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ZR 55, ZR 75, ZR 90, ZT 55, ZT 75, ZT 90
Instruction book
Atlas Copco
ZR 55, ZR 75, ZR 90, ZT 55, ZT 75, ZT 90
Instruction book
Original instructions
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2014 - 12
No. 2920 1849 00
www.atlascopco.com
Instruction book
Table of contents
1
Safety precautions..........................................................................................................5
1.1
SAFETY ICONS................................................................................................................................... 5
1.2
GENERAL SAFETY PRECAUTIONS............................................................................................................5
1.3
SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 6
1.4
SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7
1.5
SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8
General description...................................................................................................... 10
2.1
INTRODUCTION.................................................................................................................................10
2.2
AIR FLOW....................................................................................................................................... 23
2.3
ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................29
2.4
OIL SYSTEM.................................................................................................................................... 31
2.5
COOLING SYSTEM.............................................................................................................................31
2.6
ENERGY RECOVERY.......................................................................................................................... 31
2.7
LOW LOAD COMPENSATOR..................................................................................................................34
2.8
ELECTRICAL SYSTEM.........................................................................................................................35
2.9
SMARTBOX AND SMARTLINK.................................................................................................... 37
Elektronikon Graphic controller..................................................................................41
3.1
CONTROL PANEL.............................................................................................................................. 41
3.2
DIGITAL OUTPUT CONTACTS................................................................................................................42
3.3
ICONS USED.................................................................................................................................... 43
3.4
MAIN SCREEN..................................................................................................................................47
3.5
CONTROLLER MENU STRUCTURE..........................................................................................................51
3.6
WEB SERVER.................................................................................................................................. 54
Installation.....................................................................................................................62
4.1
DIMENSION DRAWINGS.......................................................................................................................62
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4.2
INSTALLATION PROPOSALS..................................................................................................................75
4.3
INSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS.....................................................................84
4.4
ELECTRIC CABLES............................................................................................................................ 91
4.5
ELECTRIC CONNECTIONS....................................................................................................................94
4.6
QUALITY OF SAFETY COMPONENTS.......................................................................................................96
4.7
COOLING WATER REQUIREMENTS.........................................................................................................97
4.8
PICTOGRAPHS............................................................................................................................... 100
Operating instructions............................................................................................... 103
5.1
OPERATION INTRODUCTION...............................................................................................................103
5.2
INITIAL START-UP............................................................................................................................103
5.3
BEFORE STARTING..........................................................................................................................115
5.4
ROUTINE STARTING.........................................................................................................................117
5.5
DURING OPERATION........................................................................................................................ 118
5.6
STOPPING.....................................................................................................................................119
5.7
TAKING OUT OF OPERATION..............................................................................................................122
Maintenance................................................................................................................ 123
6.1
MAINTENANCE WARNINGS................................................................................................................ 123
6.2
PREVENTIVE MAINTENANCE SCHEDULE................................................................................................123
6.3
SERVICE KITS................................................................................................................................ 124
6.4
SERVICE AGREEMENTS.................................................................................................................... 124
6.5
SERVICE PLAN............................................................................................................................... 124
6.6
MOTOR GREASING.......................................................................................................................... 124
6.7
OIL SPECIFICATIONS........................................................................................................................126
6.8
STORAGE AFTER INSTALLATION......................................................................................................... 126
Servicing procedures................................................................................................. 127
7.1
AIR FILTER (AF)............................................................................................................................ 127
7.2
OIL AND OIL FILTER CHANGE.............................................................................................................127
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7.3
SAFETY VALVES............................................................................................................................. 129
Problem solving..........................................................................................................130
8.1
FAULTS AND REMEDIES....................................................................................................................130
Principal data.............................................................................................................. 132
9.1
READINGS ON DISPLAY.................................................................................................................... 132
9.2
SETTINGS OF SAFETY VALVES........................................................................................................... 133
9.3
CIRCUIT BREAKERS AND FUSES......................................................................................................... 133
9.4
REFERENCE CONDITIONS................................................................................................................. 138
9.5
LIMITATIONS.................................................................................................................................. 138
9.6
COMPRESSOR DATA........................................................................................................................138
10
Pressure equipment directives................................................................................. 139
11
Documentation............................................................................................................140
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Safety precautions
1.1
Safety icons
Explanation
Danger for life
Warning
Important note
1.2
General safety precautions

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

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

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

manufacturer.
Precautions during operation

1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g.
to carry out routine checks. Wear ear protectors when opening a door.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
All guards are in place and securely fastened
All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
No leaks occur
All fasteners are tight
All electrical leads are secure and in good order
Safety valves and other pressure relief devices are not obstructed by dirt or paint
Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
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Air cooling filters of the electrical cabinet are not clogged

9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom,
take precautions against air pollution and possible contamination of the breathing air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
1.5
Safety precautions during maintenance or repair

manufacturer.
Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or
injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or
disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
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12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. Only if applicable, the following safety precautions are stressed when handling refrigerant:
Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
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General description
2.1
Introduction
Description
This unit is a two-stage screw compressor driven by an electric motor. The compressor delivers oil-free,
pulsation-free air.
ZR compressors are water-cooled.
ZT compressors are air-cooled.
Full-Feature compressors are aditionally provided with an air dryer which removes moisture from the
compressed air. The dryer is integrated in the bodywork of the compressor.
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Views of ZR
General view of ZR 55 up to ZR 90 Pack, ZR 55 up to ZR 90 Full-Feature
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Inside view of ZR 55 up to ZR 90 Pack, ZR 55 up to ZR 90 Full-Feature
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Front view of ZR 55 up to ZR 90 Pack
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Rear view of ZR 55 up to ZR 90 Pack
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Views of ZT
General view of ZT 55 up to ZT 90 Pack
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General view of ZT 55 up to ZT 90 Full-Feature
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Front inside view of ZT 55 up to ZT 90 Pack
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Rear inside view of ZT 55 up to ZT 90 Pack
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General view
Energy recovery, Full-Feature
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Energy recovery, Pack
Main components
20
Ref
Name
AF
Air filter
AO
Air outlet
AS
Silencer
BV
By-pass valve, oil cooler
Ca1
Pre-aftercooler
Ca
Ca2
Aftercooler
Ci
Intercooler
Co
Oil cooler
Dmo
Oil drain valve, gear casing
Eh
High-pressure compressor element
El
Low-pressure compressor element
ER
Energy recovery system
ERwi
Water inlet, energy recovery system
ERwo
Water outlet, energy recovery system
EWDa
Electronic water drain, aftercooler
EWDi
Electronic water drain, intercooler
E1
Elektronikon regulator
FC
Oil filler cap
FN
Cooling fan
IMD/IND
Integrated dryer
M1
Drive motor
M25
Fan motor
MTa
Moisture trap, aftercooler
MTi
Moisture trap, intercooler
OF
Oil filter
S2
Emergency stop button
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Ref
Name
SG
Oil level sight-glass
SVd
Safety valve, dryer
SVh
High-pressure safety valve
SVl
Low-pressure safety valve
TV
Load/no-load valve
US
Silencer
WI
Cooling water inlet
WO
Cooling water outlet
Y1
Loading solenoid valve
Optional equipment
Following equipment is available as an option:
Full-Feature
The compressor is additionally provided with an IMD adsoption dryer. The dryer is integrated in the
bodywork and removes moisture from the compressed air.
Connections
This compressor can be provided on the compressed air outlet and water pipes with:
ANSI flanges
DIN flanges
Motor temperature protection
PT1000s are embedded in the windings and/or bearings of the drive motor to warn the operator if the
temperature becomes too high and to shut down the compressor, thereby protecting the motor from
overheating.
Teflon-free compressor elements
The rotors of the compressor elements have an epoxy-based coating.
Automatic water shut-off
A water shut-off valve is provided in the cooling water system to shut off the system when the compressor
is not in operation.
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.
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SPM monitoring
A number of vibration sensors are provided on the drive motor and compressor elements. The readings can
be called up on the display of the Elektronikon regulator.
High ambient temperature (HAT)
The compressor is specially designed for continuous operation under humid and high ambient temperature
conditions. The maximum ambient temperature is 50C (122F).
Anchor pads
Steel plates, fitting in the forklift slots, and bolts are shipped loose with the compressor. With these plates
and bolts, the compressor frame can be fixed to the floor.
Anti-condensation heaters
Electric heaters are installed in the motor windings and connected to the compressor cubicle. When the
compressor is stopped, the heaters are automatically switched on. The heaters in the motor will prevent
condensation during stand-still.
PDP sensor
The pressure dewpoint of the compressed air leaving the IMD dryer is continuously shown on the display
of the Elektronikon regulator. This allows to monitor the performance of the dryer and to make sure that
the compressed air is dry enough for the application.
Low load compensator
The low load installation allows the dryer to be operated in low load conditions of the compressor. At these
conditions (compressor in unload) the pressure dewpoint is maintained by purging a small amount of
heated, dryed air through the rotor of the dryer.
The low load compensator is needed when the load cycle of the compressor is below 40 %.
Full-Feature ND
The Z Full-Feature ND compressor has an integrated heat of compression rotary drum dryer. The
regeneration air passes over a heater. The heater maintains a preset regeneration temperature to have a
guaranteed dew point at stated conditions. A thermostatic control puts on the heater and shuts it off
automatically based on the regeneration temperature requirements.
Smartbox
When ordering the compressor, it is possible (except for Japan and Korea) to choose the free SMARTBOX
option which is mounted in the electrical cabinet. The SMARTBOX allows read-out of the compressor
parameters on a login-protected web site called SMARTLINK. The connected antenna is mounted on the
outside of the electrical cabinet. Refer to the Smartbox and Smartlink section.
Kit for purge air during stand-still
When frequent and long standstills occur, it is recommended to install a kit for purge of dry air to guarantee
the life time of the oil-free screw elements. During standstill, condensation (which triggers corrosion)
might occur. This results in an expected element lifetime reduction or even a compressor stage blocking
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during standstill. Condensation is prevented by blowing a small amount of dry air through the small gap
between rotor-rotor and rotor-housing once the compressor is stopped. To avoid long standstills, regular
starting can be programmed in the Elektronikon controller or by a central Atlas Copco ES controller.
2.2
Air flow
Air Flow
Flow diagram, ZT 55-90 Pack
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Flow diagram, ZT 55-90 Full-Feature
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Flow diagram, ZR 55-90 Pack
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Flow diagram, ZR 55-90 Full-Feature with Energy recovery
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Flow diagram, ZR 55-90 Full-Feature
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Flow diagram, ZR 55-90 Full-Feature with Energy recovery
28
Ref
Name
(1)
Air inlet
(2)
Air outlet
(3)
Air to gearbox breathing system from air outlet
(4)
From transducer sensors
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Air flow
Air drawn through filter (100) is compressed in low-pressure compressor element (104) and discharged to
intercooler (108). The cooled air is further compressed in high-pressure compressor element (111) and
discharged through silencer (112) and aftercoolers (116). A check valve (115) is provided downstream of
the silencer (112).
The wet air from the aftercooler (116) enters water separator (117) via the nozzle of ejector (211). In
demister (212), the water droplets are removed from the air. The air is then led through rotor, which
adsorbs the water vapor.
The compressed air leaves the compressor via the air outlet (2).
Regenerating circuit of the dryer
Hot regeneration air is branched off from the aftercooler (116). The regeneration air passes through shutoff valve (115), throttle valve (223) and strainer, and is blown through the wet rotor channels.
The hot saturated air is then cooled down in the regeneration air cooler. The regeneration air is then mixed
with the wet compressed air from the compressor aftercooler (116).
2.3
Elektronikon regulated drain (ERD)
Description
The drain consists of a capacitive sensor which is incorporated in the drain collector and of a pilot valve
which is placed outside the drain collector. A drain opening delay timer is started when the collector is
filled up to the level of the capacitive sensor. As long as the delay timer is running, extra condensate will
be collected and the level will rise even higher than the position of the sensor. As soon as the delay timer
has expired, the pilot valve (normally open) is deactivated and the diaphragm opens the outlet, discharging
the condensate. From the moment that the sensor is not detecting any condensate anymore, a drain closing
delay timer is started. The pilot valve will still drain the condensate during the run of this timer to make
sure that the remaining amount of condensate is drained. The pilot valve is activated when the timer has
expired, the outlet closes quickly without wasting compressed air.
for ZR compressors
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for ZT compressors
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.
The level switch is a capacitive sensor which generates a high signal when no water is present. The
solenoid valves of the intercooler and aftercooler/integrated dryer drains are different. The solenoid valve
of the intercooler drain has a high flow but cannot handle high pressures. The solenoid valve on the
aftercooler/integrated dryer drains has less flow but can handle higher pressures. It is not allowed to open
the valves as they can loose their set point. Special attention must be paid to the correct wiring of the
different level switches and solenoid valves.
The output of the level switch can be called up on the screen of the Elektronikon regulator. The reading
does not indicate whether the solenoid valve is open or closed, but indicates whether the level switch is
detecting water in the collector. Since there is a drain opening delay timer, the display on the Elektronikon
can show "Condensate Drain IC Open", while the solenoid valve is still closed. Changes to the
Elektronikon settings are not allowed. The "Always pressurized" bit must be activated on aftercooler and
integrated dryer drains. On the intercooler it is not allowed to activate this bit.
A functionality test is possible through the Elektronikon regulator. By performing this test, all solenoid
valves will be opened for a short time (e.g. 15 seconds). Refer to the Elektronikon chapter for more details.
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2.4
Oil system
Refer to the topic Air flow for flow diagrams.
On ZR compressors, oil is circulated by pump (131) from the sump (130) of the gear casing to cooler
(132). From there, the oil flows through filter (133) towards the bearings and timing gears.
On ZT compressors, oil is circulated by pump (131) from the sump (130) of the gear casing to cooler (132).
Then, the oil flows through the cooling jackets of compressor elements (104 and 111). From there, the oil
flows through filter (133) towards the bearings and timing gears.
2.5
Cooling system
Cooling system, ZR compressors

Refer to the topic Air flow for flow diagrams.
The cooling system has two circuits:
One for the oil cooler (132) and the cooling jackets of both compressor elements (104).
One for intercooler (108) and aftercooler (116).
Full-Feature compressors have an extra cooling circuit for the regeneration cooler of the integrated dryer.
Cooling system, ZT compressors
The compressors are provided with an air-cooled oil cooler (132), intercooler (108), pre-aftercooler (116b)
and aftercooler (116). An electric motor-driven fan (150) generates the cooling air.
Full-Feature compressors have an additional regeneration air cooler; the cooling air for this cooler is
generated by an extra fan (153a).
2.6
Energy recovery
General
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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. 90, as part of the heat in the compressed air is used for regeneration in the
drying process.
A complete energy recovery system includes:
Compressor with modified cooling system (ZR)
A pump unit (PU) to transfer the recovered energy from the compressor cooling system to the heat
consumer (HC)
The heat consumer (HC), i.e. the equipment to transfer the energy to the industrial process
Modified cooling water system
The compressor cooling system has been modified to achieve both high cooling water temperatures and
sufficient cooling for the compressor.
The cooling water enters the oil cooler and then flows through the high-pressure compressor element, the
low-pressure compressor element and finally the intercooler and the aftercooler. This sequence ensures
optimal temperature differences with relation to the heat transfer in the individual components.
On Full-Feature compressors, additional connections are provided for the water circuit of the additional
aftercooler and the cooler of the IMD dryer. To ensure that the IMD dryer works properly, low-temperature
cooling water should be used for this cooling water circuit. The heat of this cooling water circuit is not
recovered by the energy recovery system.
Pump unit
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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. The other is a stand-by pump. Check valves
(CV1/2) at the delivery side of the pumps prevent backflow of water in the stand-by pump. The pump unit
is fitted with a make-up water connection, an air trap with automatic de-aeration device (AT), a pressure
and temperature gauge (PI and TI), a safety valve (SV) and an expansion tank (ET).
Cooling water requirements
Closed recirculating water systems minimize make-up water requirements. Therefore, it is economically
feasible to use softened water to eliminate the problem of scaling deposits.
Corrosion control is important. The best results are obtained by adding corrosion inhibitors as used in
engine cooling systems.
Using anti-freeze products is an alternative solution to avoid problems, e.g. adding 20 % to 30 % ethyleneglycol based anti-freeze to the tap water.
For open cooling water systems (e.g. boiler feed water preparation), consult the Atlas Copco Customer
Centre to avoid problems related to deposit control, corrosion control and microbiological growth control.
Water flow regulation through heat exchangers
Depending on the amount of energy transferred in the heat consumer (HC), the heat exchanger (HE) of the
pump unit is completely or partly by-passed by means of a thermostatic valve (RV2). The valve is normally
adjusted to achieve a cooling water temperature of 40 C (corresponding to the maximum allowable
temperature at the compressor inlet). It is advisable to adjust the setting of the valve as close as possible to
the temperature of the cooling water returning from the heat consumer (HC).
Depending on the amount of energy transferred in the heat consumer (HC), the heat exchanger (HE) of the
pump unit is completely or partly by-passed by means of a thermostatic valve (RV2). The valve is normally
adjusted to achieve a cooling water temperature of 104 F (corresponding to the maximum allowable
temperature at the compressor inlet). It is advisable to adjust the setting of the valve as close as possible to
the temperature of the cooling water returning from the heat consumer (HC).
Sufficient low-temperature cooling water must be available for the heat exchanger to achieve a water
temperature that does not exceed 40 C/104 F.
Electrical system
The pumps (WP1 and WP2) are driven by an electric motor. Each motor is equipped with manual starting
equipment including a circuit breaker.
The first time it is started, check that the rotation direction matches the direction indicated by the arrows on
the motor flanges. If necessary, stop the unit, switch off the voltage and reverse two incoming electric
lines.
Important remarks
Compressed air quality and reliability of any compressor, dryer or other equipment should never be made
subordinate to the energy recovery system. In some cases, especially installations where air dryers are
installed, an additional aftercooler is required to reduce the compressor air outlet temperature to a level at
which the dryers operate at maximum efficiency. This aftercooler and the dryer (if water-cooled) need to
be cooled separately by low-temperature water. Consult the Atlas Copco Customer Centre.
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The general temperature level of compressors with a modified cooling system for energy recovery is
approx. 20 to 25 C (68 to 77 F) higher than the level of compressors with a standard cooling system,
resulting in a slight decrease in free air delivery and a slight increase in shaft power.
In case the compressors operate in high ambient temperatures and with high water inlet temperatures, the
maximum working pressure is 0.5 bar (7.25 psi) lower than for standard compressors. Consult the Atlas
Copco Customer Centre.
Settings - limitations
2.7
Item
Setting
Maximum cooling water temperature at compressor

outlet
90 C (85 C if MD dryer is fitted)

194 F (185 F if MD dryer is fitted)
Maximum cooling water temperature at compressor

inlet
40 C
104 F
Safety valve opening pressure
2.5 bar(e)
36.3 psig
Low load compensator
Description
34
Reference
Name
Low load during unload cycle
Heater
Air net
Rotor
Motor
Cooler
Solenoid valve
Silencer
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Reference
Name
Air outlet (compressor)
10
Mechanical link
11
Drain
12
Water
13
No air flow
14
Air flow
15
Flow direction
16
Regeneration air (compressor)
Using the low load installation will allow the dryer to operate in low load conditions of the compressor. At
these conditions (compressor in unload) the PDP is maintained by purging a small amount of heated, dryed
air through the rotor (4).
This is needed when the load cycle is below 40 % (consult your Atlas Copco Customer Centre).
2.8
Electrical system
Main components
The electrical system mainly includes:
Elektronikon regulator
Emergency stop button (S2)
Electric cabinet
Drive motor (M1)
Pressure and temperature sensors
Elektronikon regulator (1) and emergency stop button (S2)
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Electric cabinet
36
Components
Description
F21
Overload relay of main motor
K21
Main contactor
K22
Star contactor
K23
Delta contactor
Q25
Circuit breaker of fan motor
K25
Contactor of fan motor
Q41
Circuit breaker of fan motor of dryer
K41
Contactor of fan motor of dryer
Q32
Circuit breaker of low load heater
K32
Contactor of low load heater
T1
Control transformer
F1, F2
Fuses of control transformer
F25
Fuse of fan motor
F32
Fuse of low load heater
F41
Fuse of fan motor of dryer
K13
Relay running
1X0
Power distribution
1X8
Ring type terminals
S2
Terminal strip
F40
Fuse of dryer motor
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Drive motor (M1)
Drive motor (M1)
2.9
SMARTBOX and SMARTLINK
General
The machine comes with a SMARTBOX mounted in the electrical cabinet.
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The SMARTBOX allows read-out of a number of parameters of the machine on a user login-protected web
site called SMARTLINK. The connected antenna is mounted on the outside of the machine.
Safety precautions
It is important to follow all regulations regarding the use of radio equipment, in particular regarding the
possibility of radio frequency (RF) interference. Please follow the safety advice given below carefully.
Respect restrictions on the use of radio equipment in fuel depots, chemical plants or other explosive
environments.
Avoid SMARTBOX operation close to inadequately protected personal medical devices such as
hearing aids and pacemakers. Consult the manufacturers of the medical device to determine if it is
adequately protected.
Avoid SMARTBOX operation close to other electronic equipment which may also cause interference
if the equipment is inadequately protected. Observe any warning signs and manufacturer
recommendations.
Respect a distance from the human body of at least 20 cm (8 inch) during SMARTBOX operation.
Do not operate the SMARTBOX in areas where cellular modems are not advised without proper
device certifications. These areas include environments where cellular radio can interfere, such as
explosive atmospheres, medical equipment, or any other equipment which may be susceptible to any
form of radio interference. The modem can transmit signals that could interfere with this equipment.
SMARTLINK
The machine is SMARTLINK-ready.
SMARTLINK is Atlas Copcos web-based platform to monitor compressed air installations. It is available
in 3 product levels:
SMARTLINK Service
SMARTLINK Service rules out all uncertainties. Scheduling maintenance visits becomes as simple
and easy as it should be; the service log book is always just one click away and the online link with
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.
SMARTLINK Uptime
SMARTLINK Uptime keeps your compressors up and running. By e-mail and/or text, you receive all
relevant machine indications (warnings and shutdowns) in advance. Based on this information, you
can then take all necessary actions and measures to avoid the risk of a breakdown.
This product level is available as a free of charge 3-month trial.
SMARTLINK Energy
SMARTLINK Energy safeguards the performance of your equipment. It enables you to continuously
monitor and analyze the energy efficiency of the compressor room. You decide which performance
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indicators, benchmarks and reports are created. You can make accurate and immediate improvements
when needed. The results can be used for energy monitoring according to ISO50001.
This product level is available as a free of charge 3-month trial.
Once a SMARTLINK level is chosen, gaining access is the next step. To gain access at least one machine
SMARTLINK-ready component (compressor, dryer, ...) is required. Follow the next steps:
Gather the information about the SMARTLINK-ready machine(s) (e.g. picture of the data plate;
invoice,)
Go to the SMARTLINK web site http://www.atlascopco.com/smartlink
Click on the left button in the screen below.
Use the data of the SMARTLINKready machine to register as a user.
You will receive an e-mail with login credentials.
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Go to the SMARTLINK web site http://www.atlascopco.com/smartlink, log in with the user

credentials.
Enjoy SMARTLINK!
In case more SMARTLINK-ready machines are available, you can add these via My Profile.
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Elektronikon Graphic controller
3.1
Control panel
Elektronikon Graphic Controller
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.
Pictogram
Service
Service LED
Lights up when service is needed.
Automatic operation LED
Indicates that the controller runs in automatic mode.
Voltage on LED
Lights up when supply is switched on. Compressor

unit might start automatically!
Pictogram
Voltage on
10
Enter key
Enter and confirmation key
11
Escape key
To navigate to previous screen or to cancel current

action
12
Scroll keys
Keys to scroll through the menu
13
Stop button
Button to stop the compressor. LED (7) dims.
14
Start button
Button to start the compressor. LED (7) lights up,

indicating that the Elektronikon controller is
operational.
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3.2
Digital output contacts
Warning
Voltage-free outputs may only be used to control or monitor functional systems. They
should NOT be used to control, switch or interrupt safety related circuits.
Stop the compressor and switch off the supply before connecting external equipment. Check
the Safety precautions.
Connections for external equipment

The Elektronikon (Mk5) always comes with expansion module IO2 that has a number of digital output
contacts which can be used to connect external equipment.
Depending on the optional equipment, extra expansion modules are added to the machine configuration
(IO2, IO34).
Expansion Module IO2 for Elektronikon (Mk5)
The digital output contacts have following specifications:
42
Relay
Connector
Maximum load
K01
3 X 31
15 A / 250 V AC
15 A / 30 V DC
RC* protected
K02
3 X 31
15 A / 250 V AC
15 A / 30 V DC
RC* protected
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Relay
Connector
Maximum load
K03
3 X 31
15 A / 250 V AC
15 A / 30 V DC
RC* protected
K04
3 X 31
10 A / 250 V AC
10 A / 30 V DC
resistive load
K05
3 X 30
10 A / 250 V AC
10 A / 30 V DC
resistive load
K06
3 X 30
10 A / 250 V AC
10 A / 30 V DC
resistive load
K07
3 X 30
10 A / 250 V AC
10 A / 30 V DC
resistive load
K08
3 X 30
10 A / 250 V AC
10 A / 30 V DC
resistive load
K09
3 X 30
10 A / 250 V AC
10 A / 30 V DC
resistive load
K10
3 X 32
10 A / 250 V AC
10 A / 30 V DC
resistive load
K11
3 X 32
10 A / 250 V AC
10 A / 30 V DC
resistive load
K12
3 X 32
10 A / 250 V AC
10 A / 30 V DC
resistive load
K13
3 X 32
10 A / 250 V AC
10 A / 30 V DC
resistive load
K14
3 X 32
10 A / 250 V AC
10 A / 30 V DC
resistive load
K15
3 X 32
10 A / 250 V AC
10 A / 30 V DC
resistive load
* = Resistor Capacitor
3.3
Icons used
Status icons
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Icon
Description
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Stopped / Running
When the compressor is stopped, the icon is motionless.

When the compressor is running, the icon rotates.
Compressor status
Motor stopped
Running unloaded
Running loaded
Local start / stop
Machine control mode

Remote start / stop
Network control
Automatic restart after voltage

failure
Automatic restart after voltage failure is enabled
Week timer
Week timer is active
Emergency stop
Active protection functions
Shutdown
Warning
Service required
Service
Error
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Main screen
Displayed when 2 or 4 line layout is picked.
Displayed when chart layout is picked.
Menu icons
Icon
Description
Service
Alarms (warnings, shutdowns)

Week timer
Info
Test
Counters
Regulation setpoints
Inputs
Outputs
Event history (saved data)
Settings
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Input icons
Icon
Description
Pressure
Temperature
Digital input
Special protection
System icons
Icon
Description
Compressor element (LP, HP, ...)
Drain(s) (icon only visible when Electronically Regulated Drain (ERD) is installed on
compressor unit)
Filter(s)
Frequency converter
Motor
Expansion module
Cooler
Network settings/problem
General alarm
Auxiliary equipment overload: dryer
Oil circuit
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Regulation
General settings
Access key / User password

Temperature rise over the low pressure compressor stage.
Navigation arrows
Icon
Description
Up
Down
3.4
Main screen
Control panel
Control panel
(1)
Enter key
(2)
Cancel / Escape key
(3)
Scroll keys
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Function
The main screen shows the status of the compressor and is the gateway to all functionality implemented in
the controller.
The main screen is shown automatically when the power is switched on. The display switches to sleep
mode when no keys are pushed for a programmable time.
Five different main screens can be chosen:
1.
2.
3.
4.
5.
Two value lines

Four value lines
Chart (High resolution)
Chart (Medium resolution)
Chart (Low resolution)
Two and four value views
Typical Main screen (Four value lines)
Text on figures
(1), (2)
Compressor Outlet
(3)
Inlet Guide Vanes % Open
(4)
Blow-Off Valve % Closed
(5)
Starting
(6)
Menu
(7)
Unload
Section A displays information regarding the compressor operation (e.g. outlet pressure, temperature
at compressor outlet ).
Section B displays Status icons. Following icon types are shown in this field:
Fixed icons
These icons are always shown in the main screen and cannot be selected by the cursor (e.g.
Compressor stopped or running)
Shortcut icons
These icons are always shown in the main screen. If the icon is selected and the Enter key is
pushed, the screen will jump to the corresponding menu (e.g. if the icon for Motor stopped or
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Running Loaded is selected, the screen will jump directly to the regulation menu after pressing
the Enter key).
Control mode icons
These icons are always shown in the main screen. If the icon is selected and the Enter key is
pushed, the screen jumps to the control mode menu. Following control modes are available:
Local control
Remote control
Network control
Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer,
automatic restart after voltage failure, etc.)
Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To show more information about displayed icons, select the icon using the scroll keys and push the
Enter key.
Section C is called the Status bar
This bar shows the text that corresponds to the selected icon.
Section D shows the Action buttons. These buttons are used:
to call-up or program settings
to reset a shutdown, service message or emergency stop
to have access to all data collected by the controller
The function of the buttons depends on the displayed menu. The most common functions are:
Designation
Function
Menu
To go to the menu
Modify
To modify programmable settings
Reset
To reset a timer or message
To enable an action button, highlight this button by using the Scroll keys and push the Enter key.
To go back to the previous menu, push the Cancel / Escape key.
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Chart views
When the Chart (High Resolution) display is selected, a chart with an X-axis covering 4 minutes is
displayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chart
dot represents 1 second.
When the Chart (Medium Resolution) display is selected, a chart with an X-axis covering 4 hours is
displayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chart
dot represents a 1 minute average value.
When the Chart (Low Resolution) display is selected, a chart with an X-axis covering 10 days is displayed.
The value displayed on the Y-axis depends on the selection made in the input screen. Each chart dot
represents a 1 hour average value.
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3.5
Controller menu structure
Main menu
Press the Enter key to go to the main menu screen that is shown below.
Menu structure
Please find the tree structure on the 2 top levels below. The items are mentioned as they appear on the
screen from top to bottom and left to right. If questions regarding lower levels appear, please consult your
local Atlas Copco Customer Centre.
SERVICE PLAN
Topic
Description
Overview
Displays an overview of the running service plans
Service Plan
Displays configuration of the service plans
Next Service
Displays the next service task
History
Displays a log of all automatic shutdowns that have appeared in the past
PROTECTIONS
Topic
Description
General
Displays a list of main protections
Element(s)
Displays a list of protections related to the compressor stages
Convertor(s)
Displays errors concerning actuators
Drain(s)
Displays protections on electronic drain failures
Main Motor
Displays motor related protections to avoid motor damage
Cooler(s)
Displays a number of temperature protections of the coolers
Oil Circuit
Displays a number of protections in the oil circuit
WEEK TIMER
Topic
Description
Week Action Schemes
Displays 4 programmable week action schemes

Each week action scheme contains 7 programmable days and these days can
contain a number of successive events on selected time slots.
Week Cycle
Contains 10 weeks and each week can be selected as 1 of the 4 week action
schemes
Status
Displays the status (On/Off) of the week timer functionality
Remaining Running
Time
Allows to set a timer to keep the compressor running for 1-240 minutes
INFORMATION
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Topic
Description
www.atlascopco.com
Refers to the company website where more detailed info on the product can be
found
More
The More button displays the software versions, addresses, licenses, ...
TEST
Topic
Description
Drain Test
Allows a functionality check of the (optional) electronic water drains
Safety Valve Test
Allows a functionality check of the safety valve. (This feature can only be
enabled by a service technician.)
COUNTERS
Topic
Description
Running hours
Displays the number of hours the compressor has been running in unloaded &
loaded mode
Loaded Hours
Displays the number of hours the compressor has been running in loaded mode
Motor Starts
Displays the number of motor starts
Load Relay
Displays the number of load relay toggles (thus unload/load transitions)
Fast Starts
Displays the number of manual motor starts that exceed the automatic motor
starts
Fan starts
Displays the number of times the fan has been started
Module Hours
Displays the number of hours the module has been powered
Emergency stops
Displays the number of compressor stops by use of the emergency stop
REGULATION
Topic
Description
Unloading pressure 1
The pressure setpoint that is higher than setpoint 1, where the loaded
compressor switches to unload
Loading pressure 1
The pressure setpoint that is lower than setpoint 1, where the unloaded
compressor switches to load
Unloading pressure 2
The pressure setpoint that is higher than setpoint 2, where the loaded
compressor switches to unload
Loading pressure 2
The pressure setpoint that is lower than setpoint 2, where the unloaded
compressor switches to load
Pressure band used
Selection of 1st or 2nd pressure band. A pressure band is a combination of a

loading pressure, a setpoint and an unloading pressure
Digital pressure band

selection
Allows a remote signal to control the pressure band selection.
INPUTS
52
Topic
Description
General
Displays a number of general readouts and bipolar states
Element(s)
Displays a list of readouts related to the compressor stages
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Topic
Description
Dryer
Displays the status of the dryer
Drains
Displays the status of the drains
Main Motor
Displays a number of readouts and bipolar states concerning the main motor
Network
Displays a number of bipolar states of remote signals
Cooler
Displays a number of cooler temperature readouts
Oil Circuit
Displays a number of readouts and bipolar states concerning the oil circuit
OUTPUTS
Topic
Description
General
Displays a number of analogue and digital outputs
Dryer
Displays the activation of the dryer
Drains
Displays the activation of the drains
Main Motor
Displays a number of digital outputs concerning the main motor status
SPM (Shock Pulse Method)

Topic
Description
Motor, drive end
Displays the vibration level at the drive end of the motor
Motor, non-drive end
Displays the vibration level at the non-drive end of the motor
Low pressure stage,

drive end
Displays the vibration level at the drive end of the low pressure compressor
stage
Low pressure stage, non- Displays the vibration level at the non-drive end of the low pressure compressor
drive end
stage
High pressure stage,
drive end
Displays the vibration level at the drive end of the high pressure compressor
stage
High pressure stage,

non-drive end
Displays the vibration level at the non-drive end of the high pressure
compressor stage
Gearbox
Displays the vibration level at the gearbox
EVENT HISTORY
Topic
Description
-
Displays a log file of all shutdowns and shows the status of the type, counters,
inputs and outputs at the moment a shutdown appeared
SETTINGS
Topic
Description
Network
Displays the CAN and ethernet configuration
Regulation
Displays settings concerning the compressed air flow regulation
General
Displays settings concerning time, date, unit and display time-out
Dryer
Displays the dryer settings
Access Key
Displays the controller access level that can be modified with password input
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3.6
Topic
Description
Automatic Restart
Only displayed when compressor motor voltage < 690V and when ARAVF is
available. Automatic Restart After Voltage Failure can only be enabled by a
service technician.
Access Key
Displays the controller access level that can be modified with password input
User Password
Displays the availability to use a password to protect the controller from

unwanted manipulation
Main Chart
Displays the input and the range of the main chart
Service
Displays a list of service settings with values that can only be adjusted by a
service technician.
Web server
All Elektronikon controllers have a built-in web server that allows direct connection to the company
network or to a dedicated PC via a local area network (LAN). This allows to consult certain data and
settings via a PC instead of the display of the controller.
Getting started
If the compressor is equipped with a SMARTBOX, the network connection of the
Elektronikon is already in use. To allow the web server functionality, the network cable
that is connected to the SMARTBOX should be unplugged and replaced by the cable of
the company network.
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 (see picture below).
USB to LAN adapter
Use a UTP cable (CAT 5e) to connect to the controller (see picture below).
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Configuration of the network card (in Windows XP)

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

IP Address 192.168.100.200
Subnetmask 255.255.255.0
Click OK and close network connections.
Configuration of the web server
Configure the web interface (for Internet Explorer)
Open Internet Explorer and click on Tools - Internet options (2).
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Click on the Connections tab (1) and then click on the LAN settings button (2).
In the Proxy server Group box, click on the Advanced button (1).
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In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be
given but they must be separated with semicolons (;).
Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Now
you add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1)
(see picture).
Click OK (2) to close the window.
Viewing the controller data
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All screen shots are indicative. The number of displayed fields depends on the selected
options.
Open your browser and type the IP address of the controller you want to view in your browser (in this
example http://192.168.100.100). The interface opens:
Screen shot (example!)
Navigation and options

The banner shows the compressor type and the language selector. In this example, three languages are
available on the controller.
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Compressor settings
All compressor settings can be displayed or hidden. Put a check mark in front of each point of interest and
it will be displayed. Only the machine status is fixed and can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference button from
the navigation menu.
Counters
Lists all current counter values from controller and compressor.
Info status
Machine status is always shown on the web interface.
Digital inputs
Lists all Digital inputs and their status.
Digital outputs
Lists all Digital outputs and their status.
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Special protections
Lists all special protections of the compressor.
Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows the running
hours. It is also possible to show the current status of the service interval.
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Installation
4.1
Dimension drawings
Dimension drawing, ZR Pack
Dimension drawing ZR 55 up to ZR 90 Pack (metric units)
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Dimension drawing ZR 55 up to ZR 90 Pack (imperial units)
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Dimension drawing ZR 55 up to ZR 90 Pack, with Energy Recovery (metric units)
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Dimension drawing ZR 55 up to ZR 90 Pack, with Energy Recovery (imperial units)
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Dimension drawing, ZR Full-Feature
Dimension drawing ZR 55 up to ZR 90 Full-Feature (metric units)
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Dimension drawing ZR 55 up to ZR 90 Full-Feature (imperial units)
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Dimension drawing ZR 55 up to ZR 90 Full-Feature, with Energy recovery (metric units)
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Dimension drawing ZR 55 up to ZR 90 Full-Feature, with Energy recovery (imperial units)
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Dimension drawings, ZT Pack
Dimension drawing ZT 55 up to ZT 90 Pack (metric units)
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Dimension drawing ZT 55 up to ZT 90 Pack (imperial units)
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Dimension drawing, ZT Full-Feature
Dimension drawing ZT 55 up to ZT 90 Full-Feature (metric units)
72
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Dimension drawing ZT 55 up to ZT 90 Full-Feature (imperial units)
Text on drawing
Ref
Name
(1)
Voltage supply entry
(2)
Compressed air outlet
(3)
Cooling air outlet
(4)
Opening for transportation
(5)
4 slotted holes only for horizontally pulling unit out of container
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74
Ref
Name
(6)
Cooling air inlet
(7)
Hole pattern ducting
(8)
Automatic drain, aftercooler
(9)
Automatic drain, intercooler
(10)
Compressed air outlet, compensator
(11)
Mass
(12)
Water in/out compensator
(13)
Water out
(15)
Automatic drain, dryer inlet
(16)
Automatic drain, regeneration air outlet
(17)
Automatic drain, dryer outlet
(18)
Cooling Full-Feature air outlet
(19)
Cooling Full-Feature air inlet
(20)
If option: Prepared for MD
(21)
Cable box included for EC variants
(22)
Cable box not included for CSA/UL variants
(23)
Automatic drain, regeneration outlet
(24)
Low load drain (optional)
(25)
Automatic drain, extra aftercooler
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4.2
Installation proposals
Installation proposal, ZR Pack (with Energy recovery) or Full-Feature
Installation proposal ZR 55 up to ZR 90 Pack (with Energy recovery) or Full-Feature (in metric units)
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Installation proposal ZR 55 up to ZR 90 Pack (with Energy recovery) or Full-Feature (in imperial units)
76
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Installation proposal, ZR Full-Feature with Energy recovery
Installation proposal ZR 55 up to ZR 90 Full-Feature with Energy recovery (in metric units)
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Instruction book
Installation proposal ZR 55 up to ZR 90 Full-Feature with Energy recovery (in imperial units)
78
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Installation proposal, ZT Pack
Installation proposal ZT 55 Pack up to ZT 90 Pack (in metric units)
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Installation proposal ZT 55 Pack up to ZT 90 Pack (in imperial units)
80
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Installation proposal, ZT Full-Feature
Installation proposal ZT 55 up to ZT 90 Full-Feature (in metric units)
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Installation proposal ZT 55 up to ZT 90 Full-Feature (in imperial units)
Text on figures
82
Ref
Name
(1)
Minimum free area to be reserved
(2)
Ventilation proposal
(3)
Cooling air outlet
(4)
Cooling air inlet
(5)
Cooling Full-Feature air outlet
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Ref
Name
(6)
Cooling Full-Feature air inlet
Description
Ref
Description
Install the compressor on a level floor suitable for taking the weight of the compressor.
Recommended minimum distance between the top of the bodywork and the ceiling:
1200 mm (46.80 in).
Remove the plastic plug or cap (if provided) from the compressor air outlet pipe and
install an air outlet valve. Close the valve and connect it to the air net.
The pressure drop over the delivery pipe can be calculated as follows:
dp = (L x 450 x Qc1.85) / (d5 x P)
dp = pressure drop (recommended maximum = 0.1 bar)
L = length of outlet pipe in m
d = inner diameter of the delivery pipe in mm
P = absolute pressure at the compressor outlet in bar(a)
Qc = free air delivery of the compressor in l/s
The connection of the compressor air delivery pipe should be made on top of the main
air net pipe to minimize carry-over of possible remainder of condensate.
The inlet grids and ventilation fan should be installed in such a way that any
recirculation of cooling air to the compressor is avoided.
The air velocity to the grids should be limited to 5 m/s (195 in/s).
The required ventilation capacity (per compressor installed) to limit the compressor
room temperature can be calculated as follows:
On ZR compressors: Qv = 0.1 N / dT
On ZT compressors: Qv = 0.92 N/ dT
Qv = required ventilation capacity in m3/s
N = shaft input of the compressor in kW
dT = temperature rise over ambient in C
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is
30 Pa. Common ducting for several compressors is not allowed.
Lay out the drain piping from automatic condensate outlets (EWD) towards the
condensate collector. The drain pipes must not dip into the water of the collector. It is
recommended to provide a funnel to allow visual inspection of the condensate flow.
Elektronikon control system with control panel.
See Electric cables for the recommended cable size of the supply cables. Check that
the electrical connections correspond to the local codes. The installation must be
earthed and protected against short circuits by fuses in all phases. An isolating switch
must be installed near the compressor.
Provide a condensate drain valve in the lowest part of the pipe between the compressor
outlet valve and the air net.
Remove the plastic plugs (if provided) from the compressor water pipes and connect the
pipes to the cooling water circuit. Provide a valve in the compressor water inlet pipe and
outlet pipe.
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4.3
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:
Axial L
Lateral R
84
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Drawing reference
Description
Atlas Copco compressor pipe end
Customer installation pipe end
Angular misalignments are NOT allowed!
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Misalignment tolerances
Single direction misalignments
Axial 1: L
mm
20
Axial 1: L
in
0.8
Lateral: R
mm
20
Lateral: R
in
0.8
= stretch or compression
2 = NO angular misalignment is tolerated!
Combined direction misalignments
Drawing reference
Description
(1)
Compression
(2)
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.
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Temperature correction factors

Medium temperature Medium temperature Correction factor for maximum working pressure of
(C)
(F)
the compensator
0
32
50
122
80
176
85
185
0.92
90
194
0.83
95
203
0.75
100
212
0.67
105
221
0.6
110
230
0.54
Torque values
Compensator bolts should be torqued in 3 successive steps
Step 1: Hand-tighten each bolt.
Step 2: Torque the bolts crosswise up to the value mentioned in the table below and allow a
stabilization period of 30 minutes before moving to step 3.
Step 3: Torque the bolts crosswise up to the value mentioned in the table below.
Mind the parallelism of the sealing.
Excessive torque will damage the sealing.
DN
(mm)
DN
(inch)
Step 1
Step 2
(Nm)
Step 2
(lbfin)
Step 3
(Nm)
Step 3
(lbfin)
20 80
23
hand tight
50
443
80
708
100 300
4 12
hand tight
50
443
100
885
350 500
14 20
hand tight
50
443
130
1551
Do's and don'ts

The supplied compensators are NOT designed:
to carry the weight of the mounted customer pipe end.
to work as a damper for unanchored pipe ends.
to carry the thrust forces of the compressed air.
Therefore, adequate supporting and anchoring of the customer pipe end should be foreseen to avoid
compensator damage.
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The compensator loads (Fg and Ft) that are mentioned on the drawing are strictly forbidden:
Weight loads Fg
Thrust forces Ft
For the design of piping and supporting structures, use an approved standard code (e.g. EN 13480 or
ASME 16.5/B31.3).
Mind that the connected pipe at customer side does not create any flow restriction
caused by e.g. section reduction.
While installing the compensator, please mind the following check points to avoid sealing damage.
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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.
Rough pipe ends will damage the rubber sealing.
Avoid contact between the pipe end and the rubber sealing.
Refer to the pictures below for a visual overview of 5 do's and don'ts when installing rubber compensators:
WRONG installation!
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CORRECT installation!
90
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Drawing reference
Description
(1)
Larger than maximum allowed installation length.
(2)
Less than or equal to maximum allowed installation length
(3)
Minimum 1 mm of free space
Do NOT:
Paint the rubber bellows of the expansion joint since:
Solvents can damage the rubber cover.
The colored coating avoids decent visual inspection of the rubber condition.
Weld, cut or grind without protecting the rubber bellows
Expose the compensator to permanent radiation heat above 90 C (194 F)
4.4
Electric cables
Remarks
The cable sizes below are applicable for the MAINS + EARTH CABLE
The cable size is valid at maximum ambient temperature of 40 C.
The cable size is valid at maximum ambient temperature of 104 F.
IEC compressors
Cables calculated according to IEC 60364-5-52
Mounting type: E (Multicore cables in free air)
Multiple circuit arrangement:
4 (Perforated cable tray)
For standard 40 C ambient temperature units: Use 70 C (158 F) cables (Type
H07V-K)
For HAT 50 C ambient temperature compressors use 90 C (194 F) cables (Type
H07V2-K)
CSA/UL compressors
Cables calculated according to CEC C22.1/NFPA 70
Multicore cables on perforated tray or ladder system
Use 90 C (194 F) cables (Type R90, RW90, T90)
The voltage drop must not exceed 10% of the nominal voltage. It may be necessary to
use cables with a larger size than those stated to comply with this requirement.
50 Hz IEC
Model
Voltage
Cables STD 40C
Cables HAT 50C
Cable
lugs
Maximum
cable
length (m)
MCA
line*
ZR/ZT 55
200 V
3x150mm+95mm
3x185mm
+95mm
M8
150
271 A
ZR/ZT 55
230 V
3x150mm+95mm
3x185mm
+95mm
M8
150
241 A
ZR/ZT 55
400 V
3x150mm+95mm
3x185mm
+95mm
M8
150
139 A
ZR/ZT 55
500 V
3x70mm+35mm
3x95mm+50mm
M8
150
112 A
ZR/ZT 55
690 V
3x70mm+35mm
3x95mm+50mm
M8
150
80 A
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Model
Voltage
Cables STD 40C
Cables HAT 50C
Cable
lugs
Maximum
cable
length (m)
MCA
line*
ZR/ZT 75
200 V
3x240mm+120mm
3x240mm
+120mm
M10
150
379 A
ZR/ZT 75
230 V
3x240mm+120mm
3x240mm
+120mm
M10
150
333 A
ZR/ZT 75
400 V
3x150mm+95mm
3x185mm
+95mm
M8
150
190 A
ZR/ZT 75
500 V
3x150mm+95mm
3x185mm
+95mm
M8
150
152 A
ZR/ZT 75
690 V
3x70mm+35mm
3x95mm+50mm
M8
150
109 A
ZR/ZT 90
200 V
2x(3x150mm
+95mm)
3x240mm
+120mm
M10
150
420 A
ZR/ZT 90
230 V
3x240mm+120mm
3x240mm
+120mm
M10
150
370 A
ZR/ZT 90
400 V
3x150mm+95mm
3x185mm
+95mm
M8
150
215 A
ZR/ZT 90
500 V
3x150mm+95mm
3x185mm
+95mm
M8
150
171 A
ZR/ZT 90
690 V
3x150mm+95mm
3x185mm
+95mm
M8
150
123 A
* MCA line = Minimum Circuit Ampacity of the line current

60 Hz IEC
92
Maximu
m cable
Cables HAT 50C Cable lugs
length
(m)
Model
Voltage
Cables STD 40C
ZR/ZT 55
200 V
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 55
220-230
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 55
380 V
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 55
440 V
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 75
200 V
3x240mm+120mm
3x240mm
+120mm
M10
150
ZR/ZT 75
220-230
3x240mm+120mm
3x240mm
+120mm
M10
150
ZR/ZT 75
380 V
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 75
440 V
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 90
200 V
2x(3x150mm
+95mm)
2x(3x185mm
+95mm)
M10
150
MCA
line*
294 A
269 A
155 A
136 A
385 A
352 A
205 A
178 A
449 A
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Maximu
m cable
Cables HAT 50C Cable lugs
length
(m)
MCA
line*
Model
Voltage
Cables STD 40C
ZR/ZT 90
220-230
2(x3x150mm
+95mm)
2x(3x185mm
+95mm)
M10
150
ZR/ZT 90
380 V
3x150mm+95mm
3x185mm
+95mm
M8
150
ZR/ZT 90
440 V
3x150mm+95mm
3x185mm
+95mm
M8
150
Maximu
m cable
length
(m)
MCA
line*
415 A
239 A
208 A

60 Hz CSA/UL
Model
Voltage
Cables STD 40C
Cables HAT 50C
Cable
lugs
ZR/ZT 55
460 V
3xAWG4/0+AWG4
3xMCM250+AWG3
M8
150
130 A
ZR/ZT 55
575 V
3xAWG4/0+AWG6
3xMCM250+AWG4
M8
150
103 A
ZR/ZT 75
460 V
3xMCM300+AWG3
3xMCM350+AWG3
M8
150
172 A
ZR/ZT 75
575 V
3xAWG4/0+AWG4
3xMCM250+AWG4
M8
150
136 A
ZR/ZT 90
460 V
3xMCM300+AWG2
3xMCM350+AWG2
M8
150
200 A
ZR/ZT 90
575 V
3xMCM300+AWG4
3xMCM350+AWG4
M8
150
160 A
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4.5
Electric connections
Example of electric cabinet
Electric connections ZR/ZT 55 up to ZR/ZT 90
94
Ref
Name
F3/4
Circuit breakers, control circuit
F17
Circuit breaker for electronically controlled automatic condensate drains
F21
Overload relay, drive motor
K11
Auxiliary relay, loading
K21
Line contactor
K22
Star contactor
K23
Delta contactor
Q1
Circuit breaker
T1
Main transformer
T2
Transformer, control circuit
1X0
Power supply terminals
1X4/5/6/7
Terminal strips
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Electric diagram
Electric diagram Z 55-90 YD MK5
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Electric diagram Z 55-90, No motor, MK5
4.6
Reference
Name
(1)
Customer's Installation
(2)
Compressor motor
(3)
Drive motor
(4)
Use the Lock out Tag out procedure to de-energize the machine for maintenance
(5)
3 Fuses in case of bridges between K21 and K23
(6)
6 Fuses
(7)
Customer motor starter
Quality of safety components

When installing a remote emergency button or a motor contactor, the following B10d values are advised:
Emergency stop button: 500 000
Main contactor: 1 333 333
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4.7
Cooling water requirements
Recommendations
The cooling water quality must meet certain minimum requirements.
No general recommendation can encompass the effects of all combinations of the various compounds,
solids and gases typically found in cooling water in interaction with different materials.
Only non-treated water must be used.
This recommendation is a general guide line for acceptable coolant quality.
Type of system
It is important to define the used cooling water system:
an open system
a closed system
In a closed system, the same cooling water circulates through a system without contact with air.
An open system is a pass-through system, or a circulating system with a cooling tower. In the latter case,
the composition of the water that enters the compressor must be considered, and not the composition of the
make-up water. Due to the evaporative effect in the cooling tower, much higher concentrations of ions can
be obtained in the circulating water than in the make-up water.
Ryznar Stability Index (RSI)
The Ryznar Stability Index (RSI) is a parameter for predicting whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling deposits and their effect are different on different
materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value
and by the saturation pH value (pHs).
The saturation pH value is determined by the relationship between the calcium hardness, the total
alkalinity, the total solids concentration and the temperature.
The Ryznar Stability Index is calculated as follows :
RSI = 2*pHs - pH
Symbol
Explanation
pH
Measured pH (at room temperature) of water sample
pHs
pH at saturation
The pHs is calculated by using :

pHs = (9.3 + A + B) - (C + D)
Symbol
Explanation
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 CaCO3)
Depends on the HCO3- concentration or M-alkalinity (mval/l)
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The values of A, B, C and D can be found in the following table.

Total dissolved
solids (mg/l)
Temperature
(C)
Ca-hardness (ppm C
CaCO3)
M-alkalinity (mval/l) D
50 - 300
0.1
0-1
2.6
10 - 11
0.6
0.20 - 0.22
1.0
400-1000
0.2
2-6
2.5
12 - 13
0.7
0.24 - 0.26
1.1
7-9
2.4
14 - 17
0.8
0.28 - 0.34
1.2
10 - 13
2.3
18 - 22
0.9
0.36 - 0.44
1.3
14 - 17
2.2
23 - 27
1.0
0.46 - 0.54
1.4
18 - 21
2.1
28 - 34
1.1
0.56 - 0.70
1.5
22 - 27
2.0
35 - 43
1.2
0.72 - 0.88
1.6
28 - 31
1.9
44 - 55
1.3
0.90 - 1.10
1.7
32 - 37
1.8
56 - 69
1.4
1.12 - 1.38
1.8
38 - 44
1.7
70 - 87
1.5
1.40 - 1.76
1.9
45 - 50
1.6
88 - 110
1.6
1.78 - 2.20
2.0
51 - 56
1.5
111 - 138
1.7
2.22 - 2.78
2.1
57 - 63
1.4
138 - 174
1.8
2.80 - 3.54
2.2
64 - 71
1.3
175 - 220
1.9
3.54 - 4.40
2.3
72 - 80
1.2
230 - 270
2.0
4.6 - 5.4
2.4
280 - 340
2.1
5.6 - 7.0
2.5
350 - 430
2.2
7.2 - 8.8
2.6
440 - 550
2.3
9.0 - 11.0
2.7
560 - 690
2.4
11.2 - 13.8
2.8
700 - 870
2.5
14.0 - 17.6
2.9
880 - 1000
2.6
17.8 - 20.0
3.0
Interpretation of the value obtained

RSI
Water condition
Action
RSI<3.9
Very high scale formation
Water cannot be used.
4.0<RSI<5.5
High boiler scale formation
Regular inspection and descaling operation

necessary.
5.6<RSI<6.2
Slight boiler scale formation
Water treatment not necessary.

Occasional inspection recommended.
6.3<RSI<6.8
Neutral water

6.9<RSI<7.5
Slight corrosion at higher

temperature

7.6<RSI<9.0
Strong corrosion
Regular inspection necessary, use of corrosion

inhibitor recommended.
9.1<RSI<11
Very strong corrosion
Regular inspection necessary, use of corrosion

inhibitor required.
RSI>11
Very strong corrosion in

complete water system
Water should not be used.
The table indicates that distilled or demineralized water should never be used, as their RSI is > 11.
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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.
pH
The effect of pH is already calculated in the Ryznar index, but the pH itself has some additional
limitations : 6.8 < pH < 8.5
Total Dissolved Solids (TDS)
This is the sum of all the ions in the water. It can be derived from the dry residue after evaporation (but not
including suspended solids), or it can be estimated from the electrical conductivity.
In a closed system, the following limits apply : TDS < 3000 mg/l (< 3800 microS/cm)
For an open system, the following limits apply : TDS < 750 mg/l ( < 960 microS/cm)
Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited:
Closed cooling system : chlorides < 500 ppm
Open cooling system : chlorides < 150 ppm
However, if the water is scaling, lower limits should be used. (See The Ryznar stability index (RSI)).
Free chlorine (Cl2)
A level of 0.5 ppm should not be exceeded for long periods.
For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies.
Sulphates (SO4--)
Closed cooling system : sulphates < 400 ppm
Open cooling system : sulphates < 150 ppm
Carbonate hardness
Closed cooling system : 50-1000 ppm CaCO3
Open cooling system : 50-500 ppm CaCO3
HCO3- / SO42- should be > 1
Ammonia
< 0.5 ppm
Copper
< 1 ppm
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Iron and manganese

< 1 ppm
Organics
No algae
No oil
Suspended solids
Non-soluble particles, size < 1 mm.
< 10 ppm
4.8
Pictographs
Explanation of pictographs
100
Reference
Name
Alarm
Service
Automatic operation
Voltage on
Enter
Escape
Scroll keys
Stop
Start
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Ref
Name
Automatic condensate outlet, intercooler
Automatic condensate outlet, aftercooler
10
Warning: under tension
11
Read Instruction book before starting the compressor
12
Switch off the voltage and depressurize the compressor before maintenance or repair
13
Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
14
Torques for steel (Fe) or brass (CuZn) bolts
15
Consult the Instruction book before greasing
16
Switch off the voltage before removing the protecting cover inside the electric cabinet
17
Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)
18
Consult the Instruction book before maintenance or repair
19
Cooling water inlet
20
Cooling water outlet
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Additional pictographs on Full-Feature compressors
102
Reference
Name
Arrow, indicating rotation direction
Warning, voltage
Instruction for delta P reading

Purge internal impulse line before any reading of delta P on U-tube (close isolation
valves of U-tube)
Indication for correct adjusting of the U-tube water level
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Operating instructions
5.1
Operation introduction
Warning
The operator must apply all relevant Safety precautions.
Ambient conditions
Consult Limits for the limits with regard to the ambient conditions and altitude operation.
Moving/lifting
In order not to damage the frame, the compressor must be moved either by a lift truck or by using lifting
equipment as described below.
When moving the compressor with a lift truck, use the slots in the frame. Make sure that the forks protrude
from the other side of the frame. When moving the compressor with a lifting device, insert beams in the
slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chains
must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The
lifting equipment must be placed in such a way that the compressor is lifted perpendicularly. Lift gently
and avoid twisting.
5.2
Initial start-up
Procedure
Consult Electric cables, Installation proposals and Dimension drawings.
A sticker dealing in short with the operation instructions is delivered with the literature set. Affix the
sticker next to the control panel.
A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect
the compressor against corrosion. Remove the plates.
The compressor and motor are secured to the frame immobilizing the vibration dampers during
transport:
At the motor side, loosen nut (1), remove bolts (2) and turn bracket (3) 90. Tighten nut (1).
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On ZR compressors, remove support (1) at the gear casing side.
On ZT compressors, remove bolts (1) and supports (2) immobilizing the vibration dampers of
the coolers. Remove support (3), immobilizing the vibration dampers of the gear casing.
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Remove flange (1) and take out the silica gel bags installed in the intercooler at the condensate drain
receiver side. Refit the flange.
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Instruction book
Position of silica gel bags on ZT compressors
106
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Position of silica gel bags on ZR compressors
On Full-Feature compressors with Low-Load option and Full-Feature ND compressors, the nozzle
type depends on the working pressure. Install the correct nozzle according to the table below.
Compressor
Nozzle at 4 bar (58 Nozzle at 7 bar

psi)
(102 psi)
Nozzle at 8.6 bar

(125 psi)
Nozzle at 10 bar
(145 psi)
Z 55 FF
1617 7572 00
1617 7571 00
1617 7571 00
1617 7571 00
Z 75 FF
1617 7573 00
1617 7571 00
1617 7571 00
1617 7571 00
Z 90 FF
1617 7440 00
1617 7572 00
1617 7572 00
1617 7571 00
The setpoint of the dryer heater depends on the working conditions, consult the Atlas Copco
Customer Centre to have the setpoint adjusted.
On ZR compressors, fit the water drain plugs (1, DP1, DP2, DP3) that are fixed to the water pipe of
one of the compressor elements (Eh, El) in a plastic bag. The plugs are painted green and their
positions are shown below.
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108
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On ZR compressors, 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.
On ZR Full-Feature, the inlet and outlet valves of the cooling water circuit of the regeneration cooler
must be opened completely.
Check that the gear casing is filled with oil: the level should be in the middle of sight-glass (SG).
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Instruction book
Check that the electrical connections correspond to the local codes. The installation must be earthed
and protected by fuses in all phases. An isolating switch must be provided.
Check the connections at the primary sides of transformers (T1 and T2).
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Switch on the voltage. Start the compressor and stop it immediately. Check for correct direction of
rotation while the motor is coasting to a stop. An arrow on the gear casing indicates the correct
rotation direction. If the rotation direction is wrong, switch off the voltage and reverse two incoming
electric lines.
On ZT compressors, remove panel (1) and check the rotation direction of the fan motor. If the rotation
direction is wrong, switch off the voltage and reverse two connections at terminals 221 up to 226 of
terminal strip (1X1).
On ZT Full-Feature compressors, also check the rotation of the fan motor of the regeneration cooler
(Cr), the correct rotation direction is indicated by an arrow on the fan motor.
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Instruction book
Run the compressor for a few minutes and check that it operates normally.
Stop the compressor. If necessary, top up the gear casing with oil to the middle of sight-glass (SG).
Adjustment of the pressure difference of the dryer compartments
1. Start and load the compressor
2. Check the rotation direction of the dryer motor, the correct rotation direction is indicated by an arrow
on the motor housing.
3. Close valves 1 and 2. Fill a transparent tube halfway with water. Install the tube to the valves. Open
the valve marked (-), slightly open the valve marked (+), while watching the water levels in the Utube.
Two conditions are possible:
The water level in the leg marked (+) rises. Close the valve at once, decrease the regeneration air
inlet pressure as described in step 4. Do this as often as necessary, until the water level drops.
The water in the leg marked (-) rises, which should normally be the case. If the level in this leg
rises 30 mm (1.17 in) above the level in the leg marked (+), close the valve at once as there is a
risk that the water will be ejected from the U-tube and dissappear into the pressure vessel.
Increase the regeneration air inlet pressure as described in step 4 and open the valve again.
4. Once the water column has stabilized, adjust the pressure difference as follows:
Remove the protecting cap from the adjusting screw.
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Loosen the check nut and turn the screw in to increase or out to decrease the pressure
differential.
The water level in the leg marked (-) must be bedween 20 and 40 mm (0.78 and 1.56 in) above
that in the leg marked (+).
Monitor the water level for about 10 minutes.
5. Stop the compressor.

Adjustment of the pressure difference of the dryer compartments
Delta P indicator
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Instruction book
View of PDP sensor
View of throttle valve
To start up the unit for the first time or after a long period of standstill, proceed as follows:
1. Check if U-tube is filled halfway with water. If not, continue as follows:
Close the valves (9 and 10) and open valve (6).
Remove the plugs (8) of the two vent valves (7) of the delta P indicator and open the valves.
Fill the U-tube halfway with water, close the valves (7) and refit the plugs.
2. On compressors equipped with a PDP sensor, close valve (11) to this sensor.
3. For dryers with low load option: Check that circuit breaker (F 32, compressor cubicle) is in the "I"
position.
4. Close the manual drain valve of the aftercooler drain trap of the compressor.
5. On ZR compressors, check for water flow.
6. Switch on the voltage at the mains.
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7. Start and load the compressor.

8. Open the valve (if installed) to the air net or air receiver and blow off some air from the air net to
keep the compressor running loaded.
9. Open valves (9 and 10). Open valve (6) slightly, while monitoring the water levels in the U-tube.
There are two possible conditions:
The water level in the leg marked (+) rises. Close valve (6) at once, decrease the regeneration air
inlet pressure (see next step). Do this as often as necessary until the water level drops.
The water level in the leg marked (-) rises, which should normally be the case. If the level in this
leg rises 30 mm above the level in the leg marked (+), close valve (6) at once, as there is a risk
that the water will escape the U-tube and disappear into the pressure vessel. Increase the
regeneration air inlet pressure (see next step) and open valve (6) again.
10. Once the water column has stabilised, adjust the pressure differential as follows:
Remove the protective cap from the adjusting screw of throttle valve (12).
Loosen its check nut (13) and turn the screw to alter the pressure differential.
Monitor the water level for about 10 minutes.
Tighten the check nut and reinstall the protective cap.
11. Check the dryer connections for air leaks.
12. On compressors equipped with a PDP sensor, open valve (11) to the PDP sensor 15 minutes after the
dryer is in operation.
13. Check that the pressure dewpoint is OK after 1 hour.
14. Close the blow-off valve of the air net, unload and stop the compressor. Close the air outlet valve of
the dryer.
15. Switch off the voltage.
16. Depressurize the dryer, see section Maintenance instructions.
5.3
Before starting
Safety
The operator must apply all related Safety precautions.
In case the water system was drained, close the drain valves and fit the drain plugs.
Procedure
Step
Action
Check the oil level, which must be in the middle of sight-glass (SG). Top up, if
necessary, with the correct type of oil.
Open the water inlet valve and outlet valve (customer's installation). Opening of the
water outlet valve can be overlooked if, after previous operation, the setting of this valve
has not been disturbed.
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Position of oil sight-glass on ZR compressors
Position of oil sight-glass on ZT compressors
116
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5.4
Routine starting
Control panel
Control panel of Elektronikon GraphicPlus controller
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. 25 seconds later (programmable), the compressor starts running loaded.
See section Readings for the cooling water temperature.

See section Compressor data for the cooling water consumption.
If the motor is stopped and automatic operation LED (7) is alight, the motor may start
automatically.
If the start/stop timer is active, the compressor can start automatically, even if it was
stopped manually.
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Instruction book
5.5
During operation
Control panel
Control panel of Elektronikon GraphicPlus controller
Procedure
When automatic operation LED (7) is alight, starting and stopping of the motor is
automatically controlled: when the motor is stopped, it may restart automatically.
118
Step
Action
Check the readings on display (1).
When reaching the preset unloading pressure, shown on display (1), the compressor will
start running unloaded. From now on, the electronic control module will calculate the
optimum moment to stop and restart the compressor motor automatically, depending on
the maximum permissible number of motor starts and on the air consumption.
To unload the compressor manually, select Unload on the display using the cursor keys
and press the Enter key.
To put the compressor back into automatic operation, select Load on the display using
the cursor keys and press the Enter key.
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5.6
Stopping
Control panel
Procedure
Position of water drain plug on LP compressor element
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Instruction book
Position of water drain plug on HP compressor element
Position of water drain plug of oil cooler
120
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Position of water drain plugs of cooler block
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
Press the test button on top of the electronic water drains while the compressor is
running loaded.
Press stop button (13): the compressor will stop and LED (7) will go out.
Close the air outlet valve.
To stop the compressor immediately, press emergency stop button (S2).
Close the cooling water inlet valve.
If the compressor is installed in a room where freezing temperatures are expected, drain
the cooling system completely:
By opening the main drain valves in the water inlet and outlet pipes (customer's
installation).
By removing drain plug (1) underneath the LP compressor element (El).
By removing drain plug (1) underneath the HP compressor element (Eh).
By removing drain plug (DP1) on the oil cooler.
By removing drain plugs (DP2 and DP3) underneath the cooler block (1).
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Instruction book
5.7
Taking out of operation
Procedure
122
Step
Action
Close the air outlet valve and stop the compressor.
Switch off the voltage.

Disconnect the compressor from the mains.
Shut off and depressurize the part of the air net which is connected to the outlet valve.
Disconnect the compressor air outlet pipe from the air net.
Drain oil and condensate circuits.
Disconnect the compressor condensate piping from the condensate drain net.
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Instruction book
Maintenance
6.1
Maintenance warnings
Warnings
Before starting any maintenance or repairs:
Stop the compressor. Close the air outlet valve.
Press the test buttons on top of the electronic water drains to depressurize the air
system.
Press the emergency stop button (S2).
Open the isolating switch (customer's installation) to switch off the voltage to the
compressor.
Warranty-Product Liability
Use only Atlas Copco authorized genuine parts. Any damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty or Product Liability.
6.2
Preventive maintenance schedule
Regular service operations

To ensure safe operation and long service life, carry out following operations at the interval (period or
running hours) which comes first. The "longer interval" checks must also include the "shorter interval"
checks.
The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the
environmental and working conditions of the compressor.
Period
Running hours
Operation
--
At initial start
Check the pressure differential of the rotor

compartments of the integrated dryer. Adjust if
necessary.
Daily
Check readings on display.
Daily
Check that condensate is discharged during

loading.
Daily
--
Check oil level. Before starting, the level should

be in the middle of the sight-glass.
Weekly
50
Check that the moisture indicator of the

integrated dryer shows blue.
Weekly
--
Drain condensate from the air receiver, if installed
Monthly
--
On Full-Feature ND compressors and FullFeature compressors with Low load option, check
that air is purged from the low load system. Clean
nozzle if necessary.
3-monthly
--
Clean compressor.
3-monthly
--
Check for possible leaks.
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Instruction book
6.3
Period
Running hours
Operation
3-monthly
500
Check coolers, clean if necessary.
Yearly
--
On compressors with Low Load option, check

nozzle and solenoid valve of the purge assembly.
2-yearly
16000
Replace the demister sponge of the integrated

dryer.
When displayed
--
Carry out the service actions according to the

displayed service plans.
Service kits
Service kits
The Customer Centres will be glad to provide you with a wide range of service kits. Service kits comprise
all parts needed for servicing components and offer the benefits of genuine parts while keeping the
maintenance budget low. All service kits are mentioned in the relevant Parts Lists.
6.4
Service agreements
The Customer Centres have a range of service agreements to suit your needs:
An Inspection plan.
A Preventive maintenance plan.
A Total responsibility plan.
Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure optimum
operational efficiency, minimize downtime and reduce the total life cycle costs.
6.5
Service plan
A number of service operations are grouped (called Level A, Level B, Level C, ...). Each level stands for a
number of service actions to be carried out at the time intervals programmed in the controller.
When reaching a level, a message will appear on the screen. After carrying out all service actions, the
interval timers are to be reset using the key "Reset" in menu "Service". Consult your Customer Centre.
6.6
Motor greasing
Fan motor of ZT compressors

The bearings of the fan motor are greased for life. Contact your Customer Center for the replacement
interval of the motor bearings.
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Drive motor (M1) of ZR compressor
Drive motor (M1) of ZT compressor
Motor grease
Stop the compressor and follow the LOTO procedure (Lock Out - Tag Out) (refer to
General Safety Precautions) before greasing.
Do not mix greases of different types.
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Instruction book
Main motor bearings

Refer to the motor re-greasing data plate for the recommended grease type, greasing quantity and interval
for the motor bearings.
Fan motor bearings of ZT compressors
The bearings of the fan motor are greased for life.
6.7
Oil specifications
Oil type
Use Atlas Copco Roto-Z oil which has been specially developed for oil-free rotary compressors. This oil
has a long service life and ensures optimum lubrication.
Never mix oils of different brands or types.
Atlas Copco Roto-Z oil

Atlas Copco Roto-Z oil can be ordered in following quantities:
6.8
Quantity
Ordering number
5 l can
1.32 Us gal can
1.10 Imp gal can
0.18 cu.ft can
2908 8503 00
20 l can
5.28 Us gal can
4.40 Imp gal can
0.70 cu.ft can
2908 8501 01
209 l drum
55.18 Us gal drum
45.98 Imp gal drum
7.32 cu.ft drum
2908 8500 00
Storage after installation

Run the compressor, e.g. twice a week, until warm.
If the compressor is going to be stored without running from time to time, protective measures must be
taken. Consult Atlas Copco.
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Servicing procedures
7.1
Air filter (AF)
Procedure
7.2
Step
Action
Stop the compressor and switch off the voltage to the compressor.
Remove the filter.
Fit the new filter.
After carrying out the service actions of the related service plan, the service warning
must be reset. See also Preventive maintenance schedule.
Oil and oil filter change
Control panel
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Instruction book
Oil system components, ZR
Oil system components, ZT
128
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Instruction book
Procedure
7.3
Step
Action
Run the compressor until warm.
Press stop button (1), wait until the compressor has stopped, press emergency stop
button (S2) and switch off the voltage to the compressor.
Remove filler plug (FC). Drain the compressor sump by opening drain valve (Dmo).
Close the valve after draining.
Drain the oil cooler by removing its drain plug and vent plug.
Remove the oil filter (OF). Clean the filter seat, oil the gasket of the new filter and screw
it into place until the gasket contacts the seat. Then tighten by hand.
Fill the compressor sump to the middle of the oil level sight-glass (SG) with oil as
specified in Oil specifications. Reinstall the filler plug.
Switch on the voltage. Unlock the emergency stop button.
Run the compressor for a few minutes. Stop the compressor. If necessary, top up the
gear casing with oil to the middle of the sight-glass (SG).
After carrying out the maintenance operations of the related service plan, the service
warning must be reset. See also Preventive maintenance schedule.
Safety valves
Testing
The valves can be tested on a separate compressed air line. If a valve does not open at the pressure
specified in Settings of safety valves, consult Atlas Copco.
Never run the compressor without safety valves.
No adjustments are allowed.
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Instruction book
Problem solving
8.1
Faults and remedies
Warnings
Before starting any maintenance or repairs, stop the compressor, wait until it has
stopped.
Close the air outlet valve and press the test button on top of the electronic water
drains to depressurize the air system.
Open the isolating switch (customer's installation) to switch off the voltage to the
compressor.
Apply all relevant Safety precautions.
Problem solving, compressor

Condition
Fault
Remedy
Compressor capacity or working

pressure lower than normal
Air consumption exceeds

capacity of compressor
Check pneumatic plant
Safety valves leaking
Remove leaking valve and have it

inspected
Oil level too low
Top up level to the middle of the oil

level sight-glass
Oil filter clogged
Replace filter
Inlet temperature too high due to

bad room ventilation or
recirculation of cooling air
Improve ventilation of compressor

room and avoid cooling air
recirculation
Air filter clogged
Replace filter
Discharge flexible clogged
Check and correct as necessary
Electronic water drain

malfunctioning
Consult Atlas Copco
Oil pressure too low
Air temperature above normal
Condensate is not discharged

from condensate traps during
operation
LED's of electronic water drain do Compressor is running unloaded

not light up
No condensate discharged when

pressing test button on EWD
130
LED's will light up when the

compressor is loaded again.
Power supply to EWD's faulty
Check power supply. Compare

power supply with voltage
mentioned on data label of EWD
Power supply board defective
Check and replace as necessary
System pressure lower than 0.8

bar(e)/11.6 psig
Load the compressor; as soon as

the system pressure exceeds 0.8
bar(e), condensate will be
discharged
Condensate inlet and/or outlet

blocked
Control board defective
Check and replace if necessary
Solenoid valve defective
Check and replace if necessary
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Instruction book
Condition
Fault
Remedy
Condensate only discharged

when test button is pressed
Sensor dirty
Clean sensor
Air pressure below minimum

pressure
Increase air pressure
EWD continuously discharges air Control air blocked
Sensor dirty
Clean sensor
Condition
Fault
Remedy
Pressure dewpoint too high
Compressor loading periods

repeatedly too short
Take necessary action to increase

duration of loading periods
Incorrect pressure difference

between dryer compartments
Check pressure difference which

should be within the range specified
in section Initial start-up. Never
operate the dryer with a pressure
difference beyond the specified
range. Always be sure that the
connections of the U-tube are
airtight
Operating pressure too low
Do not operate dryer at a pressure

less than 4 bar(e)
Rotor does not turn
Consult Atlas Copco
Rotor compartment sealing ring,

sealing sectors and rotor need
inspection
Consult Atlas Copco
Problem solving, dryer
Aftercooler air outlet temperature

too high
Regeneration cooler air outlet
temperature too high
Dryer air inlet temperature is

higher than aftercooler air outlet
temperature
Regeneration air inlet

temperature too low
2920 1849 00

temperature too low
Consult Atlas Copco
Drain system malfunctioning
Inspect system and replace parts

where necessary

temperature too high
Regeneration cooler clogged
internally
Consult Atlas Copco
Hot-air shut off valve closed
Open the valve
Compressor loading periods too

short
Take necessary action to increase

duration of loading periods
Nozzle of ejector partly

obstructed
Remove and clean nozzle.

Investigate cause
131
Instruction book
Principal data
9.1
Readings on display
Display
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.
Reference
Unit
Reading
Outlet pressure
bar(e)
Depends on pressure setpoint.
Maximum working pressure
bar(e)
See Compressor data.
Full-Feature compressors
Temperature readings
132
Item
Reading (min max)
Reading (min max)
Dryer heater outlet (optional)
130 - 210 C
266 - 410 F
Dryer PDP (optional)
(-50) - 0C
(-58) - 32 F
Dryer outlet
maximum 80 C
maximum 176 F
Regeneration air inlet
120 - 200 C
248 - 392 F
Regeneration air outlet
55 - 150 C
131 - 302 F
Dryer mix air
maximum 50 C
maximum 122 F
Dryer water out
0 - 50 C
32 - 122 F
Temperature difference, dryer outlet - inlet
maximum 25 C
maximum 45 F
Temperature difference, dryer regeneration air inlet - inlet
100 - 160 C
180 - 288 F
Temperature difference, dryer mix. - inlet
maximum 10 C
maximum 18 F
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Instruction book
Item
Reading (min max)
Reading (min max)
Temperature difference, dryer regeneration inlet - outlet
30 - 80 C
54 - 144 F
Dryer PDP - inlet temperature (optional)
-30 - (-60) C
-22 - (-76) F
Temperature difference, dryer cooling water out
0 - 10 C
0 - 18 F
Other readings
9.2
Item
Reading
Dryer rotation speed
2 - 11 rph
Dryer direction
Anti-clockwise
Settings of safety valves
Settings
9.3
Reference
Value
Value
Low-pressure safety valve
3.7 bar(e)
54 psig
High-pressure safety valve, ZT/ZR 55/75 7.25 bar/105

psi and ZT/ZR 7.5 bar/109 psi
9.3 bar(e)
135 psig
High-pressure safety valve, ZT/ZR 90 7.25 bar/105 psi

and ZT/ZR >7.5 bar/109 psi
11.0 bar(e)
160 psig
Circuit breakers and fuses
50Hz IEC
ZT/ZR 55
Voltage
F21 or Q25
F26
(A)
(A)
Q32 or
F33
FullFeature
MD
(A)
Q32 or
F33
FullFeature
ND
(A)
Q41
or
F42
(A)
F25
(A)
F41
(A)
Proposed
Short circuit
fuse gG/gL current rating
IEC (A)
(In
combination
with
installation of
the prescribed
main fuses)
200 V
127
10.0
10.0
13.0
4.5
20
3x315
50 kA
230 V
111
8.3
10.1
15.0
4.5
16
3x315
50 kA
500 V
52
4.0
4.4
6.3
2.1
3x200
50 kA
690 V
37
2.8
4.2
4.2
1.5
3x200
50 kA
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Instruction book
ZT/ZR 75
Voltage
F21
(A)
Q25
or or
F26
(A)
Q32 or
F33
FullFeature
MD
(A)
Q32 or
F33
FullFeature
ND
(A)
Q41
or
F42
(A)
F25
(A)
F41
(A)
Proposed Short circuit

IEC (A)
(In
combination
with
installation of
the prescribed
main fuses)
200 V
181
14.0
10.0
13.0
4.5
25
3x400
50 kA
230 V
157
12
10.1
15.0
4.5
25
3x400
50 kA
400 V
89
7.0
6.3
8.7
2.6
16
3x315
50 kA
500 V
72
5.5
4.4
6.3
2.1
10
3x315
50 kA
690 V
52
4.1
4.2
4.2
1.5
3x200
50 kA
Voltage
F21
(A)
Q25
Q32 or
or F26 F33
(A)
FullFeature
MD
(A)
Q32 or
F33
FullFeature
ND
(A)
Q41
or
F42
(A)
F25
(A)
F41
(A)

IEC (A)
(In
combination
with
installation of
the
prescribed
main fuses)
200 V
203
14.0
10.0
13.0
4.5
25
2x(3x315)
50 kA
230 V
176
12
10.1
15.0
4.5
25
3x400
50 kA
400 V
102
7.0
6.3
8.7
2.6
16
3x315
50 kA
500 V
82
5.5
4.4
6.3
2.1
10
3x315
50 kA
690 V
59
4.1
4.2
4.2
1.5
3x315
50 kA
ZT/ZR 90
ZR/ZT 55 up to ZR/ZT 90, No motor

Model
134
Voltage
(V)
Q25
F25
or F26 (A)
(A)
Q41 or F41 (A) Q32 or F33

F42 (A)
(A)
Full-Feature
MD
Q32 or F33
(A)
Full-Feature
ND
Short circuit
current rating (In
combination with
installation of the
prescribed main
fuses)
ZR/ZT
55
200 V
10.0
20
4.5
10.0
13.0
50 kA
ZR/ZT
55
400 V
4.7
10
2.6
6.3
8.7
50 kA
ZR/ZT
75
200 V
14.0
25
4.5
10.0
13.0
50 kA
ZR/ZT
75
400 V
7.0
16
2.6
6.3
8.7
50 kA
ZR/ZT
90
200 V
14.0
25
4.5
10.0
13.0
50 kA
2920 1849 00
Instruction book
Model
ZR/ZT
90
Voltage
(V)
Q25
F25
or F26 (A)
(A)
400 V
7.0
16
Q41 or F41 (A) Q32 or F33

F42 (A)
(A)
Full-Feature
MD
2.6
6.3
Q32 or F33
(A)
Full-Feature
ND
Short circuit
current rating (In
combination with
installation of the
prescribed main
fuses)
8.7
50 kA
60Hz IEC
ZT/ZR 55
Voltage
F21
(A)
Q25
Q32 or
or F26 F33
(A)
FullFeature
MD
(A)
Q32 or Q41 or F25

F33
F42
(A)
Full(A)
Feature
ND
(A)
F41
(A)

fuse gG/gL current
IEC (A)
rating (In
combination
with
installation
of the
prescribed
main fuses)
200 V
138
10.5
10.0
13.0
4.8
16
10
3x315
50 kA
220 V
230 V
125
8.3
10.1
15.0
4.8
16
10
3x315
50 kA
380 V
72
4.8
6.3
8.2
2.8
3x315
50 kA
440 V
63
4.5
6.3
7.1
2.8
3x315
50 kA
Voltage
F21
(A)
Q25
or
F26
(A)
Q32 or
F33
FullFeature
MD
(A)
Q32 or Q41 or F25

F33
F42
(A)
Full(A)
Feature
ND
(A)
F41
(A)
Proposed
fuse gG/gL
IEC (A)
Short circuit
current
rating (In
combination
with
installation
of the
prescribed
main fuses)
200 V
183
15
10.0
13.0
4.8
32
10 A
3x400
50 kA
220 V
230 V
166
13.5
10.1
15.0
4.8
25
10 A
3x400
50 kA
380 V
97
7.3
6.3
8.2
2.8
16
6A
3x315
50 kA
ZT/ZR 75
2920 1849 00
135
Instruction book
ZT/ZR 90
Voltage
F21
(A)
Q25 or Q32 or F33

F26
Full(A)
Feature
(A)
Q32 or F33 Q41 or

FullF42
Feature
(A)
ND
(A)
F25
(A)
F41
(A)
Propose
d fuse
gG/gL
IEC (A)
Short circuit
current rating
(In
combination
with
installation of
the
prescribed
main fuses)
200 V
217
15
10.0
13.0
4.8
32
10
2x(3x315 50 kA
)
220 V
230 V
199
13.5
10.1
15.0
4.8
25
10
2x(3x315 50 kA
)
380 V
115
7.3
6.3
8.2
2.8
16
3x315
50 kA
440 V
99
7.1
6.3
7.1
2.8
16
3x315
50 kA
136
Model
Voltage
(V)
ZR/ZT 55
200 V
Q25 or F25 (A) Q41 or F41 (A) Q32 or

F26
F42 (A)
F33 (A)
(A)
FullFeature
MD
Q32 or F33
ND (A)
FullFeature ND
Short circuit
current rating
(In combination
with
installation of
the prescribed
main fuses)
10.5
16
4.8
10
10.0
13.0
50 kA
ZR/ZT 55 220-230 V
8.3
16
4.8
10
10.1
15.0
50 kA
ZR/ZT 55
440 V
4.5
2.8
6.3
7.1
50 kA
ZR/ZT 75
200 V
15.0
32
4.8
10
10.0
13.0
50 kA
ZR/ZT 75 220-230 V
13.5
25
4.8
10
10.1
15.0
50 kA
ZR/ZT 75
440 V
7.1
16
2.8
6.3
7.1
50 kA
ZR/ZT 90
200 V
15.0
32
4.8
10
10.0
13.0
50 kA
ZR/ZT 90 220-230 V
13.5
25
4.8
10
10.1
15.0
50 kA
ZR/ZT 90
6.6
16
2.80
6.3
7.1
50 kA
440 V
2920 1849 00
Instruction book
60Hz CSA/UL
ZT/ZR 55
Voltage
F21
(A)
Q25 or Q32 or
F26
F33
(A)
FullFeature
MD
(A)
Q32 or
F33
FullFeature
ND
(A)
Q41 or
F42
(A)
F25
(A)
F41
(A)
Proposed
Short circuit
fuse LPJ
current rating
CSA/uL (A) (In
combination
with
installation of
the prescribed
main fuses)
460 V
60
4.5
6.3
7.1
2.8
3x200
65 kA
575 V
48
4.0
5.0
5.0
2.3
3x200
65 kA
Voltage
F21
(A)
Q25 or Q32 or
F26
F33
(A)
FullFeature
MD
(A)
Q32 or F33 Q41 or

FullF42
Feature
(A)
ND
(A)
F25 (A) F41

(A)

fuse LPJ
current rating
CSA/uL (A) (In
combination
with
installation of
the prescribed
main fuses)
460 V
80
7.1
6.3
7.1
2.8
12
3x250
65 kA
575 V
64
5.3
5.0
5.0
2.3
10
3x200
65 kA
Voltage
F21
(A)
Q25
or
F26
(A)
Q32 or F33
FullFeature MD
(A)
Q32 or
F33
FullFeature
ND
(A)
Q41 or
F42
(A)
F25 (A)
F41 (A) Proposed

Short circuit
fuse LPJ
current rating
CSA/uL (A) (In
combination
with
installation of
the prescribed
main fuses)
460 V
95
7.1
6.3
7.1
2.8
12
3x250
65 kA
575 V
77
5.3
5.0
5.0
2.3
10
3x250
65 kA
ZT/ZR 75
ZT/ZR 90

Q25 or F25
F26
(A)
(A)
Q41 or
F42 (A)
F41
(A)
Q32 or F33 Q32 or F33

(A)
ND
Full-Feature Full-Feature
ND (A)
Short circuit current

rating (In
combination with
installation of the
prescribed main
fuses)
Model
Voltage
(V)
ZR/ZT 55
460 V
4.5
2.8
6.3
7.1
65 kA
ZR/ZT 55
575 V
4.0
2.3
5.0
5.0
65 kA
ZR/ZT 75
460 V
7.1
12
2.8
6.3
7.1
65 kA
2920 1849 00
137
Instruction book
Q25 or F25
F26
(A)
(A)
Q41 or
F42 (A)
F41
(A)
Q32 or F33 Q32 or F33

(A)
ND
Full-Feature Full-Feature
ND (A)
Short circuit current

rating (In
combination with
installation of the
prescribed main
fuses)
Model
Voltage
(V)
ZR/ZT 75
575 V
5.3
10
2.3
5.0
5.0
65 kA
ZR/ZT 90
460 V
7.1
12
2.8
6.3
7.1
65 kA
ZR/ZT 90
575 V
5.3
10
2.3
5.0
5.0
65 kA
Location of components
See Electrical system for location of components.
9.4
Reference conditions
Contact your Atlas Copco Customer Center for specific data of your machine configuration.
9.5
Limitations
9.6
Compressor data
138
2920 1849 00
Instruction book
10
Pressure equipment directives
PED instructions
ZR/ZT 55 Pack up to ZR/ZT 90 Pack are pressure assemblies of cat. I according to 97/23/EC.
ZR/ZT 55 Full-Feature up to ZR/ZT 90 Full-Feature are pressure assemblies of cat. III according to
97/23/EC.
Parts of article 3.3 of 97/23/EC are subject to good engineering practice.
Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of
article I, section 3.6.
Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC according
to article I, section 3.3.
The following pressure bearing parts are of category higher than I :
Safety valve: Category IV
Design code: AD-Merkbltter, A2
Vessel IMD260: Category III
Design pressure 11 bar(e) (159.54 psig), content 91 l (24.02 US gal / 20.02 Imp gal / 3.19 cu.ft)
Design standard: ASME section VIII div. 1.
2920 1849 00
139
Instruction book
11
Documentation
Declaration of conformity
Typical example of a Declaration of Conformity document
140
2920 1849 00
Instruction book
Declaration of incorporation
Typical example of a Declaration of Incorporation document
2920 1849 00
141
What sets Atlas Copco apart as a company is our conviction

that we can only excel in what we do if we provide the best
possible know-how and technology to really help our customers
produce, grow and succeed.
There is a unique way of achieving that - we simply call it the
Atlas Copco way. It builds on interaction, on long-term
relationships and involvement in the customers process, needs
and objectives. It means having the flexibility to adapt to the
diverse demands of the people we cater for.
Its the commitment to our customers business that drives our
effort towards increasing their productivity through better
solutions. It starts with fully supporting existing products and
continuously doing things better, but it goes much further,
creating advances in technology through innovation. Not for
the sake of technology, but for the sake of our customers
bottom line and peace-of-mind.
No. 2920 1849 00 / 2014 - 12 - Printed in Belgium
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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ZR 55, ZR 75, ZR 90, ZT 55, ZT 75, ZT 90

ZR 55, ZR 75, ZR 90, ZT 55, ZT 75, ZT 90

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

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

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

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

ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................29

LOW LOAD COMPENSATOR..................................................................................................................34

SMARTBOX AND SMARTLINK.................................................................................................... 37

Elektronikon Graphic controller..................................................................................41

DIGITAL OUTPUT CONTACTS................................................................................................................42

CONTROLLER MENU STRUCTURE..........................................................................................................51

INSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS.....................................................................84

QUALITY OF SAFETY COMPONENTS.......................................................................................................96

COOLING WATER REQUIREMENTS.........................................................................................................97

Operating instructions............................................................................................... 103

DURING OPERATION........................................................................................................................ 118

TAKING OUT OF OPERATION..............................................................................................................122

MAINTENANCE WARNINGS................................................................................................................ 123

PREVENTIVE MAINTENANCE SCHEDULE................................................................................................123

SERVICE KITS................................................................................................................................ 124

SERVICE AGREEMENTS.................................................................................................................... 124

SERVICE PLAN............................................................................................................................... 124

MOTOR GREASING.......................................................................................................................... 124

STORAGE AFTER INSTALLATION......................................................................................................... 126

Servicing procedures................................................................................................. 127

AIR FILTER (AF)............................................................................................................................ 127

OIL AND OIL FILTER CHANGE.............................................................................................................127

SAFETY VALVES............................................................................................................................. 129

FAULTS AND REMEDIES....................................................................................................................130

Principal data.............................................................................................................. 132

READINGS ON DISPLAY.................................................................................................................... 132

SETTINGS OF SAFETY VALVES........................................................................................................... 133

CIRCUIT BREAKERS AND FUSES......................................................................................................... 133

REFERENCE CONDITIONS................................................................................................................. 138

Pressure equipment directives................................................................................. 139

General safety precautions

Safety precautions during installation

Precautions during installation

Safety precautions during operation

Precautions during operation

Air cooling filters of the electrical cabinet are not clogged

Safety precautions during maintenance or repair

Precautions during maintenance or repair

General view of ZR 55 up to ZR 90 Pack, ZR 55 up to ZR 90 Full-Feature

Inside view of ZR 55 up to ZR 90 Pack, ZR 55 up to ZR 90 Full-Feature

Front view of ZR 55 up to ZR 90 Pack

Rear view of ZR 55 up to ZR 90 Pack

General view of ZT 55 up to ZT 90 Pack

General view of ZT 55 up to ZT 90 Full-Feature

Front inside view of ZT 55 up to ZT 90 Pack

Rear inside view of ZT 55 up to ZT 90 Pack

Energy recovery, Full-Feature

Energy recovery, Pack

By-pass valve, oil cooler

Oil drain valve, gear casing

High-pressure compressor element

Low-pressure compressor element

Energy recovery system