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Atlas Copco ZR 110, Instruction Book

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Atlas Copco ZR 110 Instruction Book Download Page 318

13

Pressure equipment directives

PED instructions

ZR 110 Pack up to ZR 145 Pack compressors are a pressure assembly of cat. I according to 97/23/EC.

ZR 160 Pack up to ZR 275 Pack compressors are a pressure assembly of cat. II according to 97/23/EC.

ZT 110 Pack up to ZT 275 Pack compressors are a pressure assembly of cat. I according to 97/23/EC.

ZR/ZT 110 Full-Feature up to ZR/ZT 145 Full-Feature compressors are a pressure assembly of cat. III
according to 97/23/EC.

ZR/ZT 160 Full-Feature up to ZR/ZT 275 Full-Feature compressors are a pressure assembly of cat. IV
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 2009/105/IEC are excluded from 97/23/EC according
to article I, section 3.3.

The following pressure bearing parts are of category higher than I :

Compressor type

Pressure bearing part

ZR/ZT 110 up to ZR/ZT 275

Safety valve: Category IV

• Design code: AD-Merkblätter, A2

ZR/ZT 110 up to ZR/ZT 145

IMD 300

Compressed air dryer vessel

• Category III
• Design pressure 13.7 bar(e)
• Design code: ASME BPVC section VIII div. 1.
• Material (Cover, housing and bottom): SA-395.
• When pressurized, vessel remains under pressure.

Safety valve (only for option dryer bypass)

• Category IV
• Design code: ISO 4126.

ZR 160 up to ZR 275

Compressor

Heat exchanger at compressed air side (aftercooler)

• Design pressure 13.7 bar(e)
• Design code: ASME BPVC section VIII div. 1.
• Volume 17.6 l.

ZR/ZT 160 up to ZR/ZT 275

IMD 600

Compressed air dryer vessel

• Category IV
• Design pressure 11 bar(e)
• Design code: ASME BPVC section VIII div. 1.
• Material (housing and cover): SA-395.
• When pressurized, vessel remains under pressure.

Safety valve (only for option low load and dryer bypass)

• Category IV
• Design code: ISO 4126.

Instruction book

316

2920 1815 04

Summary of Contents for ZR 110

Page 1: ...ZR 110 ZR 132 ZR 145 ZR 160 ZR 200 ZR 250 ZR 275 ZT 110 ZT 132 ZT 145 ZT 160 ZT 200 ZT 250 ZT 275 Instruction book ...

Page 2: ......

Page 3: ...ing of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2015 09 No 2920 1815 04 www atlascopco com ...

Page 4: ...ND CONDENSATE DRAIN SYSTEM 25 2 4 ELEKTRONIKON REGULATED DRAIN ERD 27 2 5 OIL SYSTEM 31 2 6 REGULATING SYSTEM 33 2 7 ENERGY RECOVERY 36 2 8 LOW LOAD COMPENSATOR FOR IMD DRYER 39 2 9 SMARTBOX AND SMARTLINK 41 3 Elektronikon regulator 44 3 1 ELEKTRONIKON REGULATOR 44 3 2 CONTROL PANEL 46 3 3 FUNCTION KEYS 47 3 4 SCROLL KEYS 48 3 5 EMERGENCY STOP BUTTON 48 3 6 CONTROL MODE SWITCH 49 3 7 EXTERNAL COMP...

Page 5: ...1 TIMERS MENU 64 3 22 CONFIGURATION MENU 67 3 23 SAVED DATA MENU 68 3 24 SHOW MORE MENU 69 3 25 UNLOAD LOAD MENU 70 3 26 PROGRAMMABLE SETTINGS 70 4 Elektronikon regulator type overview 75 4 1 ELEKTRONIKON CONTROLLER TYPE OVERVIEW 75 5 Elektronikon regulator 77 5 1 ELEKTRONIKON REGULATOR 77 5 2 CONTROL PANEL 79 5 3 FUNCTION KEYS 80 5 4 SCROLL KEYS 81 5 5 EMERGENCY STOP BUTTON 81 5 6 EXTERNAL COMPRE...

Page 6: ... SETTINGS 99 5 20 SERVICE MENU 101 5 21 SAVED DATA MENU 103 5 22 PROGRAMMABLE SETTINGS 103 6 Elektronikon GraphicPlus controller 112 6 1 ELEKTRONIKON GRAPHICPLUS CONTROLLER 112 6 2 CONTROL PANEL 114 6 3 DIGITAL OUTPUT CONTACTS 115 6 4 ICONS USED 116 6 5 MAIN SCREEN 120 6 6 CALLING UP MENUS 125 6 7 SERVICE MENU 126 6 8 PROTECTIONS MENU 131 6 9 WEEK TIMER MENU 134 6 10 INFO MENU 144 6 11 TEST MENU 1...

Page 7: ...USES AND CABLE LENGTH 213 7 6 ELECTRIC CONNECTION 226 7 7 QUALITY OF SAFETY COMPONENTS 231 7 8 COOLING WATER REQUIREMENTS 231 7 9 GENERAL PICTOGRAPHS 234 7 10 PICTOGRAPHS ELEKTRONIKON CONTROL SYSTEM 235 8 Operating instructions 237 8 1 INITIAL START UP 237 8 2 BEFORE STARTING 261 8 3 ROUTINE STARTING 266 8 4 STARTING AFTER EMERGENCY STOP OR SHUTDOWN 269 8 5 DURING OPERATION 271 8 6 CHECKING THE DI...

Page 8: ...OIL FILTER CHANGE 287 10 3 SAFETY VALVES 289 10 4 COOLERS 289 11 Problem solving 293 11 1 PROBLEM SOLVING 293 12 Technical data 298 12 1 READINGS 298 12 2 SETTINGS OF SAFETY VALVES 299 12 3 SETTINGS FOR OVERLOAD RELAY 299 12 4 REFERENCE CONDITIONS 310 12 5 LIMITATIONS 311 12 6 COMPRESSOR DATA 313 12 7 DRYER DATA 315 13 Pressure equipment directives 316 14 Documentation 322 Instruction book 6 2920 ...

Page 9: ... the voltage Depressurize the machine Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and check w...

Page 10: ... the correct size and suitable for the working pressure 6 In case the device is a compressor the aspirated air must be free of flammable fumes vapors and particles e g paint solvents that can lead to internal fire or explosion 7 In case the device is a compressor arrange the air intake so that loose clothing worn by people cannot be drawn in 8 Ensure that the discharge pipe from the compressor to ...

Page 11: ...quipment hence some statements may not apply to your machine 1 4 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be disclaimed by the manufacturer Precautions during operation 1 Neve...

Page 12: ... the application which are not included herein Some precautions are general and cover several machine types and equipment hence some statements may not apply to your machine 1 5 Safety precautions during maintenance or repair All responsibility for any damage or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation m...

Page 13: ...oil separator vessel for carbon deposits if excessive the deposits should be removed 18 Protect the motor air filter electrical and regulating components etc to prevent moisture from entering them e g when steam cleaning 19 Make sure that all sound damping material and vibration dampers e g damping material on the bodywork and in the air inlet and outlet systems of the compressor is in good condit...

Page 14: ...2 General description 2 1 Introduction General views General view of ZR 110 ZR 132 and ZR 145 FF with Elektronikon controller Instruction book 12 2920 1815 04 ...

Page 15: ...ZR 110 ZR 132 and ZR 145 FF with Elektronikon GraphicPlus controller Model year 2010 General view of ZR 110 ZR 132 and ZR 145 FF with Elektronikon GraphicPlus controller Model year 2011 Instruction book 2920 1815 04 13 ...

Page 16: ...General view of ZR 160 up to ZR 275 FF with Elektronikon GraphicPlus controller General view of ZT 110 ZT 132 and ZT 145 FF with Elektronikon controller Instruction book 14 2920 1815 04 ...

Page 17: ...ZT 110 ZT 132 and ZT 145 FF with Elektronikon GraphicPlus controller Model year 2010 General view of ZT 110 ZT 132 and ZT 145 FF with Elektronikon GraphicPlus controller Model year 2011 Instruction book 2920 1815 04 15 ...

Page 18: ... low pressure S2 Emergency stop button WI Cooling water inlet WO Cooling water outlet These units are two stage electric motor driven screw compressors which deliver oil free pulsation free air ZR compressors are water cooled ZT compressors are air cooled The compressor is enclosed in a sound insulated bodywork and includes mainly Air filter Low pressure compressor element Intercooler High pressur...

Page 19: ...vailable as an option Full Feature The compressor is additionally provided with an IMD adsoption dryer The dryer is integrated in the bodywork and removes moisture from the compressed air Connections This compressor can be provided on the compressed air outlet and water pipes with ANSI flanges DIN flanges DIN flanges DIN to JIS adapter flanges Separate air intake This compressor is prepared to ins...

Page 20: ...ments The readings can be called up on the display of the Elektronikon regulator High ambient temperature HAT The compressor is specially designed for continuous operation under humid and high ambient temperature conditions The maximum ambient temperature is 50 C 122 F Anchor pads Steel plates fitting in the forklift slots and bolts are shipped loose with the compressor With these plates and bolts...

Page 21: ...dryer It is NOT allowed to service the dryer when it is by passed and the compressor is running Kit for purge of dry air during standstill When frequent and long standstills occur it is recommended to install a kit for purge of dry air to guarantee the life time of the oil free screw elements During standstill condensation which triggers corrosion might occur This results in an expected element li...

Page 22: ...2 2 Air system Flow diagram Flow diagram of ZR 110 up to ZR 275 and ZR 132 VSD up to ZR 315 VSD compressors Instruction book 20 2920 1815 04 ...

Page 23: ...Flow diagram of ZR 110 up to ZR 275 Full Feature compressors and ZR 132 VSD up to ZR 315 VSD Full Feature compressors Instruction book 2920 1815 04 21 ...

Page 24: ...Flow diagram of ZT 110 up to ZT 275 compressors and ZT 132 VSD up to ZT 315 VSD compressors Instruction book 22 2920 1815 04 ...

Page 25: ...am of ZT 110 up to ZT 275 Full Feature compressors and ZT 132 VSD up to ZT 315 VSD Full Feature compressors Reference Name AF Air filter AO Air outlet AS Silencer BV By pass valve Instruction book 2920 1815 04 23 ...

Page 26: ... is further compressed in high pressure compressor element Eh and discharged through silencer AS and aftercooler Ca On ZR ZT 110 up to ZR ZT 275 a check valve CV is fitted downstream of the silencer The wet air from the aftercooler enters water separator Ws via ejector nozzle Nz In demister 1 the water droplets are removed from the air The air is then led through rotor 2 which adsorbs the water va...

Page 27: ...2 3 Cooling and condensate drain system Flow diagram Flow diagram of ZR 110 up to ZR 275 compressors Instruction book 2920 1815 04 25 ...

Page 28: ...Flow diagram of ZT 110 up to ZT 275 compressors Reference Name AF Air filter AO Air outlet AS Silencer BV By pass valve Ca1 Pre aftercooler Ca Aftercooler Instruction book 26 2920 1815 04 ...

Page 29: ...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 A Full Feature compressor also contains condensate traps downstream of the dryer two traps in case of a water cooled compressor three traps in case of an air cooled compress...

Page 30: ... still drain the condensate during the run of this timer to make sure that the remaining amount of condensate is drained The pilot valve is activated when the timer has expired the outlet closes quickly without wasting compressed air for ZR compressors before model year 2014 for ZR compressors from model year 2014 Instruction book 28 2920 1815 04 ...

Page 31: ...for ZT compressors before model year 2014 for ZT compressors from model year 2014 Instruction book 2920 1815 04 29 ...

Page 32: ...oose their set point Special attention must be paid to the correct wiring of the different level switches and solenoid valves The output of the level switch can be called up on the screen of the Elektronikon regulator The reading does not indicate whether the solenoid valve is open or closed but indicates whether the level switch is detecting water in the collector Since there is a drain opening d...

Page 33: ...2 5 Oil system Flow diagram Flow diagram of ZR 110 up to ZR 275 compressors and ZR 132 VSD up to ZR 315 VSD compressors Instruction book 2920 1815 04 31 ...

Page 34: ... ZT 110 up to ZT 275 compressors and ZT 132 VSD up to ZT 315 VSD compressors Reference Name AF Air filter AO Air outlet AS Silencer BV By pass valve Ca1 Pre aftercooler Ca Aftercooler Instruction book 32 2920 1815 04 ...

Page 35: ...of the gear casing through cooler Co On ZT compressors the oil flows through the cooling jackets of the compressor elements El and Eh The oil passes through oil filters OF towards the bearings and timing gears Valve BV opens if the oil pressure should rise above a given value 2 6 Regulating system General The regulator keeps the net pressure within programmable pressure limits by automatically loa...

Page 36: ...ressure is vented from chamber 1 of unloader UA through solenoid valve Y1 and chamber 3 towards the inlet of compressor element El 2 As there is no longer any pressure difference between chambers 1 and 3 plunger 2 returns by spring force keeping full load no load valve TV closed and unloading valve UV open 3 Compressed air between check valve CV and valve UV is blown off through silencer US Check ...

Page 37: ...rough solenoid valve Y1 to chamber 1 of unloader UA As this pressure is higher than the pressure in chamber 3 full load no load valve TV starts opening 2 Intercooler pressure is building up causing diaphragm 4 to switch to the right As the pressure difference between chambers 1 and 3 increases plunger 2 moves further against the spring force until full load no load valve TV is fully open and unloa...

Page 38: ...gy to the industrial process Modified cooling water system The compressor cooling system has been modified to achieve both high cooling water temperatures and sufficient cooling for the compressor The cooling water enters the oil cooler and then flows through the high pressure compressor element the low pressure compressor element and finally the intercooler and the aftercooler This sequence ensur...

Page 39: ...irements Therefore it is economically feasible to use softened water to eliminate the problem of scaling deposits Corrosion control is important The best results are obtained by adding corrosion inhibitors as used in engine cooling systems Using anti freeze products is an alternative solution to avoid problems e g adding 20 to 30 ethylene glycol based anti freeze to the tap water For open cooling ...

Page 40: ...wo incoming electric lines Important remarks Compressed air quality and reliability of any compressor dryer or other equipment should never be made subordinate to the energy recovery system In some cases especially installations where air dryers are installed an additional aftercooler is required to reduce the compressor air outlet temperature to a level at which the dryers operate at maximum effi...

Page 41: ...2 8 Low load compensator for IMD dryer Description Flow diagram of a ZT compressor with Low Load compensator functionality during unload Instruction book 2920 1815 04 39 ...

Page 42: ... of a ZR compressor with Low Load compensator functionality during unload Reference Name 1 Outlet of compressed air air net 2a 2b Non return valve 3 Heater 4 Rotor 5 Motor 6 Cooler Instruction book 40 2920 1815 04 ...

Page 43: ...through the dryer rotor 4 2 9 SMARTBOX and SMARTLINK General The machine comes with a SMARTBOX mounted in the electrical cabinet The SMARTBOX allows read out of a number of parameters of the machine on a user login protected web site called SMARTLINK The connected antenna is mounted on the outside of the machine Safety precautions It is important to follow all regulations regarding the use of radi...

Page 44: ...ay and the online link with Atlas Copco allows to request and quickly receive quotes for spare parts or additional services This product level is free of charge and available for 3 years following the machine purchase SMARTLINK Uptime SMARTLINK Uptime keeps your compressors up and running By e mail and or text you receive all relevant machine indications warnings and shutdowns in advance Based on ...

Page 45: ...ill receive an e mail with login credentials Go to the SMARTLINK web site http www atlascopco com smartlink log in with the user credentials Enjoy SMARTLINK In case more SMARTLINK ready machines are available you can add these via My Profile Instruction book 2920 1815 04 43 ...

Page 46: ...starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case the expected unloading period is too short the compressor is kept running to prevent too short standstill periods A number of time based automatic start stop commands may be programmed Take into account that a start...

Page 47: ...ded a message will appear on display 1 to warn the operator to take the necessary action Automatic restart after voltage failure For compressors leaving the factory this function is made inactive If desired the function can be activated Consult the Atlas Copco Customer Centre If activated and provided the regulator was in the automatic operation mode and the compressor control mode local remote 1 ...

Page 48: ...tton Button to stop the compressor 7 Tabulator key Key to go to the next field of the display 8 Function keys Keys to control and program the compressor The function of the functions keys varies depending on the displayed menu The actual function is indicated above the relevant key See Function keys 9 General Alarm LED Lights up in case of a shut down Blinks in case of a shut down Blinks if an imp...

Page 49: ...ters Delete To delete compressor start stop commands Limits To show limits for a programmable setting List To list programmed start stop commands day hour Load To load the compressor manually Main Screen To return from a menu to the main display Menu Starting from the main display to initiate the main menu which gives access to submenus Starting from a submenu to return to the main menu Modify To ...

Page 50: ...e utmost right position of the display the scroll key with the same symbol can be used to see the next item As long as an upwards pointing arrow is shown at the utmost right position of the display the scroll key with the same symbol can be used to see the previous item 3 5 Emergency stop button Control panel Instruction book 48 2920 1815 04 ...

Page 51: ...solating switch customer s installation to switch off the voltage to the compressor Close the air outlet valve and open the manual condensate drain valves to depressurize the air system Apply all relevant Safety precautions 3 6 Control mode switch Control panel The switch S5 allows the operator to select four compressor control modes Instruction book 2920 1815 04 49 ...

Page 52: ... to another compressor control mode take out the key after selecting the mode The regulator will only react on a new control mode if the new position of the key switch is maintained for 3 seconds 3 7 External compressor status indication Terminal strip 1X1 is provided with auxiliary contacts for external indication of Indication Relay Terminals on strip 1X1 Maximum load Automatic operation K06 11 ...

Page 53: ...ication module 3 Connect an earth cable between the communication module and the module of the compressor regulator 4 Connect the cable delivered with the communication module from connector X3 of the communication module to a free X2 connector on a module of the compressor regulator 5 Consult Atlas Copco to check the installation and to have the communication software loaded Installation of Profi...

Page 54: ...g up the status of the compressor protection functions shut down shut down warning and motor overload Resetting of a shut down and motor overload Measured data Calling up the actually measured data and the status of the motor overload protection Hours Calling up the running hours loading hours regulator hours and number of motor starts Service Calling up and resetting the service messages of the m...

Page 55: ...o the first submenu Status data then use keys 1 to scroll to another submenu and press the key Select F2 to select this submenu Or use the key Show More F2 for a quick look at the actual status of the compressor Returning to the Main screen or other menus Whenever displayed on the bottom line of a submenu press the key Menu F1 to return to a previous menu Whenever displayed press the key MainScree...

Page 56: ...The display indicates The name of the sensor of which the actual reading is displayed The unit and actual reading of the sensor Messages regarding the compressor operating condition e g Automatically Loaded a service need or a fault motor overload shut down warning sensor error Just above the three function keys F1 F2 F3 the actual functions of these keys When more than one message needs to be dis...

Page 57: ...light and a shut down warning message automatically appears on the display if a shut down warning exists The indicators are blinking and the warning message appears alternately with the compressor status message Press the key Menu F1 Press the key Select F2 scroll to the option Warnings and select this option A screen similar to the one below appears The screen indicates that the temperature at th...

Page 58: ...pear whereupon the compressor can be restarted Press the keys Menu and MainScreen to return to the main screen 3 13 Measured data menu Control panel Function To call up the actually measured data Consult the menu flow in section Control programs If the output of the sensor is linked to a protection function the related shut down and warning settings are also shown 3 14 Hours menu Control panel Fun...

Page 59: ...5 hrs Loading hours 1973 hrs Menu Modify F1 F2 F3 By using scroll keys 1 the other items can be called up The horizontal arrow shows the parameter which can be modified if this should be required consult the Atlas Copco Customer Centre 3 15 Service menu Control panel Function To call up and reset service messages for the monitored components See the menu flow in section Control programs Procedure ...

Page 60: ...e settings Service Maximum 0 044 bar 0 6 psi Return Reset F1 F2 F3 The example shows that the service life of the filter has not yet expired If a vertical arrow is shown on the third line it can be used to call up the service level in hours The service level of almost all components is indicated in running hours similar to the example below Calling up the actual measured value and service level Ca...

Page 61: ...em must be reset individually 3 16 Test menu Control panel Procedure Starting from the Main screen see Main screen menu Press key Menu F1 Press key 1 until Test is shown on the second line Activate the menu by pressing key Select F2 The display shows the option Display test Press key Select F2 During testing the regulator will generate a series of patterns on the display which enable the operator ...

Page 62: ...n section Control programs Procedure Starting from the Main screen see Main screen menu Press key Menu F1 Press key 1 until Modify settings is shown Activate the menu by pressing key Select F2 The first item Regulation is shown Press key Select F2 and use keys 1 to scroll to the setting to be modified For each parameter the modifying procedure is similar to the example below The regulator will not...

Page 63: ...ng the shut down setting for the oil pressure Consult the section above for selecting the option Protection Press key Select F2 The first item is shown Oil pressure Press key Select F2 A display similar to that shown below will appear Oil 2 5 bar Programmable settings Shutdown Minimum 1 2 bar Menu Modify F1 F2 F3 The example indicates The name of the sensor Oil and the actual measured value 2 5 ba...

Page 64: ...nal value will be retained Delay at signal The vertical arrow on the screen above indicates to use the scroll key to show the programmed Delay at signal Oil Programmable settings Delay at Signal 15 sec Menu Modify F1 F2 F3 If it should be necessary to modify the nominal setting consult the Atlas Copco Customer Centre Modify the value by means of scroll keys 1 Press the key Program to program the n...

Page 65: ...ing the modifying procedure is similar to the example below Modifying the the setting for the oil service life Consult the section above for selecting the option Service Press key Select F2 The first item is shown Use keys 1 to scroll to Oil Lifetime Press key Select F2 A display similar to that shown below will appear Running hours 944 hrs Programmable settings Service Maximum 16000 hrs Menu Modi...

Page 66: ...n see Main screen menu Press key Menu F1 Press key 1 until Timers is shown Activate the menu by pressing key Select F2 Initially the list with start stop commands is empty hence the timer function is switched off Following screen appears The timer is Not activated Menu Modify List F1 F2 F3 Programming start stop commands Press the key List The display will show a message that the list is empty Pre...

Page 67: ...executed but remain in the memory of the regulator Displaying the list of commands Press the key List on the timer screen A typical display is shown below Monday 06 00 Start compressor Monday 17 00 Stop compressor Tuesday 07 00 Start compressor Menu Modify List F1 F2 F3 The vertical arrows at the right hand side indicate to use the vertical scroll keys to select the next and previous start stop co...

Page 68: ...mmand timewise If not the new command is not accepted and the command line remains blinking In this case either modify the command or use the key Cancel to quit the modification operation Make sure that the timer function is activated Timer active If not the programmed start stop commands will not be executed Adding a command Press the key List and scroll through the commands until the command aft...

Page 69: ...n shown is Time If another option is desired scroll through the display using scroll keys 1 and select using key 3 In case of option Time the second line on the screen indicates the actual setting e g 14 30 If it is desired to modify the time press key Modify 3 If not press key Menu to return to the submenu After pressing the key Modify the first field 14 will blink Modify the hours using scroll k...

Page 70: ...uration and other data reflecting the condition of that moment The longest unload data time date duration and other data reflecting the condition of that moment Procedure Starting from the Main screen see Main screen menu Press key Menu F1 Press key 1 until Saved data is shown Activate the menu by pressing key Select 3 The first option shown is Last shutdown 1 Use scroll keys 1 to select possible ...

Page 71: ...hat the regulator is automatically controlling the compressor i e loading unloading stopping and automatic restarting The second line indicates whether the regulator operates in local control or remote control mode Local control means that the start stop buttons on the keyboard are activated Remote control means that these functions are controlled remotely Consult the Atlas Copco Customer Centre T...

Page 72: ...Main screen menu press key Unload 2 LED 1 goes out The message Manually Unloaded appears on the display Manually loading Starting from the Main screen see Main screen menu press key Load 2 LED 1 lights up Note The compressor is not forced to loaded condition but the operation of the compressor is switched to automatic operation again and will be loaded if required by the air net pressure 3 26 Prog...

Page 73: ...59 5 130 5 150 8 Loading pressure bar e 4 0 6 0 7 4 Loading pressure psig 58 87 107 3 Loading pressure bar e 4 0 8 0 9 9 Loading pressure psig 58 116 143 6 Loading pressure bar e 4 0 6 0 8 5 Loading pressure psig 58 87 123 2 Loading pressure bar e 4 0 8 0 10 3 Loading pressure psig 58 116 149 4 Protection settings Minimum setting Factory setting Maximum setting Compressor element 1 outlet temperat...

Page 74: ... shut down warning level F 212 437 453 Compressor element 2 outlet temperature shut down level C 100 235 235 Compressor element 2 outlet temperature shut down level F 212 455 455 Protection settings Minimum setting Factory setting Maximum setting Compressor element 2 inlet temperature shut down warning level C 40 65 79 Compressor element 2 inlet temperature shut down warning level F 104 149 174 Co...

Page 75: ...the warning level is programmed at 410 F the minimum limit for the shut down level changes into 411 F The recommended difference between the warning level and shut down level is 18 F Oil Use Atlas Copco Roto Z oil The change interval for this oil is after 16000 running hours or 2 yearly Oil filters Use Atlas Copco filters The change interval is after 8000 running hours or yearly Air filters Use At...

Page 76: ...nloading is 1 bar Unloading Loading pressure The regulator does not accept illogical settings e g if the unloading pressure is programmed at 109 psi the maximum limit for the loading pressure changes into 108 psi The recommended minimum pressure difference between loading and unloading is 14 5 psi Delay at starting Is the time interval within which the oil pressure must be built up Delay at signal...

Page 77: ...on the manufacturing date or the ordered configuration the compressor is equipped with the Elektronikon controller the Elektronikon Graphic controller the Elektronikon GraphicPlus controller Elektronikon controller Elektronikon Graphic controller for fixed speed compressors Instruction book 2920 1815 04 75 ...

Page 78: ...ontroller for variable speed drive VSD compressors Elektronikon GraphicPlus controller for fixed speed compressors Elektronikon GraphicPlus controller for variable speed drive VSD compressors Instruction book 76 2920 1815 04 ...

Page 79: ...starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case the expected unloading period is too short the compressor is kept running to prevent too short standstill periods A number of time based automatic start stop commands may be programmed Take into account that a start...

Page 80: ...omatic restart after voltage failure The regulator has a built in function to automatically restart the compressor if the voltage is restored after voltage failure For compressors leaving the factory this function is made inactive If desired the function can be activated Consult the Atlas Copco Customer Centre If activated and provided the regulator was in the automatic operation mode the compress...

Page 81: ...the right can be modified 5 Function keys Keys to control and program the compressor 6 Voltage on LED Indicates that the voltage is switched on 7 General alarm LED Is lit if a shut down warning condition exists or maintenance is required 7 General alarm LED Flashes if a shut down condition exists if an important sensor is out of order or after an emergency stop 8 Automatic operation LED Indicates ...

Page 82: ...reviously shown option or menu Cancel To cancel a programmed setting when programming parameters Delete To delete compressor start stop commands Help To find the Atlas Copco internet address Limits To show limits for a programmable setting Load To load the compressor manually Mainscreen To return from a menu to the main screen Menu Starting from the main screen to have access to the submenus Menu ...

Page 83: ...scroll key with the same symbol can be used to see the previous item When the scroll key is kept pressed the scrolling is continued 5 5 Emergency stop button Control panel In case of emergency press button S2 to stop the compressor immediately At the occurrence of an emergency stop the compressor element is stopped immediately and the solenoid valve will be deactivated by Elektronikon regulator No...

Page 84: ...onnecting external equipment Consult the Safety precautions Connections for external compressor status indication Terminal strip 1X7 is fitted with auxiliary contacts for external indication of Indication Relay Terminals on strip 1X1 Maximum load Automatic operation K07 11 12 10 A 230 V AC Warning K08 13 14 10 A 230 V AC Shut down K09 15 16 10 A 230 V AC Compressor loaded K11 19 20 10 A 230 V AC C...

Page 85: ...R ZT 110 up to ZR ZT 275 and ZR 300 up to ZR 750 simplified Main menu Program Function Main screen Shows in short the operation status of the compressor Is the gateway to all functions Instruction book 2920 1815 04 83 ...

Page 86: ...ons e g temperature shut down level Service plans timers for service plans Clock functions automatic compressor start stop pressure band commands Configuration time date display language Service Calls up service plans and resets the timers after carrying out the service actions belonging to a plan Saved data Calls up the saved data last shut down last emergency stop data Unload Load Loads and unlo...

Page 87: ...menu The arrow down key 1 can be used for a quick look at the actual compressor status 5 9 Main screen menu Function Control panel The Main screen menu shows the status of the compressor operation and is the gateway to all functions implemented in the regulator Procedure The Main screen is shown automatically when the voltage is switched on If the function or arrow keys 1 2 and 3 are not used for ...

Page 88: ...sages regarding the compressor operating condition Just above the function keys 3 the actual functions of these keys 5 10 Status data menu Warning Before starting any maintenance or repairs press the stop button 4 wait until the compressor has stopped press the red emergency stop button and open the isolating switch customer s installation to switch off the voltage to the compressor Close the air ...

Page 89: ...e outlet of the compressor element Element Outlet 114 C Shutdown Maximum 110 C Menu Help Reset F1 F2 F3 The indicators are blinking The screen shows the actual reading and the shut down setting It remains possible to scroll through other menus e g to check the values of other parameters When returning to the Status Data menu the option Shutdowns will blink This option can be selected by pressing t...

Page 90: ...warning message will disappear automatically as soon as the warning condition disappears A service warning exists LED 1 is alight The Main screen will change into a screen similar to the one below Compressor Outlet 7 0 bar Service Required Menu Unload F1 F2 F3 The indicators are blinking and the service warning message appears Press the key Menu F1 and the tabulator key 2 to select the Status data...

Page 91: ...n Consult the menu flow in section Control programs Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Measured Data is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 By pressing the scroll keys 1 a number of actually measured data can be found If one of the sensors is linked to a shut down service o...

Page 92: ...rocedure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Counters is followed by a horizontal arrow Press the tabulator key 2 to activate the menu By pressing the arrow key 1 the above mentioned data can be found Example of a Counters screen Running Hours 2455 hrs Loaded Hours 1973 hrs Motor Starts 945 Menu F1 F2 F3 Instruction book 90 2920...

Page 93: ...esting the regulator will generate a series of patterns on the display which enable the operator to check that each pixel still functions normally the LEDs are lit at the same time Press the Menu key F1 to return to the submenu To test the Electronic Water Drains on compressors designed for an ambient temperature of 40 C 104 F Press the arrow down key until the option Outputs is followed by a hori...

Page 94: ...edure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Modify Parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 The first item Parameters will be followed by a horizontal arrow Press the tabulator key 2 the first items and their settings will appear Press the arrow down key 1 until the parameter t...

Page 95: ...mable settings for the most important settings 5 16 Modifying protection settings Control panel Function To modify protection settings Shutdown e g for the compressor element outlet temperature Shutdown warning e g for the compressor element outlet temperature Warning e g for the dew point temperature Service warning e g for the maximum pressure drop over the air filter To check various compressor...

Page 96: ... below shows a horizontal arrow indicating that the shut down warning value can be modified the procedure is similar to the description above The procedure to modify other items is similar For some settings a delay can be programmed Example of the screen for ZR ZT compressors Element 1 outlet 178 C Shutdown Maximum 235 C Menu Modify F1 F2 F3 The regulator will not accept new values beyond the limi...

Page 97: ... to pressure band 2 On Saturday at 18 00 stopping Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Modify Parameters is followed by a horizontal arrow Activate the menu by pressing tabulator key 2 Use the arrow down key 1 to scroll until the option Clock Function is followed by a horizontal arrow Activate the menu by pressing tabulator key 2...

Page 98: ...nd modify this line in a similar way to the following command 06 15 Pressure Band 1 Press the key Menu F1 and scroll to Friday Thursday Friday Saturday Menu Delete F1 F2 F3 Programming the command to change over at 18 o clock to Pressure Band2 is carried out in a similar way as described above Press the key Menu F1 and scroll to Saturday Programming the command 18 00 Compressor Stop is carried out...

Page 99: ...p the compressor on Saturday 18 00 is to be modified i e stopping at 17 o clock instead of 18 o clock Starting from the Main screen press the key Menu F1 press the arrow down key 1 until the option Modify Parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 Use the arrow down key 1 to scroll until the option Clock Function is followed by a horizontal arrow...

Page 100: ...wing screen appears Monday Tuesday Wednesday Menu Delete F1 F2 F3 Scroll through the display until Monday is followed by a horizontal arrow Press the tabulator key 2 Scroll through the compressor start stop pressure band commands until the first empty command line is indicated by the horizontal arrow Press the key Modify the first two digits start blinking Enter 18 00 Compressor Stop using the scr...

Page 101: ...al arrow Press the tabulator key following screen appears Clock Function Not Activated Menu Modify Delete F1 F2 F3 Deleting all commands Press the key Delete in the screen above A question to confirm the deleting operation will appear Deleting all commands of a specific day Scroll through the display until the desired day is followed by a horizontal arrow Press the key Delete a question to confirm...

Page 102: ...y Modify F2 the first field 14 will blink Use the scroll keys 1 to change the setting then press the tabulator key 2 to go to the next field 30 The setting of this field can now be modified using the scroll keys 1 Press the key Program F1 to program the new value or the key Cancel F3 to cancel the modification operation the original value will be retained The procedure to modify other parameters i...

Page 103: ...e Elektronikon regulator When a service plan interval is reached a message will appear on the screen see section Status data After carrying out the service actions related to the indicated levels the timers are to be reset Example Service plans Intervals Service plan A Every 4000 running hours Service plan B Every 8000 running hours Service plan C Every 16000 running hours Service actions accordin...

Page 104: ...s Press the arrow down key 1 to find out which service plans were carried out previously following screen appears Previous Timer Level A 4008 hrs Back F1 F2 F3 The screen shows that plan A was carried out at 4008 running hours Stop the compressor switch off the voltage and carry out the service operations related to the indicated service plans see section Preventive maintenance schedule Switch on ...

Page 105: ...r key 2 The first option is shown Last shutdown 1 Press the tabulator key 2 to find out the date time and other data reflecting the status of the compressor at the last shut down If desired scroll through the other items 5 22 Programmable settings Parameters Minimum setting Factory setting Maximum setting Load delay time star delta sec 3 10 30 Load delay time no star delta sec 13 20 30 Minimum sto...

Page 106: ...re 125 psi compressors psig 58 101 5 124 7 Unloading pressure 10 bar Pack compressors bar e 4 0 9 0 10 0 Unloading pressure 145 psi Pack compressors psig 58 130 5 145 Unloading pressure 10 bar Full Feature compressors bar e 7 5 9 0 10 0 Unloading pressure 145 psi Full Feature compressors psig 109 130 5 145 Unloading pressure 10 4 bar Pack compressors bar e 4 0 9 0 10 4 Unloading pressure 150 psi P...

Page 107: ... 6 Loading pressure 125 psi Full Feature compressors psig 94 87 124 7 Loading pressure 10 bar Pack compressors bar e 4 0 8 0 10 0 Loading pressure 145 psi Pack compressors psig 58 116 145 Loading pressure 10 bar Full Feature compressors bar e 7 5 8 0 10 0 Loading pressure 145 psi Full Feature compressors psig 109 116 145 Loading pressure 10 4 bar Pack compressors bar e 4 0 8 0 10 4 Loading pressur...

Page 108: ...Compressors designed for a maximum inlet temperature of 104 F F 212 410 428 Compressors designed for a maximum inlet temperature of 50 C C 100 225 235 Compressors designed for a maximum inlet temperature of 122 F F 212 437 455 Compressor element 1 outlet temperature shut down level 7 0 7 5 and 8 6 bar or 100 110 and 115 psi compressors Compressors designed for a maximum inlet temperature of 40 C C...

Page 109: ...ar 190 psi compressors C 256 260 260 Compressor element 1 outlet temperature shut down level 13 0 bar 190 psi compressors F 493 500 500 Compressor element 2 outlet temperature shut down warning level 7 0 7 5 and 8 6 bar or 100 110 and 115 psi compressors Compressors designed for a maximum inlet temperature of 40 C C 100 210 220 Compressors designed for a maximum inlet temperature of 104 F F 212 41...

Page 110: ...temperature of 104 F F 212 437 455 ZR Compressors designed for a maximum inlet temperature of 50 C C 100 225 235 ZR Compressors designed for a maximum inlet temperature of 122 F F 212 437 455 ZT Compressors designed for a maximum inlet temperature of 50 C C 100 255 260 ZT Compressors designed for a maximum inlet temperature of 122 F F 212 491 500 Compressor element 2 outlet temperature shut down l...

Page 111: ... to 158 F F 104 149 176 Compressor element 2 inlet temperature shut down level If an energy recovery system is provided on a Full Feature compressor the factory setting is increased to 80 C C 66 70 80 Compressor element 2 inlet temperature shut down level If an energy recovery system is provided on a Full Feature compressor the factory setting is increased to 176 F F 151 158 176 Delay at signal al...

Page 112: ...ng 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 ...

Page 113: ... recovery time Is the period within which the voltage must be restored to have an automatic restart Is accessible if the automatic restart is activated To activate the automatic restart function consult Atlas Copco Unloading Loading pressure The regulator does not accept illogical settings e g if the unloading pressure is programmed at 7 0 bar e 101 psig the maximum limit for the loading pressure ...

Page 114: ...ed and stops the compressor to reduce power consumption when it has been running unloaded for a given time In case the net pressure drops down to the loading pressure while the compressor is running unloaded the compressor is kept running and switches to load to avoid short standstills and energy waste When the compressor has stopped automatically and the net pressure decreases the controller will...

Page 115: ... remedying always check the applicable safety precautions Service warning A number of service intervals are grouped into Service Plans all with their own time frame If a service interval is reached a message will appear on the controller display to warn the operator to carry out the prescribed service actions stated in a certain Service Plan Automatic restart after voltage failure ARAVF The contro...

Page 116: ...e is needed 7 Automatic operation LED Indicates that the controller runs in automatic mode 8 Voltage on LED Lights up when supply is switched on Compressor unit might start automatically 9 Pictogram Voltage on 10 Enter key Enter and confirmation key 11 Escape key To navigate to previous screen or to cancel current action 12 Scroll keys Keys to scroll through the menu 13 Stop button Button to stop ...

Page 117: ...quipment The Elektronikon Mk5 always comes with expansion module IO2 that has a number of digital output contacts which can be used to connect external equipment Depending on the optional equipment extra expansion modules are added to the machine configuration IO2 IO34 Expansion Module IO2 for Elektronikon Mk5 The digital output contacts have following specifications Relay Connector Maximum load K...

Page 118: ...250 V AC 10 A 30 V DC resistive load K09 3 X 30 10 A 250 V AC 10 A 30 V DC resistive load K10 3 X 32 10 A 250 V AC 10 A 30 V DC resistive load K11 3 X 32 10 A 250 V AC 10 A 30 V DC resistive load K12 3 X 32 10 A 250 V AC 10 A 30 V DC resistive load K13 3 X 32 10 A 250 V AC 10 A 30 V DC resistive load K14 3 X 32 10 A 250 V AC 10 A 30 V DC resistive load K15 3 X 32 10 A 250 V AC 10 A 30 V DC resisti...

Page 119: ...tart stop Remote start stop Network control Automatic restart after voltage failure Automatic restart after voltage failure is enabled Week timer Week timer is active Active protection functions Emergency stop Shutdown Warning Service Service required Main screen Displayed when 2 or 4 line layout is picked Displayed when chart layout is picked Instruction book 2920 1815 04 117 ...

Page 120: ...icons Icon Description Service Alarms warnings shutdowns Week timer Info Test Counters Regulation setpoints Inputs Outputs SPM readings ESi Event history saved data Settings Instruction book 118 2920 1815 04 ...

Page 121: ...ion Compressor element LP HP Dryer Fan icon only visible when installed on compressor unit Drain s icon only visible when Electronically Regulated Drain ERD is installed on compressor unit Filter s Motor Expansion module Failure Cooler Energy Recovery Network settings problem Instruction book 2920 1815 04 119 ...

Page 122: ...General alarm Oil circuit Regulation General settings Access key User password Navigation arrows Icon Description Up Down 6 5 Main screen Control panel Control panel Instruction book 120 2920 1815 04 ...

Page 123: ...en is shown automatically when the voltage is switched on and a key is pushed The display switches to sleep mode when no keys are pushed for several minutes Five different main screens can be chosen 1 Two value lines 2 Four value lines 3 Chart High resolution 4 Chart Medium resolution 5 Chart Low resolution Value views Typical Main screen Two value lines Instruction book 2920 1815 04 121 ...

Page 124: ...se icons are always shown in the main screen and cannot be selected by the cursor e g Compressor stopped or running Shortcut icons These icons are always shown in the main screen If the icon is selected and the Enter key is pushed the screen will jump to the corresponding menu e g if the icon for Motor stopped or Running Loaded is selected the screen will jump directly to the regulation menu after...

Page 125: ...he text that corresponds to the selected icon Section D shows the Action buttons These buttons are used to call up or program settings to reset a shutdown service message or emergency stop to have access to all data collected by the controller The function of the buttons depends on the displayed menu The most common functions are Designation Function Menu To go to the menu Modify To modify program...

Page 126: ...s selected a chart with an X axis covering 4 hours is displayed The value displayed on the Y axis depends on the selection made in the input screen Each chart dot represents a 1 minute average value When the Chart Low Resolution display is selected a chart with an X axis covering 10 days is displayed The value displayed on the Y axis depends on the selection made in the input screen Each chart dot...

Page 127: ...keys Description When the voltage is switched on the main screen is shown automatically see section Main screen To go to the Menu screen highlight the Menu button 4 using the Scroll keys Press the Enter key to select the menu Following screen appears Instruction book 2920 1815 04 125 ...

Page 128: ...u that corresponds with the selected icon Use the Scroll keys to select an icon Press the Enter key to activate the menu or press the Escape key to return to the Main screen 6 7 Service menu Control panel Control panel 1 Enter key 2 Escape key 3 Scroll keys Menu icon Service Instruction book 126 2920 1815 04 ...

Page 129: ...e parts To reset the service plans that have been carried out To check when the next service plans should be carried out To check which service plans were carried out in the past To modify the programmed service intervals Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action key and push the Enter key Following screen appears Use the Scroll keys to move the cur...

Page 130: ... 4000 hours and Real Time Hours 8800 8760 hours 1 year A service warning will be displayed after one year or sooner after 4000 running hours if the compressor has been running a lot The figures at the left of the progress bars are the programmed service interval Running or Real Time Hours Those at the right count down and show the number of hours that need to be covered to reach the next service i...

Page 131: ...appears Text on figure 1 Service plan 2 Level 3 Running hours 4 Real time hours 5 Modify Modifying a service plan Depending on the operating conditions it might be necessary to modify the service intervals To do so use the Scroll keys to select the value to be modified A screen similar to the one below appears Push the Enter key Following screen appears Instruction book 2920 1815 04 129 ...

Page 132: ...e above the I Service level is programmed at 2000 running hours of which 0 hours have passed History The History screen shows a list of all service actions carried out in the past sorted by date The date at the top is the most recent service action To see the details of a completed service action e g Service level Running hours or Real time hours use the Scroll keys to select the desired action an...

Page 133: ...em Frequently resetting these messages without remedying may damage the compressor Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action button and push the enter key 2 Following screen appears Using the Scroll keys 1 move the cursor to the protections icon Push the Enter key 2 Following screen appears Instruction book 2920 1815 04 131 ...

Page 134: ...ual reading for the compressor outlet is 2 53 bar The screen shows also the settings for the shutdown warning 3 60 bar and shutdown 3 70 bar On the bottom of the screen are two buttons Reset to reset the alarm after remedying the problem Modify to change the alarm settings Depending on the machine type and the installed optional equipment less more different icons and or relevant underlying menus ...

Page 135: ...s Drain s Condensate Drain IC not ok IC Intercooler Condensate Drain AC not ok AC Aftercooler Condensate drain AC2 AC2 additional aftercooler for Full Feature compressors with energy recovery Condensate drain RC in RC Regeneration cooler Condensate drain RC out RC Regeneration cooler Condensate drain MD MD MD Dryer Filters Warning shutdown level Low of DP air filter DP delta pressure or pressure d...

Page 136: ...l temperature 6 9 Week timer menu Control panel 1 Enter key 2 Escape key 3 Scroll keys Menu icon Week timer Function To program time based start stop commands for the compressor To program time based net pressure band change commands The timer function allows 4 different Week Action Schemes These can be combined into a sequence of 10 weeks in a Week Cycle Instruction book 134 2920 1815 04 ...

Page 137: ...rting from the Main screen see Main screen section Move the cursor to the Menu action button and push the Enter key Use the Scroll buttons to select the Timer icon Press the Enter key on the controller Following screen appears 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Week 1 6 Remaining Running Time The selected item is highlighted in grey Select the desired item and push the Ente...

Page 138: ... 1 Week Action Schemes 2 Week Action Scheme 1 3 Week Action Scheme 2 4 Week Action Scheme 3 5 Week Action Scheme 4 When entering a Week Action Scheme the corresponding week is displayed The selected day is highlighted in grey and the desired action can be set by pushing Enter 1 Week Action Scheme 1 2 Monday 3 Tuesday 4 Wednesday 5 Thursday 6 Friday 7 Saturday 8 Sunday Instruction book 136 2920 181...

Page 139: ...Modify A new window appears Select an action from the displayed list by using the Scroll keys on the controller Push the Enter key to insert e g a first startup time 1 Monday 2 Actions 3 Remove 4 Start 5 Stop 6 Modify A new window opens The startup action is now visible on Monday of Week Action Scheme 1 4 Instruction book 2920 1815 04 137 ...

Page 140: ...ys on the controller and push the Enter key to confirm 1 Monday 2 Start 3 Save 4 Modify A window appears Use the or scroll keys to modify the hour values Use the or Scroll keys to select the minutes and modify the values using the or scroll keys Instruction book 138 2920 1815 04 ...

Page 141: ...r The Modify action button is selected Use the Scroll keys to select the action Save 1 Monday 2 Start 3 Save 4 Modify A new window appears Use the Scroll keys on the controller to select the correct actions Press the Enter key to confirm Instruction book 2920 1815 04 139 ...

Page 142: ...5 Save 6 Modify Press the Escape key to leave this window The actions are displayed below their respective day 1 Week Action Scheme 1 2 Monday 3 Start 4 Tuesday 5 Wednesday 6 Thursday 7 Friday 8 Saturday Instruction book 140 2920 1815 04 ...

Page 143: ...h week in the cycle one of the four programmed Week Action Schemes can be chosen Select Week Cycle from the main Week Timer menu list 1 Week Timer 2 Week Action Schemes 3 Week Cycle 4 Status 5 Week 1 6 Remaining Running Time A list of 10 weeks is displayed 1 Week Cycle 2 Week 1 3 Week Action Scheme 4 4 Week 2 Instruction book 2920 1815 04 141 ...

Page 144: ...on Scheme 1 1 Week Cycle 2 Week 1 3 Off 4 Week Action Scheme 1 5 Week Action Scheme 2 6 Week Action Scheme 3 7 Modify Check the status of the Week Timer Use the Escape key to return to the main Week Timer menu The status of the Week Timer is displayed in the third line Push the Enter key to adjust status 1 Week Timer 2 Week Action Schemes Instruction book 142 2920 1815 04 ...

Page 145: ... might be necessary to keep the compressor running instead of allowing the Week Timer to stop it To enable this condition Remaining Running Time was developed After scrolling to Remaining Running Time its setting can be modified by pushing Enter and adjusting the value between 5 and 240 minutes in steps of 5 minutes 1 Week Timer 2 Remaining Running Time After pushing the Enter key the Remaining Ru...

Page 146: ...tion To show the Atlas Copco internet address Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action button and push the Enter key Following screen appears Scroll the cursor to the Info icon see above section Menu icon Instruction book 144 2920 1815 04 ...

Page 147: ...ollowing additional info MAC address Expansion modules Boot software Operating system Application software PEG software Licence ESi 6 11 Test menu Control panel Menu icon Test Function To perform a safety valve test and a drain test Both actions can only be performed by authorized personnel and are protected by a security code Instruction book 2920 1815 04 145 ...

Page 148: ...loaded hours air delivery The number of motor starts The number of load cycles The number of hours that the controller has been powered module hours Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action button and press the Enter key Following screen appears Instruction book 146 2920 1815 04 ...

Page 149: ...o the Counters icon see above section Menu icon Press the Enter key Following screen appears Text on figure 1 Counters 2 Running hours 3 Loaded Hours 4 Motor starts 5 Load relay The screen shows a list of all counters and their current values Instruction book 2920 1815 04 147 ...

Page 150: ...ulation menu allows tuning of 2 pressure bands and the selection of the current pressure band Procedure Starting from the Main screen see Main screen The regulation menu is accessible in two ways a select Menu action key using the Scroll keys and push the Enter key Following screen appears Instruction book 148 2920 1815 04 ...

Page 151: ...in the Main Screen and push enter Following screen appears Text on figure 1 Regulation 2 Unloading pressure 1 3 Loading pressure 1 4 Unloading pressure 2 5 Loading pressure 2 6 Modify The screen shows the current settings To modify the settings move the cursor to the action button Modify and push the Enter key Following screen appears Instruction book 2920 1815 04 149 ...

Page 152: ...pears The upper and lower limit of the setting is shown in grey the actual setting is shown in black Use the or key of the Scroll keys to modify the settings as required and push the Enter key to accept If necessary change the other settings as required in the same way as described above 6 14 Inputs menu Control panel Instruction book 150 2920 1815 04 ...

Page 153: ...nputs Procedure Starting from the main screen see Main screen Move the cursor to the Menu action key and push the Enter key Following screen appears Text on figure 1 Menu 2 Regulation Using the Scroll keys move the cursor to the Inputs icon see above section Menu icon Push the Enter key and the screen below appears Instruction book 2920 1815 04 151 ...

Page 154: ...original icon is replaced by the warning or shutdown icon respectively Setting an input as main chart see section Main screen Navigate to the input screen as described above Push the Enter key the first input on the screen will be highlighted in grey Using the arrow keys scroll to the input to be set as main chart Push the Enter key following screen appears Text on figure 1 Inputs 2 Main chart sig...

Page 155: ...hted in grey Using the arrow keys scroll to the input to be set as main chart Push the Enter key following screen appears 1 Inputs 2 Main chart signal 3 Set as main chart signal 4 Modify Push the Enter key following screen appears 1 Main chart signal 2 Are you sure to change the main chart signal All current chart data will be lost 3 Yes 4 No Select the Yes key to confirm or the No key to cancel t...

Page 156: ...g the arrow keys scroll to the input with the small chart icon Push the Enter key following screen appears 1 Main chart signal 2 Remove from main chart Push the Enter key following screen appears 1 Main chart signal 2 Are you sure to change the main chart signal All current chart data will be lost 3 Yes 4 No Select the Yes key to confirm or the No key to cancel the modification Instruction book 15...

Page 157: ... icon Outputs Function To display information regarding the current status of the digital outputs Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action button and push the Enter key Following screen appears Instruction book 2920 1815 04 155 ...

Page 158: ...s Push the Enter key to show the actual outputs General Load Unload Automatic operation General warning General shutdown Drain s Condensate drain IC Condensate drain AC Condensate drain AC2 AC2 additional aftercooler for Full Feature compressors with energy recovery Condensate drain RC in RC Regeneration cooler Condensate drain RC out RC Regeneration cooler Condensate drain MD MD MD Dryer Main Mot...

Page 159: ...unction To display a list of all shutdowns their causes and the status of counters and in outputs at the moment of shutdown Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action button and push the Enter key Following screen appears Instruction book 2920 1815 04 157 ...

Page 160: ... data of counters and in outputs will be displayed 6 17 Modifying settings Control panel 1 Enter key 2 Escape key 3 Scroll keys Menu icon Settings Function To display and modify a number of settings e g Time Date Date format Language units Procedure Starting from the Main screen see Main screen Move the cursor to the Menu action button and push the Enter key Following screen appears Instruction bo...

Page 161: ...imilar to the one below appears Depending on the installed optional equipment less or more icons may appear The screen displays following icons Icon Function Network settings Regulation settings General settings Automatic restart after voltage failure settings Access key User password Instruction book 2920 1815 04 159 ...

Page 162: ...difying network settings Select the network settings icon as described above and push the Enter key 1 Following screen appears Text on figure 1 Network 2 CAN 3 Ethernet Scroll to the desired network and push the Enter key A screen similar to the one below appears Screen for CAN settings Instruction book 160 2920 1815 04 ...

Page 163: ...llows to view and modify the regulation settings General settings Select the General settings icon as described above and push the Enter key 1 Following screen appears Text on figure 1 General 2 Language in use 3 Time 4 Date 5 Date format The screen displays the first 4 items of a list of all settings Scroll through the list to display all other items Instruction book 2920 1815 04 161 ...

Page 164: ...n A screen appears the required parameter is adjustable and confirmed by pushing the Enter Key once more Access key A number of security levels are set in the controller e g user service technician etc The Access key menu item is used to change the security level Scroll to the correct icon using the scroll key and push the Enter key Push the Enter key twice to modify the security level code and pu...

Page 165: ...inimum 5 Maximum 6 Chart band 7 Low 8 High 9 Off The screen shows the main chart signal the current chart range and band settings To modify these settings proceed as follows Push the Enter key select chart range or chart band as desired and confirm Modifying the chart range Select the chart range as described above and proceed as follows Push the Enter key the minimum setting becomes highlighted P...

Page 166: ...Each level stands for a number of service operations to be carried out at the programmed intervals Consult your Atlas Copco Service Center Other programmable settings Unit Min Pack version Min Full Feature version Max Max with Energy Recovery Pressure regulation UN LOAD level mbar 7 bar 60 Hz 4000 5000 7005 6505 7 5 bar 50 Hz 4000 5500 7505 7005 8 6 bar 50 Hz 4000 6500 8605 8105 8 6 bar 60 Hz 4000...

Page 167: ...on timeout 10 10 60 60 6 19 Web server All controllers have a built in web server that allows direct connection to the company network or to a dedicated PC via a local area network LAN This allows to consult certain data and settings via a PC instead of the display of the controller Getting started If the unit is equipped with a SMARTBOX the network connection of the Elektronikon is already in use...

Page 168: ... below Configuration of the network card Go to Network and Sharing Center 1 Click on Change adapter settings 1 Select the Local Area Connection which is connected to the controller Click with the right button and select Properties 1 Instruction book 166 2920 1815 04 ...

Page 169: ...ess 192 168 100 200 1 Subnetmask 255 255 255 0 2 Click OK 3 and close network connections Configure a company network LAN connection Ask your IT department to generate a fixed IP address in your company s network That IP address will be excluded from the DNS server so it will be reserved for the Elektronikon Mk5 Also get the correct Gateway and Subnet mask settings For example IP 10 25 43 200 Gate...

Page 170: ...0 Connect your Elektronikon Mk5 to the company s network LAN by using a UTP cable min CAT 5e Adapt the network settings in the Elektronikon Mk5 Go to Main Menu Go to Settings 1 Go to Network 1 Instruction book 168 2920 1815 04 ...

Page 171: ...thernet 1 Switch Off 1 the Ethernet communication to allow editing the settings Adapt IP Address 1 Adapt Gateway IP 2 Adapt Subnet Mask 3 Switch On 4 the Ethernet communication Instruction book 2920 1815 04 169 ...

Page 172: ...et Explorer Also Opera Mozilla Firefox Safari and Chrome should work Viewing the controller data All screen shots are indicative The number of displayed fields depends on the selected options Open your browser and type the IP address of the controller you want to view in your browser in this example http 192 168 100 100 The interface opens Instruction book 170 2920 1815 04 ...

Page 173: ...e available on the controller On the left side of the interface you can find the navigation menu If a license for ESi is foreseen the menu contains 3 buttons Machine shows all generator settings ES shows the ESi status if a license is provided Preferences allows to change temperature and pressure unit Instruction book 2920 1815 04 171 ...

Page 174: ...moved from the main screen Analog inputs Lists all current analog input values The measurement units can be changed in the preference button from the navigation menu Counters Lists all current counter values from controller and unit Info status Machine status is always shown on the web interface Digital inputs Lists all digital inputs and their status Instruction book 172 2920 1815 04 ...

Page 175: ...ons Lists all special protections of the unit Service plan Displays all levels of the service plan and their status This screen shot underneath only shows the running hours It is also possible to show the current status of the service interval Instruction book 2920 1815 04 173 ...

Page 176: ...7 Installation 7 1 Dimension drawing Dimensions Dimension drawing of ZR 110 up to ZR 145 Instruction book 174 2920 1815 04 ...

Page 177: ...Dimension drawing of ZR 110 up to ZR 145 Full Feature page 1 Instruction book 2920 1815 04 175 ...

Page 178: ...Dimension drawing of ZR 110 up to ZR 145 Full Feature page 2 Instruction book 176 2920 1815 04 ...

Page 179: ...Dimension drawing of ZT 110 up to ZT 145 page 1 Instruction book 2920 1815 04 177 ...

Page 180: ... of ZT 110 up to ZT 145 page 2 Reference Name 1 Right side view 2 Front view 3 Motor cooling air outlet 4 Motor cooling compressor air inlet 5 Hot air version 6 Voltage supply entrance Instruction book 178 2920 1815 04 ...

Page 181: ...n 28 Automatic drain dryer outlet 29 Automatic drain regeneration outlet 30 Automatic drain prepared for MD with energy recovery 31 Manual drain dryer inlet 32 Compressor and cooling air outlet 33 Cooling compressor air inlet 34 Cooling air inlet 35 Standard version 36 Voltage supply entrance possibility 2 37 Voltage supply entrance possibility 1 38 Cooling air outlet 39 Voltage supply entrance po...

Page 182: ...ecovery Fresh water out 59 Access for PDP sensor 60 Low load option Connection for regeneration air see detail 61 For connection with pipe coupling brand Victaulic 62 Access for control cable water shut off valve 63 For option energy recovery closed circuit out 64 For option energy recovery closed circuit in 65 Low load option blow off 66 Compressor air inlet 67 Motor cooling air inlet 68 Separate...

Page 183: ...Dimension drawing of ZR 160 up to ZR 275 Pack and ZR 250 315 VSD Pack compressors in metric units Instruction book 2920 1815 04 181 ...

Page 184: ...Dimension drawing of ZR 160 up to ZR 275 Pack and ZR 250 315 VSD Pack compressors in imperial units Instruction book 182 2920 1815 04 ...

Page 185: ...Dimension drawing of ZT 160 up to ZT 275 Pack and ZT 250 315 VSD Pack compressors in metric units Instruction book 2920 1815 04 183 ...

Page 186: ...Dimension drawing of ZT 160 up to ZT 275 Pack and ZT 250 315 VSD Pack compressors in imperial units Instruction book 184 2920 1815 04 ...

Page 187: ...Dimension drawing of ZR 160 up to ZR 275 Full Feature and ZR 250 315 VSD Full Feature compressors in metric units Instruction book 2920 1815 04 185 ...

Page 188: ...Dimension drawing of ZR 160 up to ZR 275 Full Feature and ZR 250 315 VSD Full Feature compressors in imperial units Instruction book 186 2920 1815 04 ...

Page 189: ...Dimension drawing of ZT 160 up to ZT 275 Full Feature and ZT 250 315 VSD Full Feature compressors in metric units Instruction book 2920 1815 04 187 ...

Page 190: ...d ZT 250 315 VSD Full Feature compressors in imperial units Reference Description 1 Right side view 2 Front view 3 Motor cooling air outlet 4 Compressed air inlet 5 Motor cooling air inlet only for option separate air intake Instruction book 188 2920 1815 04 ...

Page 191: ...pressors with foot mounted motors 22 Top view 23 Left side view for option energy recovery 24 Compressed air outlet DN 80 PN 16 acc DIN 2633 Scale 1 5 25 Compressed air outlet 3 150 Lbs acc ANSI B16 5 Scale 1 5 26 Cooling water outlet of the energy recovery circuit 27 Circuit A 28 Cooling water outlet of the dryer circuit 29 Circuit B 30 Compressed air outlet 31 Cooling water inlet of the energy r...

Page 192: ...gh ambient temperature compressor or an oversized motor or a motor with supply voltage 690 V 1540 lb should be added in case of a high ambient temperature compressor or an oversized motor or a motor with supply voltage 690 V 58 Automatic drain of aftercooler G 1 2 female not for hot air version 59 Automatic drain of regeneration outlet 1 G 1 2 female 60 Automatic drain of regeneration outlet 2 G 1...

Page 193: ...Drawings DIN to JIS adaptor flange with inner pipe diameter ranging from 32 to 65 mm Instruction book 2920 1815 04 191 ...

Page 194: ...DIN to JIS adaptor flange with inner pipe diameter ranging from 80 to 125 mm Instruction book 192 2920 1815 04 ...

Page 195: ...4 Section X X 5 Cooling water quantity 2 Applicable for range 6 O D Outer Diameter 7 Bolt hole pitch 8 I D Inner Diameter 9 Pipe size 10 Hole for pipe 11 Air outlet quantity 1 Applicable for range 12 To be ordered through Systems Wilrijk Instruction book 2920 1815 04 193 ...

Page 196: ...7 3 Installation proposal Compressor room example Installation proposal for ZR 110 up to ZR 145 and ZR 132 160 VSD Instruction book 194 2920 1815 04 ...

Page 197: ...Installation proposal for ZR 110 Full Feature up to ZR 145 Full Feature and ZR 132 160 VSD Full Feature Instruction book 2920 1815 04 195 ...

Page 198: ...ion proposal for ZR 160 Full Feature up to ZR 275 Full Feature ZR 250 VSD Full Feature and ZR 315 VSD Full Feature without Energy Recovery and without dryer by pass option in mm Instruction book 196 2920 1815 04 ...

Page 199: ...on proposal for ZR 160 Full Feature up to ZR 275 Full Feature ZR 250 VSD Full Feature and ZR 315 VSD Full Feature without Energy Recovery and without dryer by pass option in inch Instruction book 2920 1815 04 197 ...

Page 200: ...Installation proposal for ZR 160 Full Feature up to ZR 275 Full Feature ZR 250 VSD Full Feature and ZR 315 VSD Full Feature with Energy Recovery in mm Instruction book 198 2920 1815 04 ...

Page 201: ...Installation proposal for ZR 160 Full Feature up to ZR 275 Full Feature ZR 250 VSD Full Feature and ZR 315 VSD Full Feature with Energy Recovery in inch Instruction book 2920 1815 04 199 ...

Page 202: ...Installation proposal for ZR 160 Full Feature up to ZR 275 Full Feature ZR 250 VSD Full Feature and ZR 315 VSD Full Feature with dryer by pass option in mm Instruction book 200 2920 1815 04 ...

Page 203: ...Installation proposal for ZR 160 Full Feature up to ZR 275 Full Feature ZR 250 VSD Full Feature and ZR 315 VSD Full Feature with dryer by pass in inch Instruction book 2920 1815 04 201 ...

Page 204: ...Installation proposal for ZT 110 up to ZT 145 and ZT 132 160 VSD Instruction book 202 2920 1815 04 ...

Page 205: ... 1 Minimum free area to be reserved 2 Ventilation proposal 3 Rear side view 4 Ventilation proposal without option separate air intake 5 Ventilation proposal with option separate air intake 6 Common ducting for multiple units is not allowed Instruction book 2920 1815 04 203 ...

Page 206: ...et in bar a Qc Free air delivery of the compressor in l s For British American Units Lmax 1470 x d5 x p x dp Qc1 85 Symbol Explanation d Inner diameter of the outlet pipe in inch dp Pressure drop recommended maximum 1 45 psi L Length of outlet pipe in ft p Absolute pressure at the compressor outlet in psi g Qc Free air delivery of the compressor in cfm It is strongly recommended to make the connec...

Page 207: ...he maximum allowable pressure drop over the ducts is 30 Pa 0 12 in wc Common ducting for several compressors is not allowed 5 Lay out the drain piping from the condensate outlets towards the condensate collector The drain pipes must not dip into the water in the collector It is recommended to provide a funnel to allow visual inspection of the condensate flow 6 Elektronikon control system with cont...

Page 208: ...requirements for rubber compensators Types and sizes Atlas Copco oil free air products with aftercooler are equipped with rubber compensators on the air outlet and water connections Types of misalignments The supplied compensators can cope with 2 types of minor misalignments when the customer pipe end is mounted Axial ΔL Lateral ΔR Instruction book 206 2920 1815 04 ...

Page 209: ...Drawing reference Description A Atlas Copco compressor pipe end B Customer installation pipe end Angular misalignments Δα are NOT allowed Instruction book 2920 1815 04 207 ...

Page 210: ...nment is tolerated Combined direction misalignments Drawing reference Description 1 Compression 2 Stretch Do NOT operate outside of the black polygon Do NOT exceed the misalignment tolerances to avoid compensator damage The piping system of the customer should be designed to fit the misalignment tolerances both during standstill and operation Instruction book 208 2920 1815 04 ...

Page 211: ...tep 3 Torque the bolts crosswise up to the value mentioned in the table below Mind the parallelism of the sealing Excessive torque will damage the sealing DN mm DN inch Step 1 Step 2 Nm Step 2 lbfin Step 3 Nm Step 3 lbfin 20 80 2 3 hand tight 50 443 80 708 100 300 4 12 hand tight 50 443 100 885 350 500 14 20 hand tight 50 443 130 1551 Do s and don ts The supplied compensators are NOT designed to c...

Page 212: ... piping and supporting structures use an approved standard code e g EN 13480 or ASME 16 5 B31 3 Mind that the connected pipe at customer side does not create any flow restriction caused by e g section reduction While installing the compensator please mind the following check points to avoid sealing damage Instruction book 210 2920 1815 04 ...

Page 213: ...torque to prevent damage to the bended pipes or the sealings E Rubber sealings will get damaged when the inner pipe diameter exceeds the inner sealing diameter F Rough pipe ends will damage the rubber sealing G Avoid contact between the pipe end and the rubber sealing Refer to the pictures below for a visual overview of 5 do s and don ts when installing rubber compensators WRONG installation Instr...

Page 214: ... CORRECT installation Instruction book 212 2920 1815 04 ...

Page 215: ... stated to comply with this requirement IEC compressors Cables calculated according to IEC 60364 5 52 Mounting type E Multicore cables in free air Multiple circuit arrangement 4 Single layer on a perforated horizontal or vertical tray system Use 90 C 194 F cables Type H07V2 K Cables have to be recalculated if the fuses that are used are bigger than the fuses that are proposed CSA UL compressors Ca...

Page 216: ...177 2 x 3 X 250 315 50 kA ZT ZR 145 308 339 2 X 3 X120 70 245 2 x 3 X 250 400 50 kA ZT ZR 160 371 408 4 X 3 X95 50 177 2 x 3 X 315 400 50 kA ZT ZR 200 451 496 4 X 3 X 95 50 177 2 x 3 X 315 400 50 kA ZT ZR 250 566 623 4 X 3 X 120 70 176 2 x 3 X 400 500 50 kA ZT ZR 275 7 5 bar 593 652 4 X 3 X 120 70 176 2 x 3 X 400 800 50 kA ZT ZR 275 8 6 and 10 bar 703 773 4 X 3 X 150 95 179 2 x 3 X 500 500 50 kA F...

Page 217: ...ses gL gG A Maximum cable length m ZR ZT 110 2 x 3x 120 70 2X 3X 250 260 ZR ZT 132 2 x 3x 120 70 2X 3X 250 260 ZR ZT 145 2 x 3x 120 70 2X 3X 250 260 ZR ZT 160 4 x 3x 95 50 2X 3X 315 188 ZR ZT 200 4 x 3x 120 70 2X 3X 400 184 ZR ZT 250 4 x 3x 120 70 2X 3X 400 184 ZR ZT 275 4 x 3x 150 95 2X 3X 500 188 Compressors designed for a maximum ambient temperature of 40 C 104 F with IE3 motors Type FLA MCA Pr...

Page 218: ...48 273 4 X 3 X50 25 165 2 x 3 X 200 315 50 kA ZT ZR 132 269 296 2 X 3 X120 70 319 2 x 3 X 200 400 50 kA ZT ZR 145 269 296 2 X 3 X120 70 319 2 x 3 X 200 400 50 kA ZT ZR 160 393 432 4 X 3 X 95 50 187 2 x 3 X 315 400 50 kA ZT ZR 200 483 531 4 X 3 X 150 95 238 2 x 3 X 400 500 50 kA ZT ZR 250 582 640 4 X 3 X 150 95 238 2 x 3 X 400 500 50 kA FLA and MCA based on an air cooled full option compressor Icc ...

Page 219: ...of 50 C 122 F with IE2 motors Type Cables H07V2 K IEC 60364 5 52 E 4 mm2 Fuses gL gG A Maximum cable length m ZR ZT 110 2 x 3x 150 95 2X 3X 250 420 ZR ZT 132 2 x 3x 150 95 2X 3X 250 420 ZR ZT 145 2 x 3x 150 95 2X 3X 250 420 ZR ZT 160 2 x 3x 150 95 2X 3X 250 420 ZR ZT 200 4 x 3x 95 50 2X 3X 315 235 ZR ZT 250 4 x 3x 150 95 2X 3X 400 230 Compressors designed for a maximum ambient temperature of 50 C ...

Page 220: ...5 359 2 x 3 X 125 315 50 kA ZT ZR 145 171 188 2 X 3 X50 25 359 2 x 3 X 125 315 50 kA ZT ZR 160 198 218 2 X 3 X70 35 423 2 x 3 X 160 315 50 kA ZT ZR 200 245 270 4 X 3 X35 16 193 2 x 3 X 200 315 50 kA ZT ZR 250 303 333 2 X 3 X120 70 446 2 x 3 X 250 400 50 kA ZT ZR 275 7 5 bar 327 360 2 X 3 X120 70 446 2 x 3 X 250 500 50 kA ZT ZR 275 8 6 and 10 bar 388 427 4 X 3 X 95 50 322 2 x 3 X 315 400 50 kA FLA ...

Page 221: ...ll option compressor Icc only achieved with recommended fuses Compressors without starter IEC Compressors designed for a maximum ambient temperature of 40 C 104 F Type Cables H07V2 K IEC 60364 5 52 E 4 mm2 Fuses gL gG A Maximum cable length m ZR ZT 110 3x 16 10 3X 80 80 ZR ZT 132 3x 16 10 3X 80 80 ZR ZT 145 3x 16 10 3X 80 80 ZR ZT 160 3x 16 10 3X 80 80 ZR ZT 200 3x 16 10 3X 80 80 ZR ZT 250 3x 16 1...

Page 222: ... 3 X 35 16 106 2 x 3 X 200 315 50 kA ZT ZR 145 339 373 2 X 3 X 120 70 245 2 x 3 X 250 400 50 kA ZT ZR 160 363 399 4 X 3 X 95 50 177 2 x 3 X 315 400 50 kA ZT ZR 200 441 485 2 X 3 X 185 95 258 2 x 3 X 315 500 50 kA ZT ZR 250 513 564 4 X 3 X 120 70 176 2 x 3 X 400 500 50 kA ZT ZR 275 655 720 4 X 3 X 150 95 179 2 x 3 X 500 500 50 kA FLA and MCA based on an air cooled full option compressor Icc only ac...

Page 223: ...2 E 4 mm2 Fuses gL gG A Maximum cable length m ZR ZT 110 2 x 3x 120 70 2X 3X 250 286 ZR ZT 145 2 x 3x 120 70 2X 3X 250 286 ZR ZT 160 4 x 3x 95 50 2X 3X 315 207 ZR ZT 200 4 x 3x 120 70 2X 3X 400 202 ZR ZT 250 4 x 3x 120 70 2X 3X 400 202 ZR ZT 275 4 x 3x 120 70 2X 3X 400 202 Compressors designed for a maximum ambient temperature of 104 F 40 C with IE3 motors Type FLA MCA Proposed cable mm Maximum ca...

Page 224: ...50 205 2 x 3 X 315 500 50 kA ZT ZR 250 495 545 4 X 3 X 150 95 261 2 x 3 X 400 500 50 kA FLA and MCA based on an air cooled full option compressor Icc only achieved with recommended fuses 460 V 60 Hz CSA UL Compressors designed for a maximum ambient temperature of 104 F 40 C with IE2 motors Type Cables 90 cable CEC C22 1 Fuses RK5 A Fuses LPJ A Maximum cable length m ZR ZT 110 2 x 3x MCM 250 AWG 3 ...

Page 225: ...10 2 x 3x MCM 300 AWG 3 2X 3X 175 2X 3X 600 202 ZR ZT 145 4 x 3x AWG 0000 AWG 2 2X 3X 250 2X 3X 600 133 ZR ZT 160 4 x 3x AWG 0000 AWG 2 2X 3X 250 2X 3X 600 133 ZR ZT 200 4 x 3x MCM 300 AWG 0 2X 3X 300 2X 3X 600 207 ZR ZT 250 4 x 3x MCM 350 AWG 0 2X 3X 350 2X 3X 600 152 Compressors designed for a maximum ambient temperature of 122 F 50 C with IE3 motors or with oversized motors Type FLA MCA Propose...

Page 226: ...0 AWG 0 2X 3X 300 2X 3X 600 230 Compressors designed for a maximum ambient temperature of 104 F 40 C with IE3 motors Type FLA MCA Proposed cable mm Maximum cable length m Proposed fuses A LPJ Maximum fuse A LPJ SCCR ZT ZR 110 170 187 2 X 3 X1AWG 6AWG 161 2 x 3 X 125 600 65 kA ZT ZR 145 221 243 2 X 3 X000 4AWG 208 2 x 3 X 175 600 65 kA ZT ZR 160 245 269 4 X 3 X3AWG 8AWG 108 2 x 3 X 175 600 65 kA ZT...

Page 227: ...G 8AWG 128 2 x 3 X 150 600 65 kA ZT ZR 145 203 224 4 X 3 X3AWG 8AWG 128 2 x 3 X 150 600 65 kA ZT ZR 160 265 291 2 X 3 X250CM 2AWG 277 2 x 3 X 200 600 65 kA ZT ZR 200 303 334 2 X 3 X 300MCM 2AWG 259 2 x 3 X 225 600 65 kA ZT ZR 250 351 386 4 X 3 X 00 4AWG 151 2 x 3 X 300 600 65 kA FLA and MCA based on an air cooled full option compressor SCCR only achieved with recommended fuses Compressors without ...

Page 228: ... voltage or high voltage motor take into account the information on the motor data plate and the ambient temperature plus 5 K to select the cable size of the drive motor supply Apply the local regulations for the cable size and cable specifications Compressors delivered without drive motor When the compressor is delivered without a drive motor the electrical cubicle should be supplied separately w...

Page 229: ...Electric connections Electric connections for compressors with star delta starter Model year 2003 Instruction book 2920 1815 04 227 ...

Page 230: ...Electric connections for compressors with star delta starter Model year 2014 Instruction book 228 2920 1815 04 ...

Page 231: ...Electric connections for compressors without a starter Model year 2003 Instruction book 2920 1815 04 229 ...

Page 232: ...23 smaller than 56 with 3 type 2 fuses 5 Compressor motor 6 Fan motor dryer not for ZR compressors 7 Fan motor not for ZR compressors 8 Fan motor only for units without compressor motor 9 To be installed by the customer 10 Dryer heater 11 Connection only to be made for CSA UL 12 Fan motor in motor hood of ZR ZT without a motor 13 Wound anti clockwise low pressure side 14 Wound anti clockwise high ...

Page 233: ... In a closed system the same cooling water circulates through a system without contact with air An open system is a pass through system or a circulating system with a cooling tower In the latter case the composition of the water that enters the compressor must be considered and not the composition of the make up water Due to the evaporative effect in the cooling tower much higher concentrations of...

Page 234: ... 2 2 6 2 5 12 13 0 7 0 24 0 26 1 1 7 9 2 4 14 17 0 8 0 28 0 34 1 2 10 13 2 3 18 22 0 9 0 36 0 44 1 3 14 17 2 2 23 27 1 0 0 46 0 54 1 4 18 21 2 1 28 34 1 1 0 56 0 70 1 5 22 27 2 0 35 43 1 2 0 72 0 88 1 6 28 31 1 9 44 55 1 3 0 90 1 10 1 7 32 37 1 8 56 69 1 4 1 12 1 38 1 8 38 44 1 7 70 87 1 5 1 40 1 76 1 9 45 50 1 6 88 110 1 6 1 78 2 20 2 0 51 56 1 5 111 138 1 7 2 22 2 78 2 1 57 63 1 4 138 174 1 8 2 ...

Page 235: ... unsuitable due to other factors From the table above the RSI index should be between 5 6 and 7 5 if not consult your local Atlas Copco Customer Centre pH The effect of pH is already calculated in the Ryznar index but the pH itself has some additional limitations 6 8 pH 8 5 Total Dissolved Solids TDS This is the sum of all the ions in the water It can be derived from the dry residue after evaporat...

Page 236: ...0 500 ppm CaCO3 HCO3 SO4 2 should be 1 Ammonia 0 5 ppm Copper 1 ppm Iron and manganese 1 ppm Organics No algae No oil Suspended solids Non soluble particles size 1 mm 10 ppm 7 9 General pictographs Pictographs Reference Name 1 Condensate valve intercooler 2 Automatic condensate outlet intercooler 3 Automatic condensate outlet aftercooler Instruction book 234 2920 1815 04 ...

Page 237: ...ction manual before greasing 11 Switch off the voltage before removing the protecting cover inside the electric cabinet 12 Oil the gaskets screw on the filters and tighten by hand approx one half turn 13 Consult the Instruction manual before maintenance or repair 14 Cooling water outlet 15 Cooling water inlet 7 10 Pictographs Elektronikon control system Control panel of Elektronikon Controller Ref...

Page 238: ...Control panel of Elektronikon GraphicPlus Controller Reference Name 1 Alarm 2 Service 3 Automatic operation 4 Voltage on 5 Enter 6 Escape 7 Scroll keys 8 Stop 9 Start Instruction book 236 2920 1815 04 ...

Page 239: ...not slide and that they protrude from the frame equally The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor The lifting equipment must be placed in such a way that the compressor is lifted perpendicularly Lift gently and avoid twisting General preparation Make sure that the compressor is installed correctly See Dimension drawing Installation pr...

Page 240: ... dampers are secured by means of bolts spacers Remove the bolts and spacers 1 and 2 Transport fixtures on the gear casing side in ZR ZT 110 up to ZR ZT 275 On ZR ZT 110 up to ZR ZT 275 a transport support 1 is fitted to the gear casing Remove the support Instruction book 238 2920 1815 04 ...

Page 241: ...ransport fixtures on subframe of Arr 1 Transport fixtures on subframe of Arr 1 The subframe 2 of Arr 1 units is secured by means of bolts spacers 1 These must be removed Instruction book 2920 1815 04 239 ...

Page 242: ...Silica gel bags Position of silica gel bags on ZR 110 up to ZR 145 Position of silica gel bags on ZT 110 up to ZT 145 Instruction book 240 2920 1815 04 ...

Page 243: ...Position of silica gel bags on ZT 160 up to ZT 275 Position of silica gel bags on ZR 160 up to ZR 275 Remove flange 1 and take out the silica gel bags Refit the flange Instruction book 2920 1815 04 241 ...

Page 244: ...ghtened Proceed as follows Check that all transport fixtures are removed Check that the compressor is pressureless Tighten the nuts of tie rods 1 by hand Tighten the check nuts Water circuit of ZR compressors Water drain plug HP element of ZR 110 up to 275 Instruction book 242 2920 1815 04 ...

Page 245: ...Water drain plug LP element of ZR 110 up to 275 Water drain plugs coolers of ZR 110 up to 275 Water drain plugs cooler block of ZR 110 up to 275 Instruction book 2920 1815 04 243 ...

Page 246: ... their positions are shown on the illustrations above 2 Check that the cooling water drain valves customer s installation in the inlet and outlet lines are closed 3 Open the water inlet valve and outlet valve customer s installation and check for water flow 4 Check the water flow Oil circuit Position of oil level sight glass on ZR 110 up to ZR 275 Instruction book 244 2920 1815 04 ...

Page 247: ...Position of oil level sight glass on ZT 110 up to ZT 275 Check that oil is visible in sight glass SG Instruction book 2920 1815 04 245 ...

Page 248: ...Start up Electric cabinet of compressor with starter Model year 2003 Instruction book 246 2920 1815 04 ...

Page 249: ...Electric cabinet of compressor with starter Model year 2014 Instruction book 2920 1815 04 247 ...

Page 250: ...Electric cabinet of compressor without starter Model year 2003 Instruction book 248 2920 1815 04 ...

Page 251: ...art the motor and stop it immediately 6 Check that the direction of rotation is correct as indicated by the arrow anti clockwise looking at the motor drive shaft there may also be an arrow on the coupling housing A grating through which the coupling can be observed is fitted If the direction of rotation is wrong switch off the voltage and reverse two electric inlet connections 7 Run the compressor...

Page 252: ...kon regulator shows a warning for the regeneration air temperature the mix air must be readjusted On most ZT compressors the shut off valve 1 is located in the cooler compartment and the regulating valve 2 is located in the compressor compartment The safety grating must be fitted again and the door of the cooler compartment must be closed before starting the compressor The operator must wear heat ...

Page 253: ...described below 5 Call up the regeneration air inlet temperature in the Inputs menu of the Elektronikon regulator Open regulating valve 2 until the display of the Elektronikon regulator shows a value between 180 C 356 F and 190 C 374 F 6 Check the pressure difference between the dryer compartments again If necessary repeat the previous steps Adjustment of the pressure difference of the dryer compa...

Page 254: ...Dryer components ZR Full Feature Position of throttle valve on the regeneration air inlet of the dryer on ZT Full Feature Instruction book 252 2920 1815 04 ...

Page 255: ...Position of dryer inlet outlet and by pass valves on ZT Full Feature Step Action 1 Close valves 1 Vd and Vd Instruction book 2920 1815 04 253 ...

Page 256: ...ises 30 mm above the level in the leg marked close valve Vd at once as there is a risk that the water will escape the U tube and disappear into the pressure vessel Increase the regeneration air inlet pressure see step 7 and open valve Vd again 7 Once the water column has stabilized adjust the pressure differential as follows Remove the protective cap from the adjusting screw of throttle valve Rf L...

Page 257: ...Regulation valves for ZR Full Feature compressors without dryer by pass Instruction book 2920 1815 04 255 ...

Page 258: ...Regulation valves for ZR Full Feature compressors with dryer by pass Instruction book 256 2920 1815 04 ...

Page 259: ...Regulation valves for ZR Full Feature compressors without dryer by pass Instruction book 2920 1815 04 257 ...

Page 260: ...Regulation valves for ZR Full Feature compressors with dryer by pass Instruction book 258 2920 1815 04 ...

Page 261: ...Regulation valves for ZT Full Feature compressors without dryer by pass Instruction book 2920 1815 04 259 ...

Page 262: ...valve 1 Open the dryer inlet and outlet valves Vdi and Vdo and close the dryer by pass valve Vdb 2 Start the compressor and wait for at least 5 minutes until the compressor temperatures are stable after running loaded at maximum speed 3 Adjust the Nozzle Fraction the ratio of dried air and regeneration air Scrolling to the Test screen of the Elektronikon Select Modify Enter Tuning Throttle Valve E...

Page 263: ... Elektronikon screen by pushing X repeatedly 8 2 Before starting The operator must apply all relevant Safety precautions If the water system has been drained close the drain valves and fit the drain plugs or pipe See section Stopping The number of motor starts is programmed at maximum 3 per day To modify this setting consult sections Modify parameters Oil level Oil system components ZR 110 up to Z...

Page 264: ...10 up to ZR ZT 275 the oil level must be in the middle of the sight glass SG after stopping in the case of longer standstill the oil level may increase in the sight glass Top up if necessary with the correct type of oil Instruction book 262 2920 1815 04 ...

Page 265: ...Condensate drains Drain connections on ZR 110 up to ZR 145 Drain connections on ZR 160 Pack up to ZR 275 Pack Instruction book 2920 1815 04 263 ...

Page 266: ...Drain connections on ZR 160 Full Feature up to ZR 275 Full Feature Instruction book 264 2920 1815 04 ...

Page 267: ...all Automatic drain optional low load dryer Dar1 Automatic drain regeneration outlet Dar2 Automatic drain regeneration outlet E Electrical cable for optional water shut off valve WI Water inlet WO Water outlet Open the water inlet valve and outlet valve customer s installation On ZR compressors opening of the water outlet valve can be overlooked if after previous operation the setting of this valv...

Page 268: ...rammable the compressor starts running loaded The message on display 2 changes from Automatically unloaded to Automatically loaded 5 On ZR compressors regulate the water flow with the compressor running loaded See section Readings for the cooling water temperature See section Compressor data for the cooling water consumption If the motor is stopped and automatic operation LED 8 is alight the motor...

Page 269: ...Control panel Control panel of Elektronikon GraphicPlus controller Instruction book 2920 1815 04 267 ...

Page 270: ... the latter is valid for energy recovery units The aim is to obtain a cooling water temperature rise over the complete compressor unit of 15 K in case of Pack compressors and 10 K in case of Full Feature compressors In case of Full Feature compressors also the water flow over the integrated dryer is to be regulated a cooling water temperature rise over the dryer of 5 K is to be achieved For compre...

Page 271: ...oller Procedure Step Action 1 Press the emergency stop button S2 if not yet done so 2 Switch off the voltage and then depressurize the compressor 3 Remedy the fault 4 Unlock the emergency stop button by pulling it out 5 Restart the compressor See Routine starting If the automatic restart function after voltage failure is activated and the duration of repair is shorter than the programmed power rec...

Page 272: ...nd the duration of repair is shorter than the programmed power recovery time reset the display after remedying the fault Press the key Reset the message All protection functions are OK will appear whereupon the compressor can be restarted Press the keys Menu and Main Screen to return to the main display Minimum stop time The compressor will not be allowed to restart within a programmed time 20 s a...

Page 273: ...eadings on display 2 2 When reaching the preset unloading pressure shown on display 2 the compressor will start running unloaded From now on the electronic control module will calculate the optimum moment to stop and restart the compressor motor automatically depending on the maximum permissible number of motor starts and on the air consumption 3 To unload the compressor manually press the key Unl...

Page 274: ...nloading pressure shown on display 1 the compressor will start running unloaded From now on the electronic control module will calculate the optimum moment to stop and restart the compressor motor automatically depending on the maximum permissible number of motor starts and on the air consumption 3 To unload the compressor manually select Unload on the display using the cursor keys and press the E...

Page 275: ...a service message if one of the monitored components is to be serviced Replace the component change the oil or grease the drive motor as required Reset the relevant timer 4 Check The compressor control status automatic or manual local or remote The status of the compressor start stop timer active or not The compressor is automatically started stopped if these start stop commands are programmed and...

Page 276: ...itch off the voltage and depressurize the compressor Procedure 1 Regularly check the display for readings and messages Normally the main display is shown 2 Always check the display and remedy the trouble if alarm LED 4 is alight or blinks The display will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded Carry out ...

Page 277: ...s it is loaded again manually Manual unloading Press the key Unload 5 LED 8 fades The message Manually Unloaded appears on the display Manual loading Press the key Load 5 LED 8 lights up The Load command does not force the compressor in loaded condition but it will switch the compressor to automatic operation again i e the compressor will be loaded if the air net pressure drops below the programme...

Page 278: ...ting from the main screen move the cursor so that Unload is highlighted in grey When the Enter key is pressed the compressor starts running unloaded and LED 7 fades The message Manual Unload appears on the display Manual loading Starting from the main screen move the cursor so that Load is highlighted in grey When the Enter key is pressed LED 7 lights up and the compressor starts running loaded in...

Page 279: ...mergency stop button in case of emergency Step Action 1 Close the air outlet valve 2 Press stop button 9 The compressor will run unloaded for 3 seconds and then stop 3 To stop the compressor in case of emergency press the emergency stop button S2 Alarm LED 7 starts flashing After remedying the trouble unlock the emergency stop button by pulling it out Instruction book 2920 1815 04 277 ...

Page 280: ...ts flashing After remedying the trouble unlock the emergency stop button by pulling it back Cooling water system on ZR compressors Close the cooling water inlet valve after stopping If the compressor is installed in a room where freezing temperatures are expected drain the cooling system completely By opening the main drain valves in the water inlet and outlet pipes customer s installation By remo...

Page 281: ...Water drain plugs underneath cooler casing of ZR 110 up to ZR 145 Cooler casing on ZR 160 up to ZR 275 Cooler casing on ZR 160 up to ZR 275 Instruction book 2920 1815 04 279 ...

Page 282: ...Drain plugs on high pressure compressor element Drain plugs on low pressure compressor element Instruction book 280 2920 1815 04 ...

Page 283: ...witch off the voltage and disconnect the compressor from the mains 3 Shut off and depressurize the part of the air net which is connected to the outlet valve 4 Disconnect the compressor air outlet pipe from the air net 5 Drain the oil and condensate circuits Catch the oil in a receptacle 6 Disconnect the compressor condensate piping from the condensate drain net 7 On ZR compressors drain the cooli...

Page 284: ...ce agreements to suit your needs An Inspection plan A Preventive maintenance plan A Total responsibility plan Contact your Customer Center to agree on a tailor made service agreement It will ensure optimum operational efficiency minimize downtime and reduce the total life cycle costs and ensure that all warranties are validated Warranty Product Liability Use only authorized parts at the correct in...

Page 285: ...ensate from the air receiver if installed Weekly Check for leaks Tighten leaking connections and replace damaged leaking parts 3 monthly Clean compressor 3 monthly 500 Check coolers clean if necessary 2 yearly 16000 Replace the demister sponge of the integrated dryer 2 yearly 16000 Inspect the dryer heater 2 yearly 16000 Inspect the dryer rotor When displayed Carry out service actions according to...

Page 286: ...intake valve X Check functioning of check valve 8000 hrs or annually X X X Overhaul check valve X Check condition of balance piston diaphragm X X Change balance piston diaphragm X X Check Service condensate drain s X X X Overhaul drain s X X Grease main drive motor bearings according to motor data plate X X X Clean fan cowl of electric motor X X X Check rubber inserts of drive coupling arr E X X R...

Page 287: ...o Z lubricating oil Use Atlas Copco Roto Z oil which is specially developed for oil free rotary compressors This oil has a long service life and ensures optimum lubrication Atlas Copco Roto Z oil can be ordered in following quantities Quantity l Quantity US gal Quantity Imp gal Quantity cu ft Ordering number 5 l can 1 32 US gal can 1 10 Imp gal can 0 18 cu ft can 2908 8503 00 20 l can 5 28 US gal ...

Page 288: ... Action 1 Stop the compressor and press the emergency stop button 2 Switch off the voltage and follow the LOTO procedure Refer to the Safety Precautions before acting 3 Remove nuts 1 4 Loosen clamps 2 5 Take out filter housing 3 with filter element 4 6 Replace the dirty filter element with a new one 7 Put the filter housing with the filter element back into place 8 Tighten clamps 2 and nuts 1 9 Sw...

Page 289: ...10 2 Oil and oil filter change Oil system Oil system components ZR 110 up to ZR 275 Instruction book 2920 1815 04 287 ...

Page 290: ...ors fit a proper flexible over the extension of drain plugs Dmc Drain the oil system by loosening the drain plugs Close the drain valves and tighten the drain plugs after draining 5 Remove the oil filters OF Clean the filter seats oil the gaskets of the new filters and screw the filters into place until the gaskets contact the seats Then tighten by hand 6 On ZR 110 up to ZR 275 fill the compressor...

Page 291: ...longer standstill the level may rise in the sight glass Top up if necessary 10 3 Safety valves Testing The valves can be tested on a separate compressed air line If a valve does not open at the pressure specified in Settings of safety valves consult Atlas Copco Never run the compressor without safety valves No adjustments are allowed 10 4 Coolers Testing The coolers must be serviced regularly refe...

Page 292: ...Cooler block CB of air cooled Full Feature compressors Coolers of water cooled Full Feature compressors Instruction book 290 2920 1815 04 ...

Page 293: ...system as follows Close the air outlet valve Press the emergency stop button Open the isolating switch customer s installation to switch off the voltage to the compressor and lock it Lock Out Tag Out procedure LOTO 3 Remove the compressor roof 4 Remove any dirt form the coolers with a fibre brush in the direction of the fins 5 Remove dirt from the fans 6 Clean the coolers with an air jet in the re...

Page 294: ...Step Action 7 If it is required to clean the coolers with a cleaning agent consult your Atlas Copco Customer Center 8 Re install the compressor roof Instruction book 292 2920 1815 04 ...

Page 295: ... isolating switch customer s installation to switch off the voltage to the compressor and lock it Lock Out Tag Out procedure LOTO Repairs inside the speed regulation cabinet must only be carried out by Atlas Copco Apply all relevant safety precautions Wait at least 6 minutes before starting any electrical repairs as hazardous high voltage remains on the condensers of the variable speed drive for 6...

Page 296: ...ctions and damaged leaking parts Check for leaks Tighten leaking connections and replace damaged leaking parts Oil pressure too low Oil level too low Top up level as described in section Before starting Oil filters clogged Replace filters Air temperature above normal Inlet temperature too high due to bad room ventilation or recirculation of cooling air Improve ventilation in compressor room and pr...

Page 297: ...rges air Damaged poor assembled condensate drain housing seals valve Check and correct Solenoid valve defect dirty Check and correct Level sensor defect dirty Clean sensor or replace as necessary For Full Feature compressors Condition Fault Remedy Pressure dewpoint too high Compressor loading periods repeatedly too short Take necessary action to increase duration of loading periods Incorrect dryer...

Page 298: ... Center Regeneration air inlet temperature too low Shut off valve closed for dryer by pass Open the valve Operating pressure too low Do not operate the dryer at a pressure lower than the one specified in Compressor data Compressor loading periods too short Take necessary action to increase duration of loading periods Nozzle of ejector partly obstructed Remove and clean nozzle Investigate cause War...

Page 299: ... the circuit breaker in the dryer control box is switched on Check that the gear motor cable is correctly connected to the terminals of the dryer control box Consult your Atlas Copco Customer Center Instruction book 2920 1815 04 297 ...

Page 300: ...oler pressure loaded condition 1 7 3 bar e 24 6 43 5 psig Intercooler pressure unloaded condition 0 65 0 70 bar e 9 43 10 15 psig Oil pressure depends on climatic conditions 1 8 3 5 bar e 26 1 50 8 psig Temperature readings for ZR compressors Item Reading Reading Oil temperature Approx 40 C Approx 104 F Air outlet temperature Approx 25 C Approx 77 F Cooling water inlet temperature Below 40 C Below...

Page 301: ... 13 bar 190 psi compressors 13 7 bar e 200 psig 12 3 Settings for overload relay 50 Hz compressors ZT ZR 110 compressors designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 128 8 400 122 2 500 97 6 690 70 4 ZT ZR 110 compressors designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommende...

Page 302: ...pply voltage V Recommended overload setting F21 A 380 144 400 135 500 109 690 79 ZT ZR 132 compressors designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 153 8 400 146 1 500 116 9 690 83 7 ZT ZR 132 compressors designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommended overload settin...

Page 303: ...voltage V Recommended overload setting F21 A 380 169 3 400 159 3 500 127 5 690 92 3 ZT ZR 132 compressors with oversized IE3 motor Supply voltage V Recommended overload setting F21 A 380 156 400 147 500 118 690 86 ZT ZR 145 compressors designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 169 3 400 159 3 500 127 5 690 92 3 ZT ...

Page 304: ...commended overload setting F21 A 380 156 400 147 500 118 690 86 ZR ZT 160 compressors designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 189 400 183 500 146 690 106 ZR ZT 160 compressors designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommended overload setting F21 A 380 199 400 189 ...

Page 305: ...mended overload setting F21 A 380 242 400 229 500 183 690 133 ZR ZT 200 compressors designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommended overload setting F21 A 380 246 400 236 500 189 690 136 ZR ZT 200 compressors designed for a maximum inlet temperature of 50 C 122 F with IE2 motor or equipped with oversized IE2 motor Supply voltage V Recommended over...

Page 306: ...ng F21 A 380 281 400 239 500 232 690 184 ZR ZT 250 compressors designed for a maximum inlet temperature of 50 C 122 F with IE2 motor or equipped with oversized IE2 motor Supply voltage V Recommended overload setting F21 A 380 341 400 312 500 254 690 182 ZR ZT 250 compressors designed for a maximum inlet temperature of 50 C 122 F with IE3 motor or equipped with oversized IE3 motor Supply voltage V ...

Page 307: ...90 psi designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 341 400 312 500 254 690 182 ZR ZT 275 8 6 up to 13 bar 125 up to 190 psi designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommended overload setting F21 A 380 381 400 356 500 283 690 210 60 Hz compressors ZT ZR 110 compressors ...

Page 308: ...rature of 50 C 122 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 180 1 440 155 9 460 149 6 575 119 9 ZT ZR 110 compressors designed for a maximum inlet temperature of 50 C 122 F with IE3 motor Supply voltage V Recommended overload setting F21 A 380 168 440 143 460 137 575 110 ZT ZR 110 compressors with oversized IE2 motor Supply voltage V Recommended overload setting F21...

Page 309: ...ly voltage V Recommended overload setting F21 A 380 184 440 156 460 149 575 120 ZT ZR 145 compressors designed for a maximum inlet temperature of 50 C 122 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 172 6 440 149 8 460 140 7 575 112 7 ZT ZR 145 compressors designed for a maximum inlet temperature of 50 C 122 F with IE3 motor Supply voltage V Recommended overload settin...

Page 310: ...ly voltage V Recommended overload setting F21 A 380 236 440 204 460 209 575 167 ZR ZT 160 compressors designed for a maximum inlet temperature of 50 C 122 F with IE3 motor or equipped with oversized IE3 motor Supply voltage V Recommended overload setting F21 A 380 219 440 187 460 181 575 146 ZR ZT 200 compressors designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage ...

Page 311: ...ized IE3 motor Supply voltage V Recommended overload setting F21 A 380 257 440 219 460 213 575 168 ZR ZT 250 compressors designed for a maximum inlet temperature of 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 288 440 249 460 234 575 187 ZR ZT 250 compressors designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommended over...

Page 312: ... 40 C 104 F with IE2 motor Supply voltage V Recommended overload setting F21 A 380 312 440 269 460 272 575 217 ZR ZT 275 designed for a maximum inlet temperature of 40 C 104 F with IE3 motor Supply voltage V Recommended overload setting F21 A 380 349 440 302 460 266 575 212 Compressors with medium voltage and high voltage motors For compressors with a medium voltage or high voltage motor apply the...

Page 313: ...ZR ZT 160 275 Motor shaft speed for 50 Hz fixed speed compressors rpm except for ZR ZT 275 7 5 bar 109 psi 1485 Motor shaft speed for 50 Hz fixed speed unit ZR ZT 275 7 5 bar 109 psi rpm 2980 Motor shaft speed for 60 Hz fixed speed compressors rpm 1780 12 5 Limitations Minimum maximum ambient temperature for standard compressors 0 40 C 32 104 F Minimum maximum ambient temperature for High Ambient ...

Page 314: ...o 18 F Maximum pressure of cooling water inlet 10 bar g 145 psi g Minimum maximum oil pressure 1 2 4 5 bar g 17 4 65 3 psi g Minimum maximum oil temperature for standard compressors 0 70 C 32 158 F Minimum maximum oil temperature for High Ambient Temperature compressors 0 80 C 32 176 F Working pressure Minimum Maximum bar g Pack Full Feature 7 bar 60 Hz 4 7 5 5 7 5 7 5 bar 50 Hz 4 7 5 5 7 5 8 6 ba...

Page 315: ...00 235 C for 7 7 5 8 6 bar High Ambient Temperature compressors 100 235 C for 10 10 4 bar compressors 100 235 C for 13 bar compressors Air outlet Approx 25 C Inlet of cooling water Below 40 C Outlet of cooling water Below 50 C Temperature Reading Oil Approx 104 F Outlet of low pressure stage 248 428 F for 7 7 5 8 6 bar standard compressors 248 455 F for 7 7 5 8 6 bar High Ambient Temperature compr...

Page 316: ...ressure stage 248 428 F for 7 7 5 8 6 bar standard compressors 248 455 F for 7 7 5 8 6 bar High Ambient Temperature compressors 248 455 F for 10 10 4 bar standard compressors 248 500 F for 10 10 4 bar High Ambient Temperature compressors Outlet of high pressure stage 212 428 F for 7 7 5 8 6 bar standard compressors 212 455 F for 7 7 5 8 6 bar High Ambient Temperature compressors 212 455 F for 10 1...

Page 317: ...above ambient temperature Dryer inlet for ZT 160 275 ZT 250 315 VSD compressors Approx 10 C 18 F above ambient temperature Dryer mixed air Approx 2 C 3 6 F till 4 C 7 2 F above dryer inlet temperature Dryer outlet Approx 5 C 9 F till 25 C 45 F above dryer mixed air temperature Difference between inlet and outlet of regeneration air Should not exceed 60 C 108 F Instruction book 2920 1815 04 315 ...

Page 318: ... excluded from 97 23 EC according to article I section 3 3 The following pressure bearing parts are of category higher than I Compressor type Pressure bearing part ZR ZT 110 up to ZR ZT 275 Safety valve Category IV Design code AD Merkblätter A2 ZR ZT 110 up to ZR ZT 145 IMD 300 Compressed air dryer vessel Category III Design pressure 13 7 bar e Design code ASME BPVC section VIII div 1 Material Cov...

Page 319: ...ated within the specified limits as given on the data plate Original bolts have to be used after opening for inspection Specified torque has to be taken into consideration This vessel has been designed and built to guarantee an operational lifetime in excess of 20 years Therefore there is no intrinsic need for in service inspection of the vessel when used within its design limits and in its intend...

Page 320: ...10 0 Torispherical part 10 0 Cover 1 0 Housing 1 0 Bottom 1 0 1023 528 Cover 0 8 Housing 0 8 Bottom 0 8 Used abbreviations V Internal volume Liter MWT Minimum wall thickness as manufactured mm CA Corrosion allowance mm H Height of the vessel mm D Diameter of the vessel mm CF Casting factor according ASME BPVC section VIII div 1 Vessel for MD dryers on ZR ZT 160 up to ZR ZT 275 Instruction for use ...

Page 321: ...n the data plate Original bolts have to be used after opening for inspection Specified torque has to be taken into consideration This vessel has been designed and built to guarantee an operational lifetime in excess of 20 years Therefore there is no intrinsic need for in service inspection of the vessel when used within its design limits and in its intended application National legislation however...

Page 322: ...ical cooler 16 5 Cover 1 0 Bottom 1 0 898 713 Cover 0 8 Bottom 0 8 Used abbreviations V Internal volume Liter MWT Minimum wall thickness as manufactured mm CA Corrosion allowance mm H Height of the vessel mm D Diameter of the vessel mm CF Casting factor according ASME BPVC section VIII div 1 Heat exchanger ZR 160 up to ZR 275 Reference Name 1 Intercooler 2 Aftercooler 3 Position of data plate Inst...

Page 323: ...ng factor 0 8 0 8 Minimum wall thickness after corrosion Covers 8 mm Shell 10 mm Covers 8 mm Shell 10 mm Shellside Tubeside Shellside Tubeside Medium Water group 2 Air group 2 Water group 2 Air group 2 Volume 92 l 21 4 l See intercooler 17 6 l Design pressure 15 bar 4 5 bar 15 bar 13 7 bar Design temperature 95 C 240 C 95 C 240 C 1 The maintenance instructions given in the user manual must be appl...

Page 324: ...3 Standards used On the Declaration of Conformity Declaration by the Manufacturer the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 322 2920 1815 04 ...

Page 325: ...ndards used On the Declaration of Conformity Declaration by the Manufacturer the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 2920 1815 04 323 ...

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Page 328: ...ves It means having the flexibility to adapt to the diverse demands of the people we cater for It s the commitment to our customers business that drives our effort towards increasing their productivity through better solutions It starts with fully supporting existing products and continuously doing things better but it goes much further creating advances in technology through innovation Not for th...

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