Instruction Book ZT145

Atlas Copco Stationary Air Compressors
ZT145-10-60/E
Instruction Book
Serial Number:
S 992245 01 v00
Customer:
PEMEX, MEXICO
Copyright
2007,
Atlas
Copco
Airpower
n.v.,
Antwerp,
Belgium.
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book meets the requirements for instructions specified by the
machinery directive 98/37/EC and is valid for CE as well as non-CE labelled
machines
Note: The PED instructions for this machine are included at the end of the book.
www.atlascopco.com
2007-11
Instruction Book
This instruction book describes how to handle and operate the subject machine(s) to ensure safe operation,
optimum working economy and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper
maintenance from the beginning. The maintenance schedule comprises measures for keeping the compressor in
good repair.
Keep the book available for the operator(s) and make sure that the compressor is operated and that maintenance
is carried out according to the instructions. Record all operating data, maintenance work effected, etc. in an
operator's logbook available from Atlas Copco. Follow all applicable safety precautions, amongst others those
mentioned in this book.
Repairs must be carried out by trained personnel from Atlas Copco who can also be contacted for any further
information.
In all correspondence mention the type and the serial number, shown on the data plate.
The company reserves the right to make changes without prior notice.
OWNERSHIP DATA
Compressor type:.............................................................
Unit serial No. compressor: ........................
Air dryer type:...................................................................

Motor type: .......................................................................
Delivery date: ...................................................................
Service Plan:....................................................................
Unit serial No. dryer:...................................

Motor serial No.: .........................................
First start-up date: ......................................
Owner's machine No.: ................................
Selected lubricants
Compressor: ....................................................................
Bearing grease type, electric motor: ................................
Dryer gearbox ..................................................................
Capacity: ....................................................
Printed Matter Nos.

Atlas Copco compressor instruction book: ......................
Atlas Copco compressor parts list: ..................................
Atlas Copco logbook:.......................................................
Atlas Copco air dryer .................................

instruction book: .........................................
Atlas Copco air dryer parts list: ..................
Local Atlas Copco Representative

Name: ..............................................................................
Address:...........................................................................
Telephone: ...................................
Contact persons:
Telex: ...........................................
E-mail address .............................
S 992245 01 v00
Capacity: ....................................................
Service: .......................................................
Parts: ..........................................................
Instruction Book
Important notes :
A) Operation instructions and Spare parts lists of Non-Atlas Copco components
Although any document that was delivered with the part is shipped with the machine, paper documents are often
lost or put aside.
Documentation of parts used in this machine fabricated by other manufacturers than Atlas Copco can best be
found on their internet website. (i.e. flow control products, motors, regulators ).
Most of them have a documentation sub-website where all information can be found.
If you have difficulties to find the information contact your Customer Centre.
B) Paint
If the unit is delivered with :
- customer specified top colour for canopy and/or frame
- other powder coating thicknesses
- semi-offshore coating or offshore painting
Spare parts of these items will be delivered in standard Atlas Copco grey for the canopy and standard black for the
frame. (Spare part numbers of standard parts are printed in the Spare parts list.)
C) Hydrostatic witnessed parts

If the unit is delivered with hydrostatic witnessed parts, spare part numbers of not witnessed standard parts are
printed in the Spare parts list.
To overcome long delays by ordering spare parts, part numbers of hydrostatic witnessed parts will not be
supported.
D) Service Kits
In the Spare parts list only standard Service kits are printed. Service kits of special parts will not be supported.
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Instruction Book
CONTENTS
CONTENTS ................................................................ 4
3 INSTALLATION...................................................33
SAFETY PRECAUTIONS .......................................... 5
3.1
DIMENSION DRAWINGS............................33
1 LEADING PARTICULARS.................................... 8
3.2
INSTALLATION PROPOSALS ....................35
1.1
GENERAL DESCRIPTION............................ 8
3.3
WIRING DIAGRAMS ...................................37
1.2
CONTROL SYSTEM ................................... 10
3.4
PICTOGRAPHS...........................................40
4 OPERATING INSTRUCTIONS .............................41
1.2.1
During unloading ................................... 11
1.2.2
During loading ....................................... 11
4.1
INITIAL START-UP......................................41
AIR FLOW ................................................... 11
4.2
BEFORE STARTING ...................................42
1.4
OIL SYSTEM ............................................... 11
4.3
ROUTINE STARTING..................................42
1.5
COOLING SYSTEM .................................... 11
4.4
1.6
CONDENSATE DRAIN SYSTEM ............... 11
STARTING AFTER EMERGENCY

STOPPING OR SHUT-DOWN ....................42
4.5
DURING OPERATION.................................42
4.6
CHECKING THE DISPLAY .........................43
4.7
MANUAL UNLOADING/LOADING ..............43
4.8
STOPPING ..................................................43
4.9
TAKING OUT OF OPERATION...................43
1.3
2 ELEKTRONIKON REGULATOR ........................ 13

2.1
INTRODUCTION ......................................... 13
2.1.1
Automatic control of compressor

operation ............................................... 13
2.1.2
Protecting the compressor .................... 13
2.1.3
Service warning..................................... 13
2.1.4
Automatic restart after voltage failure ... 13
2.2
5 MAINTENANCE...................................................44
5.1
PREVENTIVE MAINTENANCE SCHEDULE

FOR THE COMPRESSOR...........................44
CONTROL PANEL AND BUTTONS OF

ELEKTRONIKON REGULATOR ................ 14
5.1.1
Regular service operations....................44
2.3
FUNCTION BUTTONS................................ 15
5.1.2
Service kits ............................................45
2.4
SCROLL BUTTONS .................................... 15
5.1.3
Service agreements...............................45
2.5
EMERGENCY STOP BUTTON................... 16
5.1.4
Service plan ...........................................45
2.6
EXTERNAL COMPRESSOR STATUS

INDICATION ............................................... 16
5.2
DRIVE MOTOR GREASING .......................46
5.3
OIL SPECIFICATIONS ................................46
2.7
CONTROL PROGRAMS ............................. 17
5.4
STORAGE AFTER INSTALLATION............46
2.8
CALLING UP MENUS ................................. 18
5.5
SERVICE KITS ............................................46
2.9
MAIN SCREEN MENU ................................ 19
6 SERVICING PROCEDURES...............................47
2.10 STATUS DATA MENU ................................ 19
6.1
AIR FILTER..................................................47
2.11 MEASURED DATA MENU.......................... 21
6.2
OIL AND OIL FILTER CHANGE..................47
2.12 COUNTERS MENU..................................... 22
6.3
SAFETY VALVES ........................................48
2.13 TEST MENU................................................ 22

2.14 MODIFY PARAMETERS MENU ................. 23
2.15 MODIFYING PARAMETERS ...................... 23
7 PROBLEM SOLVING ..........................................49

8 PRINCIPAL DATA...............................................50
8.1
SETTING OF SAFETY VALVE...................50
8.2
SETTING OF OVERLOAD RELAY AND

FUSES.........................................................50
2.18 PROGRAMMING CLOCK FUNCTION ....... 25
8.3
MOTOR SPECIFICATIONS ........................50
2.19 MODIFYING CONFIGURATION SETTINGS28
8.4
ELECTRICAL SPECIFICATIONS................50
2.20 SERVICE MENU ......................................... 29
8.5
COMPRESSOR SPECIFICATIONS............50
2.16 MODIFYING PROTECTION SETTINGS .... 23

2.17 MODIFYING SERVICE PLANS .................. 24
2.21 SAVED DATA MENU .................................. 31
General information ...........................................50
2.22 PROGRAMMABLE SETTINGS................... 31
Performance data ..............................................50
2.22.1 Regulation settings & parameters .......... 31
9 FLOW DIAGRAM ................................................52
2.22.2 Protection settings .................................. 32
10 PRESSURE EQUIPMENT DIRECTIVES ............54
2.22.3 Service plans .......................................... 32
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Instruction Book
SAFETY PRECAUTIONS
To be read attentively and acted accordingly before
installing, operating or repairing the unit.
All responsibility for damage or injury resulting
from neglecting these precautions, or nonobservance of the normal caution and care
required for installation, operation, maintenance
and repair, even if not expressly stated, will be
disclaimed by Atlas Copco.
General precautions
1. The operator must employ safe working practices
and observe all related local work safety
requirements and regulations.
2. If any of the following statements does not
comply with local legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair
work must only be performed by authorised,
trained, specialised personnel.
4. The compressor is not considered capable of
producing air of breathing quality. For air of
breathing quality, the compressed air must be
adequately purified according to local legislation
and standards.
5. Before any maintenance, repair work, adjustment
or any other non-routine checks, stop the
compressor, press the emergency stop button,
switch off the voltage and depressurise the
compressor. In addition, the power isolating
switch must be opened and locked.
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.
Precautions during installation
1. The machine must only be lifted using suitable
equipment in accordance with local 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. 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 minimise the entry of moisture
at the inlet air.
3. Any blanking flanges, plugs, caps and desiccant
bags must be removed before connecting the
pipes.
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4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
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.
The aspirated air must be free of flammable
fumes, vapours and particles, e.g. paint solvents,
that can lead to internal fire or explosion.
Arrange the air intake so that loose clothing worn
by people cannot be sucked in.
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.
No external force may be exerted on the air outlet
valve; the connected pipe must be free of strain.
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 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.
The electrical connections must correspond to
the local 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.
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.
In multiple compressor systems, manual valves
must be installed to isolate each compressor.
Non-return valves (check valves) must not be
relied upon for isolating pressure systems.
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 pressurerelieving device or devices as required.
Pipework or other parts with a temperature in
excess of 80C (176F) and which may be
accidentally touched by personnel in normal
operation must be guarded or insulated. Other
high-temperature pipework must be clearly
marked.
If the ground is not level or can be subject to
variable inclination, consult the Atlas Copco
Customer Centre.
Instruction Book
Precautions during operation
1. 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.
2. 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.
3. Never operate the machine when there is a
possibility of taking in flammable or toxic fumes,
vapours or particles.
4. Never operate the machine below or in excess of
its limit ratings.
5. 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.
6. People staying in environments or rooms where
the sound pressure level reaches or exceeds 90
dB(A) shall wear ear protectors.
7. 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
There are no leaks
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
8. 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.
9. Do not remove any of, or tamper with, the sounddamping material.
10. 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 pressurerelieving device or devices as required.
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Precautions during maintenance or repair

1. Always wear safety glasses.
2. Use only the correct tools for maintenance and
repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken
when the machine has cooled down.
5. A warning sign bearing a legend such as "work
in progress; do not start" shall be attached to
the starting equipment.
6. Persons switching on remotely controlled
machines shall take adequate precautions to
ensure that there is no one checking or working
on the machine. To this end, a suitable notice
shall be affixed to the remote start equipment.
7. Before removing any pressurized component,
effectively isolate the machine from all sources of
pressure and relieve the entire system of
pressure.
8. Never use flammable solvents or carbon
tetrachloride for cleaning parts. Take safety
precautions against toxic vapours of cleaning
liquids.
9. Scrupulously
observe
cleanliness
during
maintenance and repair. Keep dirt away by
covering the parts and exposed openings with a
clean cloth, paper or tape.
10. 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.
11. Whenever there is an indication or any suspicion
that an internal part of a machine is overheated,
the machine shall be stopped but no inspection
covers shall be opened before sufficient cooling
time has elapsed; this to avoid the risk of
spontaneous ignition of the oil vapour when air is
admitted.
12. Never use a light source with open flame for
inspecting the interior of a machine, pressure
vessel, etc.
13. Make sure that no tools, loose parts or rags are
left in or on the machine.
14. 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.
15. 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.
Instruction Book
16. Protect the motor, air filter, electrical and
regulating components, etc. to prevent moisture
from entering them, e.g. when steam-cleaning.
17. Make sure that all sound-damping material, e.g.
on the bodywork and in the air inlet and outlet
systems of the compressor, is in good condition.
If damaged, replace it by genuine Atlas Copco
material to prevent the sound pressure level from
increasing.
18. Never use caustic solvents which can damage
materials of the air net, e.g. polycarbonate bowls.
19. The following safety precautions are stressed
when handling refrigerant:
Never inhale refrigerant vapours. Check that
the working area is adequately ventilated; if
required, use breathing protection.
Always wear special gloves. In case of
refrigerant contact with the skin, rinse the skin
with water. If liquid refrigerant contacts the
skin through clothing, never tear off or
remove the latter; flush abundantly with fresh
water over the clothing until all refrigerant is
flushed away; then seek medical first aid.
20. Protect hands to avoid injury from hot machine
parts, e.g. during draining of oil.
Note :
Some precautions are general and may not apply to
your machine.
Important :
If the compressor air inlet is located inside a
potentially explosive atmosphere, the customer
is aware that increased pressure in the
compressor will decrease auto ignition
temperature of the gas.
Customer is
responsible for checking and accepts full
responsibility for this.
If the compressor air inlet is located outside a
potentially explosive atmosphere, the customer
has to install duct and a gas analyzer in order
to shut down the compressor unit in case gas
is entering the air suction duct. Apparatus
shall be conform the applicable directives and
standards.
If customers installation includes high risk of
falling objects, the customer has to install
cooling air inlet- and outlet ducts.
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Instruction Book
LEADING PARTICULARS
1.1
General description
The ZT145 is a two-stage, air-cooled, ex-proof screw

compressor unit, which delivers oil-free and pulsationfree air. The compressor is driven by an electric motor.
The electric motor is flanged to the gear casing by
means of a coupling housing. The motor/gear casing
unit is supported on the frame by vibration dampers.
The unit is suitable for operation in ex-proof zone 2,
Group IIA, T2. Therefore temperature and pressure
transmitters, make Rosemount, are mounted and
control push buttons are mounted in an EEX(e)
housing. Furthermore an EEx compressor drive motor
and fan motor is installed.
The compressor is enclosed in a sound-insulated

bodywork and includes mainly:
- Air filter
-
Low-pressure compressor element
Intercooler
High-pressure compressor element
Aftercooler
Water separators
Flanged electric drive motor
Drive coupling
Gear casing
Elektronikon control system
Low and high pressure safety valves
5
6
7
1. Sound-insulated bodywork
5. Compressed air outlet connection
2. Service door to interior
6. Condensate drain outlet connections of inter/aftercooler
3. Elektronikon regulator (behind cover)
7. Earthing boss at each diagonally opposite side of the base

frame
4. Control panel with push buttons
Fig. 1 Outside view
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Instruction Book
1
2
6
7
8
9
10
11
12
5
13
1. Air inlet silencer
8. Load/no-load throttle valve
2. Air filter
9. Condensate drain collector, aftercooler
3. Drive motor and coupling housing
10. Condensate drain collector, intercooler
4. Gear casing breather
11. Low-pressure compressor element
5. Gear casing
12. High-pressure compressor element
6. Condensate trap, aftercooler
13. Silencer
7. Condensate trap, intercooler

Fig. 2 Inside views
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Instruction Book
1.2
Control system
The Elektronikon regulator keeps the net pressure

within pre-programmed set points by automatically
loading and unloading the compressor depending on
the air consumption.
The Elektronikon checks all trip and alarm conditions

for a healthy status before start-up and during
operation. Trip conditions initiate a compressor unit
stop and lock the compressor into manual mode.
M2
FN
SVh
AV
MTa
Ca1
Ca
Ci
Ci1
WDa
UV TV UA
Co Y1
23
ER
AF
Elektronikon
F1
F3
AS
US
AIR INLET
AIR FLOW
OIL FLOW
AIR OUTLET
F2
OF
El
CV
SVl
Eh
During loading
MTi
OP
AF Air filter
AS Silencer
AV Air outlet valve (customers
installation)
Ca Aftercooler
Ca1 Pre-aftercooler
El Low-pressure compressor
element
ER Elektronikon regulator
FN Cooling fan
MTa Condensate trap; aftercooler
MTi Condensate trap; intercooler
WDi
US Blow-off silencer
UV Unloading valve
WDa Condensate drain collector
with float valve; aftercooler
WDi Condensate drain collector
with float valve; intercooler
Y1 Loading solenoid valve
Ca Aftercooler
M2 Fan motor
Ci1 Pre-intercooler
OF Oil filter
1 Chamber
OP Oil pump
2 Plunger
Ci Intercooler
Co Oil cooler
SVh High-pressure safety valves
CV Check valve
SVl Low-pressure safety valve
Eh High-pressure compressor
element
TV Load/no-load valve
3 Chamber
4 Diaphragm
UA Unloader
Fig. 3 Regulating system
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10
Instruction Book
1.2.1 During unloading

(see Fig. 3)
If the air consumption is less than the air delivery of
the compressor, the net pressure increases. When
the net pressure reaches the upper limit of the
working pressure (unloading pressure), solenoid
valve (Y1) is de-energized. The plunger of solenoid
valve (Y1) moves by spring force shutting off the
supply of control air to unloader (UA):
1. Control pressure is vented from chamber (1) of
unloader (UA) through solenoid valve (Y1) and
chamber (3) towards the inlet of compressor
element (El).
2. As there is no longer any pressure difference
between chambers (1 and 3), plunger (2) returns
by spring force keeping throttle valve (TV) closed
and unloading valve (UV) open.
3. Compressed air between check valve (CV) and
valve (UV) is blown off through silencer(s) (US).
Check valve (CV) closes.
4. As vacuum prevails in intercooler (Ci), diaphragm
(4) switches to the left.
Air delivery is stopped (0%), the compressor runs
unloaded.
1.2.2 During loading

(see Fig. 3)
When the net pressure decreases to the lower limit of
the working pressure (loading pressure), solenoid
valve (Y1) is energized. The plunger of solenoid
valve (Y1) moves against spring force opening the
supply port of control air to unloader (UA):
1. Atmospheric pressure is allowed through solenoid
valve (Y1) to chamber (1) of unloader (UA). As
this pressure is higher than the pressure in
chamber (3), throttle valve (TV) starts opening.
2. Intercooler pressure is building up causing
diaphragm (4) to switch to the right. As the
pressure difference between chambers (1 and 3)
increases, plunger (2) moves further against
spring force until throttle valve (TV) is fully open
and unloading valve (UV) closed.
Air delivery is resumed (100%), the compressor runs
loaded
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1.3
Air flow
(see Fig. 4)
Air drawn through the inlet (pre-) filter (AF) is
compressed in low-pressure compressor element (El)
and discharged via silencer (AS) to pre-intercooler
(Ci1) and intercooler (Ci). The cooled air is further
compressed in high-pressure compressor element
(Eh) and discharged through silencer (AS) to preaftercooler (Ca1) and aftercooler (Ca). A check valve
(CV) is provided downstream of the silencer (AS).
The compressed air leaves the compressor unit via
the air outlet (AO).
1.4
Oil system
(see Fig. 4)
Oil is circulated by the oil pump (OP) from the sump
of the gear casing (GC) through air-cooled oil cooler
(Co) and the cooling jackets of the low-pressure and
high-pressure compressor elements (El and Eh) and
oil filter (OF) towards the bearings and timing gears.
Oil by-pass valves (OBV) open if the oil pressure
should rise above a given value.
1.5
Cooling system
(see Fig. 4)
The compressors are fitted with oil cooler (Co),
intercoolers (Ci1 and Ci) and aftercoolers (Ca1 and
Ca). The coolers are air-cooled, the cooling air is
generated by fan (FN).
1.6
Condensate drain system
(see Fig. 4)
Two moisture traps are installed: one downstream of
the intercooler (MTi) to prevent condensate from
entering compressor element (Eh) and one
downstream of the aftercooler (MTa) to prevent
condensate from entering the air outlet pipe.
The two moisture traps (MTi and MTa) are provided
with a condensate drain collector with float valve
(WDi and WDa) in order to drain condensate
automatically. The condensate can also be drained
by means of a manual by-pass valve.
11
Instruction Book
ER
AF
AS
AO
BOS
Ca
Ca1
Ci
Ci1
Co
CV
El
AF
TV
OF
OBV
Eh
El
OP
AS
AS
GC
CV
OBV
Ca1
SVh
MTa
Ci1
Ci
Ca
Co
MTi
WDi
WDa
AO
FN
Fig. 4 Flow diagram
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SVl
Air inlet (pre-) filter

Silencer
Air outlet
Blow-off silencer
Aftercooler
Pre-aftercooler
Intercooler
Pre-intercooler
Oil cooler
Check valve
Low-pressure
compressor element
Eh
High-pressure
compressor element
ER
Elektronikon regulator
FN
Fan air coolers
GC
Gear casing
MTa Moisture trap,
aftercooler
MTi Moisture trap,
intercooler
OBV Oil circuit by-pass
valve
OF
Oil filter
OP
Oil pump
SVh High-pressure safety
valve
SVl
Low-pressure safety
valve
TV
Throttle control valve
WDa Condensate drain
collector with float
valve, aftercooler
WDi Condensate drain
collector with float
valve, intercooler
12
Instruction Book
ELEKTRONIKON REGULATOR
2.1
Introduction
Control panel
In general, the Elektronikon regulator has following

functions:
- Automatic control of the compressor
- Protecting the compressor
- Monitoring components subject to service
- Automatic restart after voltage failure (made
inactive)
2.1.1 Automatic control of compressor

operation
The regulator maintains the net pressure between
programmable limits by automatically loading and
unloading the compressor.
A number of programmable settings, e.g. the
unloading and loading pressures, the minimum stop
time and the maximum number of motor starts are
taken into account.
The regulator stops the compressor whenever
possible to reduce the power consumption and
restarts it automatically when the net pressure
decreases. In case the expected unloading period is
too short, the compressor is kept running to prevent
too short standstill periods.
Warning
A number of time-base automatic start/stop
commands may be programmed. Take into account
that a start command will be executed (if
programmed and activated), even after manually
stopping the compressor.
2.1.2 Protecting the compressor

Shut-down and motor overload
Several temperature and pressure sensors are
provided on the compressor.
If one of these
S 992245 01 v00
measurements exceeds the programmed shut-down

level, the compressor will be stopped. This will be
indicated on the display (1) and general alarm LED
(2) will blink.
The compressor will also be stopped in case of
overload of the compressor drive motor.
Remedy the trouble and reset the message.
Before remedying, consult the Safety precautions.
See also the Status data menu in section 2.10.
Shut-down warning
A shut-down warning level is a programmable level
below the shut-down level.
If one of the measurements exceeds the
programmed shut-down level, a message will appear
on the display (1) and general alarm LED (2) will light
up to warn the operator that the shut-down warning
level is exceeded.
The message disappears as soon as the warning
condition disappears.
2.1.3 Service warning

A number of service operations are grouped (called
Level A, B, C, ...). Each level has a programmed
time interval. If a time interval is exceeded, a
message will appear on display (1) to warn the
operator to carry out the service actions belonging to
that level.
2.1.4 Automatic restart after voltage

failure
The regulator has a built-in function to automatically
restart the compressor if the voltage is restored after
voltage failure. For compressors leaving the factory,
this function is made inactive. If desired, the function
can be activated. Consult the Atlas Copco Customer
Centre.
Warning
If activated and provided the module was in the
automatic operation mode, the compressor will
automatically restart if the supply voltage to the
module is restored within a programmed time period.
The power recovery time (the period within which the
voltage must be restored to have an automatic
restart) can be set between 1 and 3600 seconds or to
Infinite.
If the power recovery time is set to Infinite, the
compressor will always restart after a voltage failure,
no matter how long it takes to restore the voltage.
A restart delay can also be programmed, allowing
e.g. two compressors to be restarted one after the
other.
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Instruction Book
2.2
Control panel and buttons of Elektronikon regulator

2
10
(S2)
1
(S11)
9
(S12)
5
(S13)
5
(S14)
5
(S15)
3
(S16)
4
(S17)
3
(S18)
Fig. 5 Elektronikon regulator (behind window) and external push buttons with emergency stop button
Parts and functions (Only the external push buttons should be used)
Push
buttons
Reference
2
3
4
5
6
7
9
10
Designation
Function
Push button to start the compressor. LED (8) lights up

indicating that the electronic regulator is operative (in
S11
Start button
automatic operation). The LED goes out after unloading
the compressor manually.
Indicates messages concerning the compressor operating
Display
condition, a service need or a fault. See sections "Status
data submenu" and "Service submenu".
Buttons to scroll upwards or downwards through the
S16-S18
Scroll buttons
display.
Button to select the parameter indicated by a horizontal
S17
Tabulator button
arrow. Only the parameters followed by an arrow pointing
to the right are accessible for modifying.
S13-S14-S15 Function buttons F1-F2-F3 Buttons to control and program the compressor.
Voltage on LED
Indicates that the voltage is switched on.
Is lit if a shut-down warning condition exists.
General alarm LED
Flashes if a shut-down condition exists, if an important
sensor is out of order or after an emergency stop.
Indicates that the electronic regulator is automatically
controlling the compressor: the compressor is loaded,
Automatic operation LED
unloaded, stopped and restarted depending on the air
consumption and the limitations programmed in the
regulator.
S12
Stop button
Push button to stop the compressor. LED (8) goes out.
Push button to stop the compressor immediately in case of
S2
Emergency stop button
emergency. After remedying the trouble, unlock the button.
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Instruction Book
2.3
Function buttons
The buttons 5 (F1, F2, F3) are used:

- To manually load/unload the compressor
- To call up or to program settings
- To reset an active motor overload, shut-down
or service message or an emergency stop
- To access all data collected by the regulator
10
F1
F2
F3
The functions of the buttons vary depending on the

displayed menu. The actual function is indicated
on the bottom line of the display just above the
relevant button. The most common functions are
listed below:
Designation
Function
Add
To add compressor start/stop commands (day/hour)
Back
To return to a previously shown option or menu
Cancel
To cancel a programmed setting when programming parameters
Delete
To delete compressor start/stop commands
Extra
To find the module configuration of the regulator
Help
To find the Atlas Copco internet address
Limits
To show limits for a programmable setting
Load
To load the compressor manually
Main Screen
To return from a menu to the main screen
Menu
Starting from the main screen, to have access to submenus
Menu
Starting from a submenu, to return to a previous menu
Modify
To modify programmable settings
Program
To program modified settings
Reset
To reset a timer or message
Return
To return to a previously shown option or menu
Unload
To unload the compressor manually
2.4
Scroll buttons
The buttons 3 ( , ) allow the operator to scroll

through the display.
As long as a downwards pointing arrow is shown at
the utmost right position of the display, the scroll
button with the same symbol can be used to see
the next item.
As long as an upwards pointing arrow is shown at
the utmost right position of the display, the scroll
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button with the same symbol can be used to see the

previous item.
When the scroll button is kept pressed, the scrolling is
continued.
10
F1
F2
F3
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Instruction Book
2.5
Emergency stop button
10
In case of emergency, press button (10) to stop the
compressor immediately.
2.6
Warning :
Before starting any maintenance or repairs, wait until
the compressor has stopped and open the isolating
switch (= customer's part of installation) to switch off
the voltage to the compressor.
Open the manual condensate drain by-pass valves in
order to depressurize the air system of the
compressor unit.
Apply all relevant Safety precautions.
External compressor status indication
Terminal strip (1X7-Fig. 6) is provided with auxiliary contacts for

external indication of:
Relay/
comp.
Indication
Terminals
Max.
on strip
load
1X7
11 - 12
10A/230VAC
Automatic operation
K07
General warning
K08
13 - 14
10A/230VAC
General shut-down
K09
15 - 16
10A/230VAC
Compressor loaded
K11
17 - 18
10A/230VAC
Compressor running
K13
19 - 20
10A/230VAC
Starter compressor motor
K13
21 - 22
10A/230VAC
Starter fan motors
K13
23 - 24
10A/230VAC
Fanmotors running
K15
25 - 26
10A/230VAC
U1
T1
T2
1X5
K11
K13
K14
K15
Stop the compressor and switch off the voltage before

connecting external equipment.
F1/2
Fuse links, supply 440V/60Hz transformer T1
F3/4/5
Circuit breakers, control circuit
F10
Circuit breaker, power supply
K11
Auxiliary relay, loading
K13
Auxiliary relay, compressor motor starter
K15
Auxiliary relay, fan motor starters
T1
Transformer 440 / 115V for control circuit
T2
Transformer 115 / 24V
U1
Power supply 24VDC for transmitters
1X0
Terminal strip 440V/60Hz for power supply
1X3
Earth rail
1X4
Terminal strip 115V/60Hz for control circuit
1X5
Terminal strip 24V/60Hz for control circuit
1X6
Terminal strip 24VDC for Elektronikon module
1X7
Terminal strip for remote contacts
1 X 11
Terminal strip 24VDC for supply transmitters
1 X 12
Terminal strip 24VDC for transmitters
1 X 13-14
Terminal strip PT100 for temperature sensors
1 X 16-18
Terminal strip 24VDC for digital inputs
1X16
1X11
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1X12
1X18
1X5
1X13
1X14
1X4
1X6
1X7
1X0
1X3
Fig. 6 Electric cabinet
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Instruction Book
2.7
Control programs
Description
In order to facilitate programming and controlling the compressor, menu-driven programs are implemented in the
electronic module.
A simplified menu flow is shown in Fig. 7.
Fig. 7 Menu flow (typical example)
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Main menu
Program
Function
Main screen
Shows in short the operation status of the compressor. It is the gateway to all functions.
Calling up the status of the compressor protection functions:
Status data
- Shut-down
- Shut-down warning
- Service warning
- Warning
Resetting of a shut-down, motor overload and service condition.
Calling up:
Measured data
Actually measured data

The status of a number of inputs
Calling up the:
Counters
Test
Running hours
Regulator (module) hours
Number of motor starts
Display test.
Modifying the settings for:
Modify
parameters
Parameters ( e.g. loading and unloading pressures)

Protections (e.g. temperature shut-down level)
Service plans (timers for service plans)
Clock functions (automatic compressor start/stop/pressure band commands
Configuration (time, date, display language, )
Service
Calling up service plans and resets the timers after carrying out the service actions
belonging to a service plan.
Saved data
Calling up the saved data: last shut-down, last emergency stop data
Unload/Load
Loads and unloads the compressor manually
2.8
Calling up menus
Description
10
F1
F2
F3
When the voltage is switched on, the Main screen is shown automatically.
Example of Main Screen:
Compressor outlet
.
Automatically Loaded
Menu
F1
7.5 bar
F2
Unload
F3
After pressing the Menu (F1) button, the option Status data will be followed by a horizontal arrow:
Either press the tabulator button (4) to select this menu,
Or use the arrow down button (3) until the desired submenu is followed by a horizontal arrow and then press the
tabulator button (4) to select this menu.
The arrow down button (3) can be used for a quick look at the actual compressor status.
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Instruction Book
2.9
Main screen menu
Function
10
F1
F2
F3
The Main screen menu shows the status of the compressor operation and is the gateway to all functions
implemented in the regulator.
Procedure
The Main screen is shown automatically when the voltage is switched on.
If the arrow or function buttons (3, 4 and 5) are not used for some minutes, the regulator will automatically return to
the Main screen.
Whenever displayed on a submenu screen, press the Mainscreen (F1) button to return to the Main screen.
Example of Main screen:
Compressor outlet
.
Automatically Loaded
Menu
F1
7.5 bar
Unload
F3
F2
The display indicates:

The name of the sensor and its actual reading
Messages regarding the compressor operating condition
Just above the function keys (3), the actual functions of these keys
2.10 Status data menu

Warning: Before starting any maintenance or repairs, press the stop button (9), wait until the compressor has
stopped, press the red emergency stop button (10) and open the isolating switch (customer's part of
installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.
Function
10
F1
F2
F3
The Status data submenu gives information regarding the status of the compressor protection functions (shutdown, shut-down warning and service warning) and allows resetting of a shut-down, motor overload and service
condition.
Procedure
Starting from the Main screen (see Main screen menu):
Press the button Menu (F1): the option Status data will be followed by a horizontal arrow.
Press the tabulator button (4).
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No message exists
General alarm LED (7) -Fig. 5 is out and the message on the display will indicate that all conditions are normal:
All conditions are OK
Menu
F1
Help
F2
F3
A shut-down message exists

In case the compressor is shut down, LED (7) -Fig. 5 will blink.
In case of a shut-down due to too high a temperature at the outlet of the compressor element:
Element Outlet
Shutdown
Menu***
F1
114C
Maximum
Help
F2
110C
***Reset
F3
The indicators (***) are blinking. The screen shows the actual reading and the shut-down setting.
It remains possible to scroll through other menus, e.g. to check the values of other parameters.
When returning to the Status data menu, the option Shutdowns will blink. This option can be selected by
pressing the tabulator key (4) to return to the above shut-down screen.
Shut-down reset
Switch off the voltage and remedy the trouble. After remedying and when the shut-down condition has
disappeared, switch on the voltage and press the key Reset (F3).
Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor by means of
start button (1).
A shut-down warning message exists
A shut-down warning level is a programmable level below the shut-down level.
If a shut-down warning exists, LED (7) -Fig. 5 is alight. The Main screen will change into a screen similar to the
one below:
Compressor outlet
***
Menu***
F1
7.0 bar
Shutdown Warning
F2
***
***Unload
F3
The message Shutdown Warning appears.

Press the key Menu (F1) and the tabulator key (4) to select the Status data menu; the option Protection is
blinking.
Scroll to this option and select it by pressing the tabulator key (4). A screen similar to the one below appears:
Element 1 Outlet
.
Shutd Warn Maximum
Menu***
F1
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103 C
F2
100C
***
F3
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Instruction Book
The screen indicates that the temperature at the outlet of compressor element 1 exceeds the programmed shutdown warning level.
If necessary, stop the compressor by means of stop button (9) and wait until it has stopped.
Switch off the voltage, inspect and remedy.
The warning message will disappear automatically as soon as the warning condition disappears.
A service warning exists
LED (7) -Fig. 5 is alight. The Main screen will change into a screen similar to the one below:
Compressor Out
7.0 ar
*Service required*
Menu***
F1
***Unload
F3
F2
The indicators (***) are blinking and the service-warning message appears.
Press the key Menu (F1) and the tabulator key (4) to select the Status data menu: the option Service is
blinking.
Scroll to this option and select it by pressing the tabulator key (4); two options may blink:
o Inputs: if the programmed service level of a component is exceeded (e.g. the maximum pressure drop of
the air filter).
o Plans: if a service plan interval is exceeded.
Stop the compressor and switch off the voltage.
In case the service message was referring to Inputs (air filter): replace the filter, switch on the voltage, scroll in
the Status data menu to Inputs and press the Reset key to reset the service message.
In case the service message was referring to Plans: carry out the service actions related to the indicated
plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See Service menu.
2.11 Measured data menu

Control panel
10
F1
F2
F3
Function
To call up information regarding the actually measured data and the status of some inputs such as the motor
overload protection. Consult the menu flow in section Control programs.
Procedure
Press the key Menu (F1).
Press the arrow down key (3) until Measured data is followed by a horizontal arrow.
Activate the menu by pressing the tabulator key (4).
By pressing the scroll keys (3), a number of actually measured data can be found.
If one of the sensors is linked to a shut-down, service or warning function, both the actually measured value as
well as the corresponding shut-down, warning or service level can be called up by pressing key (4).
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Instruction Book
2.12 Counters menu

Control panel
10
F1
F2
F3
Function
To call up:
The running hours
The loaded hours
The number of motor starts
The number of hours the regulator (module) has been under tension
The number of load cycles
Procedure
Press the arrow down key (3) until Counters is followed by a horizontal arrow.
Press the tabulator key (4) to activate the menu.
By pressing the arrow key (3), the above-mentioned data can be found.
Example of a Counters screen
Running hours
Loaded hours
Motor starts
Menu
F1
2455 hrs
1973 hrs
945 number
F2
F3
2.13 Test menu

Control panel
10
F1
F2
F3
Function
To carry out a display test, i.e. to check whether the display and LEDs are still intact.
Procedure
Press the Menu (F1) key.
Press arrow down key (3) until Test is followed by a horizontal arrow.
The option Display test will be followed by a horizontal arrow.
To test the display, press the key (4). During testing, the regulator will generate a series of patterns on the
display which enable the operator to check that each pixel still functions normally; the LEDs are lit at the same
time.
Press the Menu key (F1) to return to the submenu.
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2.14 Modify parameters menu

Function
To modify a number of programmable settings:
Parameters (see section Modifying parameters).
Protections (see section Modifying protections).
Service plan settings (see section Modifying service plan settings).
Clock function settings (see section Modifying clock function settings).
Configuration settings (see section Modifying configuration settings).
2.15 Modifying parameters

Control panel
10
F1
F2
F3
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
Press the arrow down key (3) until Modify parameters is followed by a horizontal arrow.
The first item Parameters will be followed by a horizontal arrow.
Press the tabulator key (4): the first items and their settings will appear.
Press the arrow down key (3) until the parameter to be modified is followed by a horizontal arrow.
Modifying the loading pressure setpoint
If desired, the operator can program two pressure bands (Loading pressure/Unloading pressure and Loading
pressure 2/ Unloading pressure 2).
Consult the section Procedure to select Loading pressure.
The screen shows the current setting. To modify this setting, press the key Modify (F2); the setting will blink.
The key Limits (F2) can be used to find out the limitations for the parameter.
Use the scroll keys (3) to change the setting.
Press the key Program (F1) to program the new value or the key Cancel (F3) to cancel the modification
operation.
The procedure to modify other parameters pressure is similar.
Note: The regulator will not accept new values beyond the limitations. Press the key Limits to check the
limitations for the parameter. Consult Programmable settings for the most important settings.
2.16 Modifying protection settings

Control panel
10
Function
To modify protection settings:
F1
F2
F3
Shutdown, e.g. for the compressor element outlet temperature
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Instruction Book
Shutdown warning, e.g. for the compressor element outlet temperature
Service warning, e.g. for the maximum pressure drop of the air filter
To check various compressor conditions, e.g. the status of the emergency stop button. Some parameters cannot
be modified.
Procedure
Press the Menu (F1) key.
Press the arrow down key (3) until Protections is followed by a horizontal arrow.
Press the tabulator key (4): the first items will appear.
Press the arrow down key (3) until the item to be modified is followed by a horizontal arrow and press the
tabulator key (4).
Modifying settings for the compressor element temperature
Consult the section Procedure to select the parameter Element 1 outlet.
The screen (see example below) shows the current temperature on the first line and the shut-down setting on
the third line. To modify the setting, press the Modify (F2) key; the setting will flash.
The Limits (F2) key can be used to find out the limits for the parameter.
Use the scroll keys (3) to change the setting.
Press Program (F1) to program the new value or Cancel (F3) to cancel the modification operation.
The screen (see example below) shows a horizontal arrow indicating that the shut-down warning value can be
modified (the procedure is similar to the description above).
The procedure to modify other items is similar. For some settings, a delay can be programmed.
Example of the screen
Element 1 Outlet
.
Shutdown
Menu
F1
178C
Maximum
Modify
F2
235C
F3
Note: The regulator will not accept new values beyond the limitations. Press the key Limits to check the
limitations for the parameter. Consult Programmable settings for the most important settings.
2.17 Modifying service plans

Function
To modify the hour intervals for the service levels.
Service plans
The service actions to be carried out are grouped in plans called Service level A, B, C or D. When reaching an
interval, a message will appear on the screen indicating which Service plans are to be carried out.
Note: Always consult your Atlas Copco Customer Centre in case any timer should be changed. The intervals
must not exceed the programmed nominal values.
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Instruction Book
2.18 Programming clock function

Control panel
10
F1
F2
F3
Function
To program:
Time-based start/stop commands for the compressor
Time-based change-over commands for the net pressure band
Programming start, stop and pressure band commands
In this example, the compressor will be programmed as follows:
On Monday at 06:15 starting in pressure band 1
On Friday at 18:00 changing over to pressure band 2
On Saturday at 18:00 stopping
Activate the menu by pressing tabulator key (4).
Use the arrow down key (3) to scroll until the option Clock function is followed by a horizontal arrow.
Activate the menu by pressing tabulator key (4); following screen appears:
Clock Function
.
.
Menu
F1
Not activated
Modify
F2
Delete
F3
Press the tabulator key (4), following screen appears:

Monday
Tuesday
Wednesday
Menu
F1
F2
Delete
F3
Use the scroll keys (3) until the day on which a command must be programmed is followed by a horizontal
arrow. Press the tabulator key (4); following screen appears:
--:---:---:-Menu
F1
---------------------------------------------------------------Modify
F2
Delete
F3
Press the key Modify (F2). The first two dashes will flash. Use the scroll keys (3) to enter 06. Press the
tabulator key (4) to jump to the following two dashes. Use the scroll keys to enter 15. Press the tabulator key
to jump to the row of dashes. Use the scroll keys to enter the command Start Compressor.
Press the key Program to program the command : 06:15 Start Compressor.
Press the arrow down key (3): the horizontal arrow indicates that the second line is accessible. Press the key
Modify and modify this line in a similar way to the following command: 06:15 Pressure Band 1.
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Instruction Book
Press the key Menu (F1) and scroll to Friday:
Thursday
Friday
Saturday
Menu
F1
F2
Delete
F3
Programming the command to change over at 18 oclock to Pressure Band 2 is carried out in a similar way as
described above.
Press the key Menu (F1) and scroll to Saturday. Programming the command 18:00 Compressor Stop is
carried out in a similar way as described above.
Activating/deactivating the timer
The timer can only be activated if at least one start/stop command is programmed.
Starting from the Main screen, press the key Menu (F1).
Use arrow down key (3) until the option Modify Parameters is followed by a horizontal arrow.
Press the tabulator key (4) to activate the menu.
Use the arrow down key until the option Clock Function is followed by a horizontal arrow, press the tabulator
key (4), following screen appears:
Clock Function
Not activated
.
Menu
F1
Modify
F2
Delete
F3
Press the key Modify, Not Activated starts blinking.

Press the arrow down key (3) Not Activated changes in Activated.
Press the key Program.
Note: It is necessary to program the start/stop commands in successive order time wise. Program the commands
from Monday till Sunday, e.g.:
07.30 Start Compressor
07.30 Pressure Band 1
08.30 Pressure Band 2
18.00 Stop Compressor
Make sure that the timer function is activated (Activated). If not, the programmed start/stop commands will
not be executed.
The timer can be deactivated again. In this case, the programmed start/stop commands will not be
executed (but remain in the memory of the regulator).
Modifying a command
Suppose the command to stop the compressor on Saturday 18:00 is to be modified, i.e. stopping at 17 o'clock
instead of 18 o'clock.
Starting from the Main screen, press the key Menu (F1), press the arrow down key (3) until the option Modify
Parameters is followed by a horizontal arrow.
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Use the arrow down key (3) to scroll until the option Clock Function is followed by a horizontal arrow. Press the
tabulator key (4), following screen appears:
Clock Function
Not activated
.
Menu
F1
Modify
F2
Delete
F3

Monday
Tuesday
Wednesday
Menu
F1
F2
Delete
F3
Scroll through the display until Saturday is followed by a horizontal arrow. Press the tabulator key (4).
If necessary, scroll through the commands until the command to be modified is followed by a horizontal arrow.
Press the key Modify, the first two digits of the command start blinking. Modify as required using the scroll
keys, i.e. in the example above change 18 into 17 using the arrow up key (3).
If necessary, press the tabulator key (4) to go to the next field to be modified, the minutes indication and the
start/stop/pressure band indication.
Press the key Program to program the new command or the key Cancel to quit without reprogramming.
Adding a command at the end of an existing list
Starting from the Main screen, press the key Menu (F1), press the arrow down key until the option Modify
Use the arrow down key (3) to scroll until the option Clock Function is followed by a horizontal arrow. Press
the tabulator key (4), following screen appears:
Clock Function
Not activated
.
Menu
F1
Modify
F2
Delete
F3
Suppose the command to stop the compressor at 18:00 must be added to the list of Monday.
Monday
Tuesday
Wednesday
Menu
F1
F2
Delete
F3
Scroll through the display until Monday is followed by a horizontal arrow. Press the tabulator key (4).
Scroll through the compressor start/stop/pressure band commands until the first empty command line is
indicated by the horizontal arrow.
Press the key Modify; the first two digits start blinking. Enter 18:00 Compressor Stop using the scroll keys (3)
to modify a field and the tabulator key (4) to jump from one field to another.
Press the key Program to program the new command or the key Cancel to quit without reprogramming.
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Adding a command between two existing commands
Suppose the command 17:00 Pressure Band 2 must be added to the following list:
06:00 Start Compressor
06:00 Pressure Band 1
18:00 Stop Compressor
The regulator does not allow entering a new command, which is situated before the last command in the list time
wise.
Scroll through the display until the command before which the new command must be entered is followed by a
horizontal arrow (in the example above: 18:00 Stop Compressor) and press the key Modify.
Change this command to the new command (in the example above 17:00 Pressure Band 2)
Press the arrow down key (3) and add the last command of the list (in the example above 18:00 Stop Compressor
and press the key Program.
Deleting a command
Starting from the Main screen, press the key Menu (F1), press the arrow down key until the option Modify
Use the scroll keys (3) to scroll until the option Clock Function is followed by a horizontal arrow. Press the
tabulator key (4), following screen appears:
Clock Function
Not activated
.
Menu
F1
Modify
F2
Delete
F3
Deleting all commands

Press the key Delete in the screen above. A question to confirm the deleting operation will appear.
Deleting all commands of a specific day
Scroll through the display until the desired day is followed by a horizontal arrow. Press the key Delete, a
question to confirm the deleting operation will appear.
Deleting a specific command
Scroll through the display until the command to be deleted is followed by a horizontal arrow. Press the key
Delete, a question to confirm the deleting operation will appear.
2.19 Modifying configuration settings

Control panel
10
F1
F2
F3
Function
To modify a number of parameters. Consult the menu flow in section Control programs.
Procedure
Press the arrow down key (3) until Modify parameters is followed by an arrow pointing to the right.
Press the arrow down key (3) to scroll until Configuration is followed by a horizontal arrow.
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Activate the menu by pressing tabulator key (4): the first item Time will appear. If another option is desired,
scroll through the display until the option is followed by a horizontal arrow. Select the option by pressing the
tabulator key (4).
In case of the option Time, the second line on the screen indicates the actual setting, e.g. 14:30. To modify
this setting, press the key Modify (F2); the first field 14 will blink.
Use the scroll keys (3) to change the setting, then press the tabulator key (4) to go to the next field 30. The
setting of this field can now be modified using the scroll keys (3).
Press the key Program (F1) to program the new value or the key Cancel (F3) to cancel the modification
operation (the original value will be retained).
The procedure to modify other parameters is similar.
Programming compressor control modes
The compressor can be controlled locally, remotely or via a local area network (LAN).
Procedure
Activate the menu Configuration as described above.
The first option shown is Time, scroll through the display until the option CCM is indicated and press the
Modify key. Following screen appears:
.
CCM
.
Program
F1
Local Control
Cancel
F3
F2
Local Control is blinking, use the scroll keys (3) to select the desired control mode.
Press the key Program to program the new control mode or Cancel to quit without reprogramming.
2.20 Service menu

Control panel
10
F1
F2
F3
Function
To reset the service plans which are carried out.
To check when the next service plans are to be carried out.
To find out which service plans were carried out previously.
Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a number of
service actions to be carried out at the time intervals programmed in the Elektronikon regulator.
When a service plan interval is reached, a message will appear on the screen, see section Status data.
After carrying out the service actions related to the indicated levels, the timers are to be reset.
Example
Service plans
Intervals
Service plan A
Every 4000 running hours
Service plan B
Service plan C
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Service actions according to
Intervals
Service plan A
4000 running hours
Service plan A and B
8000 running hours
Service plan A
12000 running hours
Service plan A, B and C
16000 running hours
...
...
Procedure
Press the arrow down key (3) until Service is followed by a horizontal arrow.
A screen similar to the one below appears:
Service Timer
Running Hours
.
Menu
F1
F2
7971 hrs
Reset
F3
The screen shows that the total compressor running time is 7971 hours.
Next Timer
Level
.
Back
F1
F2
AB
8000 hrs
Reset
F3
The screen shows that the next service plans to be carried out are plans A and B and that these plans are to be
carried out every 8000 running hours.
Press the arrow down key (3) to find out which service plans were carried out previously, following screen
appears:
Previous Timer
Level
.
Back
F1
A
4008 hrs
F2
F3
The screen shows that plan A was carried out at 4008 running hours.
Stop the compressor, switch off the voltage and carry out the service operations related to the indicated service
plans, see section Preventive maintenance schedule.
Switch on the voltage and scroll to the Next Timer service screen.
Press the Reset button (F3). Confirm the question for resetting.
Note: The Reset button only appears when the Next Timer level is almost reached.
After pressing the arrow down key in the Service Timer screen, the Life Time hours are shown, i.e. the
number of hours elapsed since initial programming ex-factory. This timer is not taken into account.
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2.21 Saved data menu

Control panel
F1
F2
9
5
5
1
10
Function
To call up some data saved by the regulator. These data are:
F3
5
Last shut-down data

Last emergency stop data
Procedure
Press the arrow down key (1) until Saved data is followed by a horizontal arrow.
The first option is shown Last shutdown 1.
Press the tabulator key (4) to find out the date, time and other data reflecting the status of the compressor at the
last shut-down.
If desired, scroll through the other items.
2.22 Programmable settings

A number of regulation parameters (e.g. loading and unloading pressures) and protection settings (e.g. shut-down
level for the compressor element temperature) are programmable. See "Submenu MODIFY PARAMETERS").
2.22.1 Regulation settings & parameters
Loading pressure (1)
bar
Minimum
setting
4.0
Unloading pressure (1)
bar
9.1
Overpressure setting (2)
bar
10.405
Overpressure Timeout (2)
sec
240
Y-Time
sec
10
15
30
Load Delay
sec
10
30
72
120
Nr Of Starts/Day
Factory
setting
Maximum
Setting
9.0
9.9
10.0
10.405
Minimum Stop Time
sec
20
20
99
Programmed Stop Time
sec
20
Permissive Start Time
sec
30
255
Communication Time-Out (3)
sec
10
20
60
Power Recovery Time (ARAVF) (3)
sec
15
15
3600
Start Delay Time (ARAVF) (3)
sec
255
Drain Duration (Manual Drain Test)
sec
10
60
(1) Pressure band 2 set identical to Pressure band 1.

The regulator does not accept illogical settings, e.g. if the Unloading pressure is programmed at 7.0 bar,
the maximum limit for Loading changes to 6.9 bar.
(2) Only active in Remote control mode. Will force the compressor into unload when reached.
(3) ARAVF (automatic restart after voltage failure) factory setting: inactive, see Elektronikon regulator.
Special Note: Settings deviating from standard-settings are printed in "Italic"
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2.22.2 Protection settings

Minimum
setting
Factory
setting
Maximum
setting
Compressor Outlet Shutd.Warn.(1)
bar
0.0
11.0
11.9
Compressor Outlet Shutdown (1)
bar
11.1
12.0
17.0
Dp Air Filter Service Warning (2)
bar
-0.050
-0.044
-0.044
Delay At Signal, Dp Air Filter
sec
60
255
Dp Air Filter Shutd.Warn.Minimum (2)
bar
-0.065
Dp Air Filter Shutdown Minimum (2)
bar
-0.065
Oil Pressure Shutd.Warn.(1) (2)
bar
1.21
1.30
2.00
Oil Pressure Shutdown (1) (2)
bar
1.00
1.20
1.29
Delay At Start, Oil Pressure
sec
15
15
20
Delay At Signal, Oil Pressure
sec
Element 1 Outlet Shutd.Warn.(1)
100
225
234
Element 1 Outlet Shutdown (1)
226
235
235
Delay At Signal, Element 1 Outlet
sec
Element 2 Inlet Shutd.Warn.(1)
40
65
69
Element 2 Inlet Shutdown (1)
66
70
80
Delay At Signal, Element 2 Inlet
sec
Element 2 Outlet Shutd.Warn.(1)
100
225
234
Element 2 Outlet Shutdown (1)
226
235
235
Delay At Signal, Element 2 Outlet
sec
Cooling Air In Warning (2)
51
51
51
Oil Temperature Shutd.Warn.(1) (2)
40
65
69
Oil Temperature Shutdown (1) (2)
66
70
80
Delay At Start, Oil Temperature
sec
50
70
100
Delay At Start, Overload Motor Shutdown
sec
Delay At Signal, Overload Motor Shutdown
sec
Delay At Start, Overload Fanmotor Shutdown
sec
Delay At Signal, Overload Fanmotor Shutdown
sec
(1) The regulator does not accept illogical settings, e.g. if the warning level is programmed at 65C,
the minimum limit for the shutdown level changes into 66C (= logic for pressure, step = 0.1 bar).
(2) Contact = open, Check area: Unload & Load
Special Note: Settings deviating from standard-settings are printed in "Italic"
2.22.3 Service plans

Minimum
setting
Factory
setting
Maximum
setting
Service plan A (operating hours)
hr
See remark
4000
See remark
Service plan B (operating hours)
hr
See remark
8000
See remark
Service plan C (operating hours)
hr
See remark
16000
See remark
Service plan D (operating hours)
hr
See remark
40000
See remark
Service plan I (operating hours)
hr
See remark
2000
See remark
Remark
A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of service
operations to be carried out at the programmed intervals. Consult your Atlas Copco Service Centre.
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3
3.1
INSTALLATION
Dimension drawings
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3.2
Installation proposals
1
7
5
8
Fig. 8 Installation proposal, typical example
1. Install the compressor unit on a level floor suitable

for taking the weight of the unit.
Outdoor/altitude operation
If the compressor unit is installed outdoors and
the ambient temperature can be below 0 C/32 F,
winterization precautions must be taken. If this is
the case, or if the compressor is being operated at
high altitudes, consult the Atlas Copco Customer
Centre.
Moving/lifting
In order not to damage the base 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.
2. Remove - if present - the plastic cap from the air
outlet connection and store the cap for future use.
Install an air outlet valve, close the valve and
connect the valve to the air net.
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3. The pressure drop over the delivery pipe can be

calculated as follows:
P = (L x 450 x Qc
1.85
) / (d5 x P)
P = pressure drop (recommended maximum =

0.1 bar)
L = length of delivery pipe in m
d = inner diameter of the delivery pipe in mm
P = the absolute pressure at the compressor
outlet in bar(a)
Qc = free air delivery of the compressor in l/s
It is recommended that the connection of the
compressor air delivery pipe is made on top of the
main air net pipe to minimize carry-over of
possible remainder of condensate.
As a rule of thumb, following formula can be used
to calculate the recommended volume of the air
net:
V = (30 x C x p x Q) / P
V = recommended air net volume in l
P = pressure difference between unloading
and loading pressures in bar
(recommended minimum = 0.6)
p = compressor inlet pressure in bar
absolute
Q = free air delivery of compressor in l/s
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Instruction Book
C = correction factor, see table.
Air consumption divided by
compressor air delivery
0.9
0.10
0.8
0.15
0.7
0.20
0.5
0.25
0.3
0.20
0.2
0.15
0.1
0.10
4. Provide a condensate drain valve in the lowest

part of the pipe between the compressor outlet
valve and the air net.
5. Fit a flexible to the condensate drain outlet
connections and lay out the drain piping from
condensate outlets 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
6. Elektronikon control system with separate control
panel
7. Electrical connections to the power supply net are
to be made by the customer on site. Connect
compressor drive motor and fan motor to the
starting
equipment
(=customers
part
of
installation). 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.
8. Make use of the two earthing bosses fitted at
diagonally opposite site of the base frame.
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Instruction Book
3.3
Wiring diagrams
The following diagrams show the wiring of transmitters, switches and components of the control panel in the
electrical cubicle the common local control cubicle.
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3.4
Pictographs
2
3
1. Start
2. Scroll keys
3. Tabulator key
4. Voltage on
5. Alarm
6. Automatic operation
7. Stop
Fig. 9 Pictographs on Elektronikon regulator
8.
Consult the Instruction book before maintenance

or repair
9.
Warning: under tension
10. Read Instruction book before starting the

compressor
11. Switch off the voltage and depressurize the
compressor before maintenance or repair
12. Before connecting the compressor electrically,
consult the Instruction book for the drive motor
rotation direction
13. Torques for steel (Fe) or brass (CuZn) bolts

14. Consult the Instruction book before greasing
15. Switch off the voltage before removing the
protecting cover inside the electric cabinet
16. Oil the gaskets, screw on the filters and tighten by
hand (approx. one half turn)
17. Automatic condensate outlet, intercooler
18. Automatic condensate outlet, aftercooler
Fig. 10 Pictographs at various locations on the unit
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Instruction Book
OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all related safety precautions
including those mentioned in this book.
4.1
6. Before initial start-up, the tie rods (1) must be

tightened. Proceed as follows:
Check that all transport fixtures are removed
Check that the compressor is without pressure
Initial start-up
1. Make sure the compressor is installed correctly.

Consult section 3 for the installation proposal and
dimension drawing.
2. A sticker with a summery of the operation
instructions is delivered with the compressor. Affix
the sticker next to the control panel.
3. A number of VCI (Volatile Corrosion Inhibitor)
plates are provided inside the bodywork to protect
the compressor against corrosion. Remove the
plates.
4. The gear casing and compressor drive motor are
secured to the base frame immobilizing the
vibration dampers during transport. All transport
fixtures are painted red and must be removed:
- At the motor side, remove bolts and bracket (A).
- At the gear casing side, remove bolts and beam
(B).
Tighten the nuts of tie rods by hand

Tighten the check nuts
Position of tie rods

7. Check that the gear casing is filled with oil. Oil
should be visible in the sight-glass (SG).
SG
Transport fixtures at motor and gear casing side

5. Remove flange (1) on the
intercooler manifold and
take out the silica gel bags.
Refit the flange.
Position of silica gel bags
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Position of oil level sight-glass

8. Check the voltage selecting wires at primary side
of the transformers (T1/T2-Fig. 6) are connected
correctly. An instruction label is provided. Check
that the electrical installation meets local
regulations.
9. Switch on the voltage. Start the motor and stop it
immediately. Check for correct direction of rotation
of both the compressor drive motor and the cooling
fan motors. When facing the drive end of the
motors, the correct direction of rotation is counterclockwise.
First check the compressor motor. If the rotation
direction is wrong, switch off the voltage and
reverse two incoming electric lines.
Then check the fan motors. If the rotation direction
is wrong, switch off the voltage and reverse two
electric connections of the fan motor.
10. Run the compressor for a few minutes and check
that it operates normally. Stop the compressor
and check the oil level, which should be in the
middle of the sight-glass (In case of longer
41
Instruction Book
standstill, the oil level in the sight-glass may
increase). Top up, if necessary, with the correct
type of oil.
4.2
Before starting
Attention
The operator must apply all relevant safety
precautions, including those mentioned in this
instruction book.
Check the oil level, which must be in the middle of the
sight-glass. Top up, if necessary, with the correct
type of oil.
Open the air outlet valve (customer's installation).
4.3
Manual restarting
In automatic operation, the regulator limits the number
of motor starts.
On compressors with a low-voltage motor, observe a
minimum interval of 20 minutes between two manual
starts.
4
3
2
5
1
Routine starting
1. Switch on the voltage and check that voltage on

LED (6) lights up.
2. Press start button (1). The compressor starts
running in unloaded condition and automatically
operation LED (8) lights up.
3. Approx. 25 seconds later (programmable), the
compressor starts running loaded. The message
on the display (2) changes from Automatically
unloaded to Automatically loaded.
Warning
- If the compressor is stopped and automatic
operation Led (8) is alight, the drive motor may start
automatically.
- If the start/stop timer is active, the compressor can
start automatically, even if it was stopped manually.
4.4
time will be memorised; automatic operation LED (8)

lights up. The compressor will start when the minimum
stop time has run out.
Starting after emergency

stopping or shut-down
1. Press the emergency stop button (10); if not yet

done so.
2. Switch off the voltage and then depressurize the
compressor.
3. Remedy the fault.
4. Unlock the emergency stop button by pulling it out.
5. Restart the compressor. See Routine starting.
Note:
If the automatic restart function after voltage failure is
activated and the duration of repair is shorter than the
programmed power recovery time, reset the display
after remedying the fault. Press the button Reset;
the message All protection functions are OK will
appear, whereupon the compressor can be restarted.
Press the buttons Menu and Main Screen to return
to the main display.
10
4.5
During operation
Warning
When automatic operation LED (8) is alight, starting
and stopping of the drive motor are automatically
controlled: when the drive motor is stopped, it may
restart automatically.
1. Check the readings on display (2). See section
4.5.
2. On reaching the pre-set unloading pressure,
shown on display (2), the compressor will run
unloaded. From now on, the electronic control
module will calculate the optimum moment to stop
and restart the compressor drive motor
automatically, depending on the maximum
permissible number of motor starts and on the air
consumption.
3. To unload the compressor manually, press the
button Unload (5). To put the compressor back
into automatic operation, press the button Load
(5).
Note:
If the Load or Unload function is not indicated on
the bottom line of the display (2), press button Menu
(5) until the function Main Screen appears above key
(F1) on the display (2) of the Elektronikon. Then
press the button Main screen.
Minimum stop time

The compressor will not be allowed to restart within a
programmed time (20 s) after a stop for any reason at
all. A start command given during the minimum stop
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Instruction Book
4.6
Checking the display
1. Regularly check the display (2) for readings and

messages. Normally, the main screen is shown,
indicating the compressor outlet pressure, the
status of the compressor and the functions of the
keys below the display.
2. Always check the display (2) and remedy the
trouble if alarm LED (7) is alight or flashing.
3. The display will show a service message if one of
the monitored components is to be serviced.
Replace the component, change the oil or grease
the drive motor as required. Reset the relevant
timer.
Warning
Before carrying out any maintenance, repair or
adjustment work, stop the compressor, press
emergency stop button (10), switch off the voltage
and depressurize the compressor.
4.8
Stopping
3. Close the air outlet valve.

4. Press stop button (9). The compressor will run for
a few seconds, after which it will stop.
5. To stop the compressor in case of emergency,
press emergency stop button (10). Alarm LED (7)
starts blinking.
After remedying the trouble,
unlock the emergency stop button.
Warning
Frequently stopping the compressor using the
emergency stop button may damage the
compressor; only use the emergency stop button
in case of emergency.
6. Open the manual condensate drain valves in
order to depressurize the air system of the
compressor unit.
4. Regularly check the actual compressor status by

pressing the button from the main screen.
Note:
Whenever a warning, service request, sensor error or
motor overload message is displayed, the free spaces
on the display (2) between the function buttons (5) are
filled with flashing indicators (**).
When more than one message needs to be displayed
(e.g. both warning and service), the messages are
continuously displayed for 3 seconds each.
4.7
Manual unloading/loading
Normally, the compressor runs in automatic operation,

i.e. the electronic regulator loads, unloads, stops and
restarts the compressor automatically. LED (8) is then
alight.
Manually unloading
Press button Unload (5). LED (8) goes out. The
message Manually Unloaded appears on the
display. The compressor remains running unloaded
unless it is loaded again manually.
Manually loading
10
4.9
Taking out of operation
At the end of the service life of the compressor,

proceed as follows:
1. Close the air outlet valve and stop the compressor.
2. Open the manual condensate drain valves in order
to depressurize the air system of the compressor
unit.
Press button Load (5). LED (8) lights up. The

command Load does not force the compressor in
loaded condition, but it will switch the compressor to
automatic operation again: the compressor will be
loaded if the air net pressure drops below the
programmed level.
3. Switch off the voltage and disconnect the control

cabinet from the mains.
Note:
If the Load or Unload function is not indicated on
the bottom line of the display (2), press button Menu
(5) until the function Main Screen appears above key
(F1) on the display (2) of the Elektronikon. Then
press the button Main screen.
5. Drain the oil and condensate circuits. Catch the oil

in a receptacle.
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4. Shut off and depressurize the part of the air net,

which is connected to the air outlet valve.
Disconnect the compressor air outlet pipe from the
air net.
6. Disconnect the compressor condensate piping from

the condensate drain net.
43
Instruction Book
MAINTENANCE
Warning
Before starting any maintenance, repair or adjustment
work:
-
Stop the compressor and press the emergency

stop button.
Switch off the voltage and close the air outlet

valve.
Open the manual condensate drain by-pass valves

in order to depressurize the air system of the
compressor unit.
Take precautions to avoid an accidental restart.

Apply all relevant safety precautions, including
those mentioned in this book.
Period 2)
Running
hours 2)
5.1 Preventive maintenance

schedule for the compressor
5.1.1 Regular service operations
To ensure safe operation and long service life, carry
out following operations at the interval (period or
running hours), which comes first.
The "longer
interval" checks must also include the "shorter
interval" checks.
The schedule contains a summary of the maintenance
instructions. Read the related section before taking
maintenance measures.
In servicing, replace all removed gaskets, O-rings and
washers.
Operations 1)
Check the Elektronikon display for warnings.
Check that condensate is discharged from the drain receivers during loading.
--
Check oil level. Before starting, the oil level should be in the middle of the sight-glass.
--
Clean compressor.
--
Check for possible leaks. Any leak should be attended to immediately.
--
Have safety valves tested. Preferably to be carried out by an Atlas Copco Customer
Centre.
--
Have the compressor inspected by an Atlas Copco Service representative.
--
Have operation of transmitters, electrical interlockings and components tested by an

electrician.
--
Carry out service actions according to the displayed service warnings or service
plans.
Daily
Weekly
3-monthly
Yearly
When
displayed
1) Use only authorized parts. Any damage or

malfunction caused by the use of unauthorized
parts is not covered by Warranty or Product
Liability.
2) Whichever interval comes first. The local Atlas
Copco Customer Centre may overrule the
maintenance schedule, especially the service
intervals, depending on the environmental and
working conditions of the compressor.
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Important
Grease the drive motor bearings at the correct interval
and with the correct grease type and quantity as
mentioned on the motor data plate and in this
instruction book.
44
Instruction Book
5.1.2 Service kits
5.1.4 Service plan
Atlas Copco Customer Centres will be glad to provide

you with a wide range of service kits. Service kits
comprise all parts needed for servicing components
and offer the benefits of genuine Atlas Copco parts
while keeping the maintenance budget low. See also
section 5.5.
A number of service operations are grouped (called

Level A, Level B, Level C, ...). Each level stands for a
number of service actions to be carried out at the
time intervals programmed in the Elektronikon
regulator.
5.1.3 Service agreements

Atlas Copco Customer Centres have a range of
service agreements to suit your needs:
- An Inspection plan
- A Preventive maintenance plan
- A Total responsibility plan
When a level is reached, a message will appear on

the screen. After carrying out all service actions,
reset the interval timers using the key "Reset" in the
"Service" menu.
Contact your Customer Centre to agree on a tailormade service agreement. It will ensure optimum
operational efficiency, minimize downtime and
reduce the total life cycle costs.
Service activities
Level A
Level B
Level C
Take service readings (oil, air temperature and pressure)
Check cooler functions (approach temperature)
Change intercooler condensate check valve
Service intercooler blow-down valve

Check for air and oil leakage
X
X
Change Roto Z oil (16000 hrs or 2-yearly)
NA
NA
Change compressor oil filter (8000 hrs or annually)
NA
Inspect/change air filter element
Replace filter element of gear case breather
Check cycle of air intake throttle valve
Replace diaphragm of air throttle valve
Replace bearing block (air intake valve)
Check operation of safety valves

Check for presence of water in lube oil
Overhaul air intake valve
Check functioning of check valve (8000 hrs or annually)
Overhaul check valve
Check condition of balance piston diaphragm
Change balance piston diaphragm
Check/Service condensate drain(s)
Clean fan cowl of electric motor
Check rubber inserts of drive coupling (arr. E)
Replace inserts of drive coupling (arr. E)
Inspect electrical contactors
Check all electrical connections
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Instruction Book
5.2
Drive motor greasing
General
Safety precautions.
Stop the compressor and switch off the voltage.
The operator must apply all related safety precautions.
The data below are valid for an air intake temperature of maximum 40 C!
Consult your Atlas Copco Customer Centre for higher intake temperatures.
Reset the regreasing service warning after regreasing.
Also check the motor data plate.
DRIVE MOTOR
Make
Type
SIEMENS
1MJ1 313-2AC
DRIVE MOTOR GREASING

Lithium base grease, dropping point ~180 oC
Type
4000 h
Interval
35 g D-End, 35 g ND-End
Quantity (per bearing)
After 15 re-lubrications remove worn-out
FAN MOTOR GREASING
The bearings of the fan motors are greased for life, contact your Customer Centre for the replacement interval of
the motor bearings.
Important
Never mix greases of different brands of types
5.3
Oil specifications
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.
Atlas Copco Roto-Z oil can be ordered in following
quantities:
Quantity
Ordering number
5-litre can
2908 8503 00
20-litre can
2908 8501 01
209-litre drum
2908 8500 00
5.4
Storage after installation
Run the compressor, e.g. twice a week, until warm.

Load and unload the compressor a few times.
If the compressor is going to be stored without
running from time to time, protective measures must
be taken. Consult Atlas Copco.
5.5
Service kits
Service kits comprise all standard parts needed for

servicing components and offer the benefits of
genuine Atlas Copco parts while keeping the
maintenance budget low. All standard service kits are
mentioned in the relevant Parts Lists. Service kits of
special parts will not be supported.
Important
Never mix oils of different brands or types.
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Instruction Book
SERVICING PROCEDURES
6.1
Air filter
6. 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.
7. Fill the gear casing sump to the maximum mark of
the oil level sight-glass (SG) with oil as specified
in section 5.3. Reinstall the filler plug.
8. Switch on the voltage. Unlock the emergency
stop button.
9. 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).
10. After carrying out the maintenance operations of
the related service plan, the service warning must
be reset.
FC
Location of air filter

Important :
The filters must be serviced regularly; consult section
Preventive maintenance schedule.
Never install damaged or clogged filters.
OF
1. Stop the compressor, press the emergency stop

button and switch off the voltage to the
compressor unit.
2. Remove nuts (1) and loosen clamps (2).
Dco
3. Take out filter housing (3) with filter element (4).

4. Replace the dirty filter element with a new one.
5. Put the filter housing with the filter element back
into place.
SG
6. Tighten clamps (2) and nuts (1).

7. Switch on the voltage.
Dco
8. Unlock the emergency stop button and reset the

air filter service warning.
6.2
1.
2.
3.
4.
5.
Oil and oil filter change

Run the compressor until warm.
Stop the compressor, press the emergency stop
button and switch off the voltage to the
compressor unit.
The filler plug and drain points are painted
yellow. Remove filler plug (FC).
Drain the gear casing sump by opening oil drain
valve (Dmo). Close the valve after draining.
Fit a proper flexible over the extension of drain
plugs (Dco) and drain the oil system by
loosening the drain plugs. Tighten the plugs
after draining.
S 992245 01 v00
Dmo
Dco
Dmo
FC
OF
SG
Drain plugs of oil cooler

Drain valve of gear casing
Oil filler plug
Oil filter
Oil level sight glass
Oil system components
47
Instruction Book
6.3
Safety valves
Testing
The safety valves can be tested on a separate
compressed air line. If a valve does not open at the
pressure specified in section 8.1, consult Atlas Copco.
Warning
- Never run the compressor without safety valves.
- No adjustments are allowed.
S 992245 01 v00
48
Instruction Book
PROBLEM SOLVING
Warning
Before starting
adjustment work:
any
maintenance,
repair
or
Stop the compressor and press the emergency

stop button.
Switch off the voltage and close the air outlet

valve.
Open the manual condensate drain by-pass

valves in order to depressurize the air system of
the compressor unit.
Take precautions to avoid an accidental restart.

Apply all relevant safety precautions, including
those mentioned in this book.
10
Faults and suggested remedies

1
A shut-down warning message appears on

the display
Oil pressure too low

a. Oil level too low
LED (7) will light up. If necessary, stop the

compressor, switch off the voltage and
remedy. Consult the section "Status data
menu". The message disappears as soon as
the cause of the trouble is remedied
a. Top up level to the middle of the oil level

sight-glass
b. Oil filter clogged
b. Replace filter
Unit is shut down

LED (7) will blink. Consult the section "Status
data menu" to remedy the trouble and to reset
the message.
a. Insufficient cooling air or recirculation of

cooling air
Compressor starts running, but does not

load after a delay time
a. Check for cooling air restriction. Improve

ventilation and prevent recirculation of
cooling air
a. Pressure in air net is above pre-set loading

pressure
b. Fan motor shut down

b. Check fan and setting of circuit breakers
a. Compressor will load when pressure in air

net drops to pre-set loading pressure
c. Air filter clogged
b. Loading solenoid valve inoperative
c. Replace filter
b. Check and, if necessary, replace the valve
d. Unloading pressure incorrectly set
c. Full-load/no-load valve malfunctioning
d. Elektronikon regulator; see Modifying

parameters
c. Have the valve inspected

4
Air temperature above normal
Compressor capacity or working pressure

below normal
a. Air consumption exceeds air delivery of
compressor
Condensate is not discharged

condensate traps during loading
a. Discharge flexible clogged
a. Check and correct as necessary
a. Check pneumatic plant
b. Float valves malfunctioning
b. Safety valves leaking
b. Check and correct as necessary
b. Remove leaking valve

inspected or replaced
S 992245 01 v00
and
have
from
it
49
Instruction Book
PRINCIPAL DATA
8.1
Setting of safety valve
The LP safety valve has an opening pressure setting

of 3.7 bar(e) and the HP safety valve has an opening
pressure setting of 11 bar(e).
8.2
Setting of overload relay and

fuses
Supply
440 V / 60 Hz
F26 (Fan motor M26; 2.8 kW)
6.1 A
F27 (Fan motor M27; 2.8 kW)
6.1 A
Overload relay F21
169 A
8.3
Motor specifications
The motor is flanged to the gear casing by means of

a coupling housing. The motor/gear casing unit is
supported on the frame by vibration dampers.
The motor has the following characteristics:
Special electrical items additional information:

Voltage free contacts for starters
IP65 Eex d enclosure Eex e terminal box
Cubicle including window over Elektronikon
control panel; module built-in in Eex(d) cubicle
Eex (e) housing with push buttons for local control
2 x DIOE module for 8 digital inputs
1 x AIE2 module for 4 x 4-20 mA inputs
2 x AIE3 module for 6 x PT100 inputs
Stainless steel ex-proof solenoid valve Eex(d)
(normally closed)
Eex(n) fan motors
Eexd blow down solenoid valve (normally open)
8.5
Compressor specifications
General information
Compressed medium
Air
Max. working pressure
10.4 bar(g)
Max. ambient temperature
40 C
Pressure vessel approval
CE
440 V 10 %
Fan motor(s)
440 V / 60 Hz
Frequency
60 Hz
Oil capacity
49 liter
Speed
3580 rpm
Max. cooling air temperature
40 C
Performance data
Connection of windings
DELTA
CONDITION 1 - DESIGN
Insulation class
Ambient pressure
1 bar(a)
Temperature rise
Air inlet pressure
1 bar(a)
Enclosure
IP55
Air outlet pressure
Construction form
IBM35
Air inlet temperature
35 C
Full Load efficiency
95.6 %
Air inlet relative humidity
95 %
Power factor
0.88
Volume flow rate ( 4 %)
317 l/s
Nominal current
293 Amp
Normal capacity ( 4 %)
986 Nm3/h
Make
Siemens
Type
1MJ1 313-2
Shaft power
185 kW
Service factor (SF)
Voltage
Starting current
Nominal torque
Starting torque
Max altitude
8.4
690 %
507 Nm
220 %
Specific shaft input ( 5 %; excl. fan)
1000 masl
Drive speed
Electrical specifications
ELECTRICS
Electrical cubicle; excluding starter for main drive
Elektronikon regulation, 115 V - 60 Hz
Control or auxiliary voltage supply, 440V - 60 Hz
Solenoid valve: 24 V - 60 Hz
S 992245 01 v00
Shaft input ( 6 %; excl. fan)
10 bar(g)
141 kW
443 J/l
3570 RPM
MRS LP
12835 RPM
MRS HP
21563 RPM
LP outlet temperature
210 C
HP inlet temperature
50 C
HP outlet temperature
Air discharge temperature
203 C
51 C
50
Instruction Book
CONDITION 2 - TEST
Ambient pressure
1 bar(a)
Air inlet pressure
1 bar(a)
Air outlet pressure

Air inlet temperature
10 bar(g)
20 C
Air inlet relative humidity
0%
Volume flow rate ( 4 %)
331 l/s
Normal capacity ( 4 %)
1096 Nm3/h
Shaft input ( 6 %; excl. fan)

Specific shaft input ( 5 %; excl. fan)
Package power input ( 6 %)
142 kW
429 J/l
148.5 kW
Specific package power input ( 5 %)
449 J/l
Shaft input at no-load ( 20 %; excl. fan)
26 kW
Unload package power (excl. fan)

Drive speed
27.2 kW
3570 RPM
MRS LP
12835 RPM
MRS HP
21563 RPM
LP outlet temperature
184 C
HP inlet temperature
28 C
HP outlet temperature
Air discharge temperature
S 992245 01 v00
174 C
26 C
51
Instruction Book
FLOW DIAGRAM
S 992245 01 v00
52
Instruction Book
Symbols
S 992245 01 v00
53
Instruction Book
10
PRESSURE EQUIPMENT DIRECTIVES
PED Instructions
This machine is a pressure assembly of cat I
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 part is of category

higher than I :
Safety valve : Category IV
Design code : AD-Merkbltter, A2
S 992245 01 v00
54

Instruction Book ZT145

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Atlas Copco Stationary Air Compressors

Unit serial No. compressor: ........................

Air dryer type:...................................................................

Unit serial No. dryer:...................................

Printed Matter Nos.

Atlas Copco air dryer .................................

Local Atlas Copco Representative

C) Hydrostatic witnessed parts

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

INSTALLATION PROPOSALS ....................35

WIRING DIAGRAMS ...................................37

CONTROL SYSTEM ................................... 10

4 OPERATING INSTRUCTIONS .............................41

During unloading ................................... 11

During loading ....................................... 11

AIR FLOW ................................................... 11

BEFORE STARTING ...................................42

OIL SYSTEM ............................................... 11

COOLING SYSTEM .................................... 11

CONDENSATE DRAIN SYSTEM ............... 11

STARTING AFTER EMERGENCY

CHECKING THE DISPLAY .........................43

MANUAL UNLOADING/LOADING ..............43

TAKING OUT OF OPERATION...................43

2 ELEKTRONIKON REGULATOR ........................ 13

Automatic control of compressor

Protecting the compressor .................... 13

Automatic restart after voltage failure ... 13

PREVENTIVE MAINTENANCE SCHEDULE

CONTROL PANEL AND BUTTONS OF

Regular service operations....................44

Service kits ............................................45

SCROLL BUTTONS .................................... 15

EMERGENCY STOP BUTTON................... 16

Service plan ...........................................45

EXTERNAL COMPRESSOR STATUS

DRIVE MOTOR GREASING .......................46

OIL SPECIFICATIONS ................................46

CONTROL PROGRAMS ............................. 17

STORAGE AFTER INSTALLATION............46

CALLING UP MENUS ................................. 18

SERVICE KITS ............................................46

MAIN SCREEN MENU ................................ 19

2.10 STATUS DATA MENU ................................ 19

2.11 MEASURED DATA MENU.......................... 21

OIL AND OIL FILTER CHANGE..................47

2.12 COUNTERS MENU..................................... 22

SAFETY VALVES ........................................48

2.13 TEST MENU................................................ 22

7 PROBLEM SOLVING ..........................................49

SETTING OF SAFETY VALVE...................50

SETTING OF OVERLOAD RELAY AND

2.18 PROGRAMMING CLOCK FUNCTION ....... 25

MOTOR SPECIFICATIONS ........................50

2.19 MODIFYING CONFIGURATION SETTINGS28

2.20 SERVICE MENU ......................................... 29

2.16 MODIFYING PROTECTION SETTINGS .... 23

2.21 SAVED DATA MENU .................................. 31

General information ...........................................50

2.22 PROGRAMMABLE SETTINGS................... 31

Performance data ..............................................50

2.22.1 Regulation settings & parameters .......... 31

9 FLOW DIAGRAM ................................................52