety Valves
High-pressure safety valve(s) for 13 bar (190 psi) compressors 13.7 bar(e) 200 psig 12.3 Settings for overload relay 50 Hz compressors ZT/ZR 110 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor Supply voltage Recommended overload setting F21 128.8 122.2...
Page 302 Instruction book ZT/ZR 110 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZT/ZR 110 compressors with oversized IE2 motor Supply voltage Recommended overload setting F21 153.8 146.1 116.9 83.7...
Page 303 Instruction book Supply voltage Recommended overload setting F21 166.0 159.3 127.5 92.3 ZT/ZR 132 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZT/ZR 132 compressors with oversized IE2 motor Supply voltage Recommended overload setting F21 169.3...
Page 304 Instruction book Supply voltage Recommended overload setting F21 ZT/ZR 145 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE2 motor Supply voltage Recommended overload setting F21 166.0 159.3 127.5 92.3 ZT/ZR 145 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZR/ZT 160 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor...
Page 305 Instruction book Supply voltage Recommended overload setting F21 ZR/ZT 160 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE3 motor or equipped with oversized IE3 motor Supply voltage Recommended overload setting F21 ZR/ZT 200 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor Supply voltage Recommended overload setting F21 ZR/ZT 200 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor...
Page 306 Instruction book Supply voltage Recommended overload setting F21 ZR/ZT 250 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor Supply voltage Recommended overload setting F21 ZR/ZT 250 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZR/ZT 250 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE2 motor...
Page 307 ZR/ZT 275 8.6 up to 13 bar (125 up to 190 psi) designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor Supply voltage Recommended overload setting F21 60 Hz compressors ZT/ZR 110 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor 2920 1815 04...
Page 308 120.6 110.2 88.0 ZT/ZR 110 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZT/ZR 110 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE2 motor...
Page 309 Instruction book Supply voltage Recommended overload setting F21 ZT/ZR 145 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor Supply voltage Recommended overload setting F21 180.1 155.9 149.6 119.9 ZT/ZR 145 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZT/ZR 145 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE2 motor...
Page 310 Instruction book Supply voltage Recommended overload setting F21 ZR/ZT 160 compressors designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor Supply voltage Recommended overload setting F21 ZR/ZT 160 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE2 motor or equipped with oversized IE2 motor Supply voltage Recommended overload setting F21...
Page 311 Instruction book Supply voltage Recommended overload setting F21 ZR/ZT 200 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE2 motor or equipped with oversized IE2 motor Supply voltage Recommended overload setting F21 ZR/ZT 200 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE3 motor or equipped with oversized IE3 motor Supply voltage Recommended overload setting F21...
Page 312: Reference Conditions
Instruction book Supply voltage Recommended overload setting F21 ZR/ZT 250 compressors designed for a maximum inlet temperature of 50 ˚C/122 ˚F with IE3 motor or equipped with oversized IE3 motor Supply voltage Recommended overload setting F21 ZR/ZT 275 designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE2 motor Supply voltage Recommended overload setting F21 ZR/ZT 275 designed for a maximum inlet temperature of 40 ˚C/104 ˚F with IE3 motor...
Page 313: Limitations
Instruction book Air inlet temperature 20 °C 68 °F Effective working pressure 9 bar(g) for 10/10.4 bar compressors 131 psi(g) for 145/151 psi compressors 7 bar(g) for 7/7.5/8.6 bar compressors 102 psi(g) for 102/109/125 psi compressors 12 bar(g) for 13 bar compressors 174 psi(g) for 188 psi compressors Temperature of cooling medium (water or air) inlet 20 °C...
Page 314 Instruction book Maximum temperature of cooling water inlet - open 40 °C circuit 104 °F Maximum temperature of cooling water outlet 50 °C 122 °F Maximum temperature of cooling water outlet of 90 °C compressors with Energy Recovery- closed circuit 194 °F Maximum rise of cooling water temperature (for up to 35 °C...
Page 315: Compressor Data
Instruction book Item Reading in bar(g) Reading in psi(g) Pressure drop over air filter Below 0.044 Below 0.64 Intercooler pressure (loaded condition) 1.7-3 24.6-43.5 Intercooler pressure (unloaded condition) (-0.65)-(-0.70) (-9.43)-(-10.15) Oil pressure (depends on climatic conditions) 1.2-4.5 17.4-65.3 12.6 Compressor data ZR compressors Temperature Reading...
Page 316 Air outlet for Hot Air variants Outlet of high pressure stage Oil quantity in the lubrication system of the compressor Compressor type cu.ft Imp gal US gal ZR 110, ZR 132, ZR 145 1.02 6.38 7.66 ZT 110, ZT 132, ZT 145 1.94 12.10 14.53...
Page 317: Dryer Data
Instruction book 12.7 Dryer data Temperature Reading Dryer inlet for ZR compressors Approx. 5 °C (9 °F) above inlet temperature of cooling water Dryer inlet for ZT 110-145, ZT 132/160 VSD compressors Approx. 7 °C (12.6 °F) above ambient temperature Dryer inlet for ZT 160-275, ZT 250/315 VSD compressors Approx.
Page 318: Pressure Equipment Directives
PED instructions ZR 110 Pack up to ZR 145 Pack compressors are a pressure assembly of cat. I according to 97/23/EC. ZR 160 Pack up to ZR 275 Pack compressors are a pressure assembly of cat. II according to 97/23/EC.
Page 319 Instruction book Vessel for MD dryers on ZR/ZT 110 up to ZR/ZT 145 Instruction for use (vessel) Reference Name Cover Bottom Bolt Washer Housing • This vessel can contain pressurized air; please be aware of its potential danger in case of misuse. •...
Page 320 Instruction book Part number V in liter MWT in mm CA in mm H in (US gal/Imp gal/ cu.ft) Water-cooled: Cover: Cover: 1.0 1023 528 Cover: 0.8 1617 5966 99 (52.57/443.77/7.0 • Torispherical part: Housing: 1.0 Housing: 0.8 Air-cooled: 13.0 Bottom: 1.0 Bottom: 0.8 1617 5968 99...
Page 321 Instruction book Reference Name Cover Bottom Bolt Washer • This vessel can contain pressurized air; please be aware of its potential danger in case of misuse. • This vessel shall only be used as an air dryer to a compressor and operated within the specified limits as given on the data plate.
Page 322 Instruction book Part number V in liter MWT in mm CA in D in (US gal/Imp gal/ cu.ft) 1627 2472 99 270 Cover: Cover: 898 713 Cover: 0.8 (71.33/59.40/9.53) • Cylindrical part: Bottom: 0.8 10.0 Bottom: • Torispherical part: 13.5 Bottom: •...
Page 323 Instruction book Heat exchanger ZR 160-275 PED Category CAT II Design code ASME BPVC Section VIII, div 1 Material SA-395 Bolts Interval of periodic 5 years or the frequency as given in national legislation inspection by 3rd party (1) Intercooler Aftercooler Casting factor Minimum wall...
Page 324: Documentation
Instruction book Documentation Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: (2): Applicable directives (3): Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this device.
Page 325 Instruction book Declaration of incorporation Typical example of a Declaration of Incorporation document (1): Contact address: (2): Applicable directives (3): Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this device.
Page 328 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.

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