Atlas Copco ZR-55 Page 45 Instruction Book Download

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3.2

Control panel

Elektronikon regulator

Control panel

Parts and functions

Reference

Designation

Function

Start button

Button to start the compressor. LED (8) lights up
indicating that the Elektronikon regulator is operative.

Display

Shows messages about the compressor operating
condition, a service need or a fault.

Scroll keys

Keys to scroll upwards or downwards through the
display.

Tabulator key

Key to select the parameter indicated by the horizontal
arrow. Only the parameters followed by an arrow
pointing to the right can be modified.

Function keys

Keys to control and program the compressor.

Voltage on LED

Indicates that the voltage is switched on.

General alarm LED

Is lit if a shut-down warning condition exists.

General alarm LED

Flashes if a shut-down condition exists, if an important
sensor is out of order or after an emergency stop.

Automatic operation LED

Indicates that the regulator is automatically controlling
the compressor.

Stop button

Button to stop the compressor. LED (8) goes out.

Emergency stop button

Push button to stop the compressor immediately in the
event of an emergency. After remedying the trouble,
unlock the button by pulling it out.

Instruction book

Summary of Contents for ZR-55

Page 1: ...Stationary Air Compressor www atlascopco com ZR 55 ZR 75 ZR 90 ZT 55 ZT 75 ZT 90 Instruction book ...

Page 2: ...From serial No onwards PNA 811329 Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings Use only authorized parts Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability Printed Matter No ZR 55 ZR 75 ZR 90 ZT 55 ZT 75 ZT 90 ...

Page 3: ...19 2 3 CONDENSATE DRAIN SYSTEM 26 2 4 OIL SYSTEM 29 2 5 COOLING SYSTEM 31 2 6 ENERGY RECOVERY 35 2 7 LOW LOAD COMPENSATOR 38 2 8 ELECTRICAL SYSTEM 39 3 Elektronikon regulator 42 3 1 ELEKTRONIKON REGULATOR 42 3 2 CONTROL PANEL 44 3 3 FUNCTION KEYS 45 3 4 SCROLL KEYS 46 3 5 EMERGENCY STOP BUTTON 46 3 6 CONTROL PROGRAMS 47 3 7 CALLING UP MENUS 49 3 8 MAIN SCREEN MENU 50 3 9 STATUS DATA MENU 51 3 10 M...

Page 4: ...E MENU 66 3 21 SAVED DATA MENU 68 3 22 PROGRAMMABLE SETTINGS 69 4 Installation 73 4 1 DIMENSION DRAWINGS 73 4 2 INSTALLATION PROPOSALS 80 4 3 ELECTRIC CABLES 85 4 4 ELECTRIC CONNECTIONS 86 4 5 COOLING WATER REQUIREMENTS 90 4 6 PICTOGRAPHS 93 5 Operating instructions 96 5 1 OPERATION INTRODUCTION 96 5 2 INITIAL START UP 96 5 3 BEFORE STARTING 107 5 4 STARTING 109 5 5 DURING OPERATION 110 5 6 STOPPI...

Page 5: ...ing procedures 119 7 1 AIR FILTER AF 119 7 2 OIL AND OIL FILTER CHANGE 121 7 3 SAFETY VALVES 122 8 Problem solving 123 8 1 FAULTS AND REMEDIES 123 9 Principal data 126 9 1 READINGS ON DISPLAY 126 9 2 SETTINGS OF SAFETY VALVES 127 9 3 CIRCUIT BREAKERS AND FUSES 127 9 4 REFERENCE CONDITIONS 128 9 5 LIMITATIONS 128 9 6 COMPRESSOR DATA 129 10 Pressure equipment directives 135 10 1 PRESSURE EQUIPMENT D...

Page 6: ...ing quality For air of breathing quality the compressed air must be adequately purified according to the applicable legislation and standards 5 Before any maintenance repair work adjustment or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurise the compressor In addition the power isolating switch must be opened and locked 6 Neve...

Page 7: ...quate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet 11 The electrical connections must correspond to the applicable codes The machines must be earthed and protected against short circuits by fuses in all phases A lockable power isolating switch must be installed near the compressor 12 On machines with automatic sta...

Page 8: ... only the correct type and size of hose end fittings and connections When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury Make sure that a hose is fully depressurized before disconnecting it 2 Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on ...

Page 9: ... comply with the applicable legislation the stricter of the two shall apply 3 Installation operation maintenance and repair work must only be performed by authorised trained specialised personnel 4 The compressor is not considered capable of producing air of breathing quality For air of breathing quality the compressed air must be adequately purified according to local legislation and standards 5 ...

Page 10: ...shut down devices are fitted and that they function correctly If removed check that the coupling guard of the compressor drive shaft has been reinstalled 17 Protect the motor air filter electrical and regulating components etc to prevent moisture from entering them e g when steam cleaning 18 Make sure that all sound damping material and vibration dampers e g damping material on the bodywork and in...

Page 11: ...mpressors are water cooled ZT compressors are air cooled Full Feature compressors are aditionally provided with an air dryer which removes moisture from the compressed air The dryer is integrated in the bodywork of the compressor Views of ZR General view of ZR 55 up to ZR 90 Pack ZR 55 up to ZR 90 Full Feature and ZR 55 up to ZR 90 Pack with Energy Recovery Instruction book 10 ...

Page 12: ...General view of ZR 55 up to ZR 90 Full Feature with Energy Recovery Instruction book 11 ...

Page 13: ...Front view of ZR 55 up to ZR 90 Pack Instruction book 12 ...

Page 14: ...Rear view of ZR 55 up to ZR 90 Pack Front view of ZR 55 up to ZR 90 Full Feature with Energy Recovery Instruction book 13 ...

Page 15: ...Views of ZT General view of ZT 55 up to ZT 90 Pack Instruction book 14 ...

Page 16: ...General view of ZT 55 up to ZT 90 Full Feature General view Instruction book 15 ...

Page 17: ... cooler Daa Automatic condensate outlet aftercooler Dai Automatic condensate outlet intercooler Dmo Oil drain valve gear casing Eh High pressure compressor element El Low pressure compressor element ER Energy recovery system ERwi Water inlet energy recovery system ERwo Water outlet energy recovery system EWDa Electronic water drain aftercooler Instruction book 16 ...

Page 18: ...solenoid valve 1 Flange connection to MD dryer 2 Flange access to silica gel bags Optional equipment Following equipment is available as an option Full Feature The compressor is additionally provided with an IMD adsoption dryer The dryer is integrated in the bodywork and removes moisture from the compressed air Connections This compressor can be provided on the compressed air outlet and water pipe...

Page 19: ...on is ready to start The proper piping the wiring and the connectors will be delivered with the MD dryer The settings and parameters for the MD dryer are downloaded in the Elektronikon regulator of the compressor Anchor pads Steel plates fitting in the forklift slots and bolts are shipped loose with the compressor With these plates and bolts the compressor frame can be fixed to the floor Anti cond...

Page 20: ...t of compression rotary drum dryer The regeneration air passes over a heater The heater maintains a preset regeneration temperature to a have guaranteed dew point at stated conditions A thermostatic control puts on the heater and shuts it off automatically based on the regeneration temperature requirements 2 2 Air flow Flow diagram ZR Instruction book 19 ...

Page 21: ...Flow diagram ZR Full Feature Instruction book 20 ...

Page 22: ...Flow diagram ZR Full Feature ND and ZR Full Feature with Low Load option Instruction book 21 ...

Page 23: ...Flow diagram ZT Instruction book 22 ...

Page 24: ...Flow diagram ZT Full Feature Instruction book 23 ...

Page 25: ...Flow diagram ZT Full Feature ND and ZT Full Feature with Low Load option Ref Name 1 Air inlet 2 Air flow 3 Oil flow 4 Air outlet 5 Water flow Instruction book 24 ...

Page 26: ...In demister 19 the water droplets are removed from the air The air is then led through rotor 12 which adsorbs the water vapour The compressed air leaves the compressor via the air outlet Regenerating circuit of the dryer Hot regeneration air is branched off from the aftercooler The regeneration air passes through shut off valve 8 throttle valve 9 and strainer 10 and is blown through the wet rotor ...

Page 27: ...2 3 Condensate drain system Flow diagram ZR Instruction book 26 ...

Page 28: ...Flow diagram ZT Explanation of arrows Ref Name 1 Air inlet 2 Air flow 3 Oil flow 4 Air outlet 5 Water flow Instruction book 27 ...

Page 29: ...s the liquid level As soon as the collector is filled up to a certain level pilot valve 4 is activated and diaphragm 5 opens outlet 6 discharging the condensate When the collector has been emptied the outlet closes quickly without wasting compressed air When the controller registers a malfunction the red alarm LED starts flashing and the electronic drain valve will automatically change to the alar...

Page 30: ...nd check that the valve opens for condensate discharge Checking the alarm signal Press the test button for at least 1 minute Check that the alarm LED flashes Release the test button 2 4 Oil system Flow diagram ZR Instruction book 29 ...

Page 31: ...et 2 Air flow 3 Oil flow 4 Water flow 4 5 Air outlet Oil system On ZR compressors oil is circulated by pump OP from the sump of the gear casing to cooler Co From there the oil flows through filter OF towards the bearings and timing gears Instruction book 30 ...

Page 32: ...er Co Then the oil flows through the cooling jackets of compressor elements El and Eh From there the oil flows through filter OF towards the bearings and timing gears Valve BV opens if the oil pressure should rise above a given value 2 5 Cooling system Flow diagram ZR Instruction book 31 ...

Page 33: ...Flow diagram ZR Full Feature Instruction book 32 ...

Page 34: ...Flow diagram ZT Instruction book 33 ...

Page 35: ...Flow diagram ZT Full Feature Explanation of arrows Ref Name 1 Air inlet 2 Air flow 3 Oil flow 4 Air outlet 5 Water flow Instruction book 34 ...

Page 36: ...ing air for this cooler is generated by an extra fan 13 2 6 Energy recovery General The system recovers the major part of the compression heat The percentage of shaft input power available for recovery is between 80 and 95 depending on the operating conditions If an MD dryer is installed downstream of the compressor this percentage is reduced to approx 70 of the shaft input instead of approx 90 as...

Page 37: ...ling water circuit is not recovered by the energy recovery system Pump unit Atlas Copco supplies pump units to transfer the energy recovered from the compressor to the heat consumer HC The pump unit constitutes a closed water circuit with the compressor cooling system Two water pumps WP1 2 are fitted One pump circulates the hot cooling water from the compressor through the heat consumer and back t...

Page 38: ...of the cooling water returning from the heat consumer HC Sufficient low temperature cooling water must be available for the heat exchanger to achieve a water temperature that does not exceed 40 C 104 F Electrical system The pumps WP1 and WP2 are driven by an electric motor Each motor is equipped with manual starting equipment including a circuit breaker The first time it is started check that the ...

Page 39: ...er temperature at compressor inlet 40 C 104 F Safety valve opening pressure 2 5 bar e 36 3 psig 2 7 Low load compensator Description Reference Name 1 Low load during unload cycle 2 Heater 3 Air net 4 Rotor 5 Motor 6 Cooler 7 Solenoid valve 8 Silencer 9 Air outlet compressor 10 Mechanical link 11 Drain 12 Water 13 No air flow 14 Air flow 15 Flow direction Instruction book 38 ...

Page 40: ...by purging a small amount of heated dryed air through the rotor 4 This is needed when the load cycle is below 40 consult your Atlas Copco Customer Centre 2 8 Electrical system Main components The electrical system mainly includes Elektronikon regulator Emergency stop button S2 Electric cabinet Drive motor M1 Pressure and temperature sensors Elektronikon regulator 1 and emergency stop button S2 Ins...

Page 41: ...Electric cabinet Typical example Typical example Instruction book 40 ...

Page 42: ...Drive motor M1 Drive motor M1 Instruction book 41 ...

Page 43: ...rogrammable settings e g the unloading and loading pressures the minimum stop time and the maximum number of motor starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases In case the expected unloading period is too short the compressor is kept running to prevent too short stand...

Page 44: ... message will appear on display 1 to warn the operator to carry out the service actions belonging to that level Automatic restart after voltage failure The regulator has a built in function to automatically restart the compressor if the voltage is restored after voltage failure For compressors leaving the factory this function is made inactive If desired the function can be activated Consult the A...

Page 45: ...n arrow pointing to the right can be modified 5 Function keys Keys to control and program the compressor 6 Voltage on LED Indicates that the voltage is switched on 7 General alarm LED Is lit if a shut down warning condition exists 7 General alarm LED Flashes if a shut down condition exists if an important sensor is out of order or after an emergency stop 8 Automatic operation LED Indicates that th...

Page 46: ... to a previously shown option or menu Cancel To cancel a programmed setting when programming parameters Delete To delete compressor start stop commands Help To find the Atlas Copco internet address Limits To show limits for a programmable setting Load To load the compressor manually Mainscreen To return from a menu to the main screen Menu Starting from the main screen to have access to the submenu...

Page 47: ...y the scroll key with the same symbol can be used to see the previous item When the scroll key is kept pressed the scrolling is continued 3 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 regula...

Page 48: ... 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 programs Description In order to facilitate programming and controlling menu driven control programs have been implemented in the regulator Instruction book 47 ...

Page 49: ... Shows in short the operation status of the compressor Is the gateway to all functions Status data Calls up the status of the compressor protection functions shut down shut down warning service warning and warning Resets a shut down motor overload and service condition Instruction book 48 ...

Page 50: ...and commands Configuration time date display language Service Calls up service plans and resets the timers after carrying out the service actions belonging to a plan Saved data Calls up the saved data last shut down last emergency stop data Unload Load Loads and unloads the compressor manually 3 7 Calling up menus Description Control panel When the voltage is switched on the Main screen is shown a...

Page 51: ...e regulator Procedure The Main screen is shown automatically when the voltage is switched on If the function or arrow keys 1 2 and 3 are not used for some minutes the regulator will automatically return to the Main screen Whenever displayed on a submenu screen press the Mainscreen F1 key to return to the Main screen Example of Main screen of ZR ZT 55 up to ZR ZT 90 Compressor Outlet 7 5 bar Automa...

Page 52: ...ata submenu gives information regarding the status of the compressor protection functions shut down shut down warning and service warning and allows resetting of a shut down motor overload and service condition Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 the option Status Data will be followed by a horizontal arrow Press the tabulator key 2 No message exists ...

Page 53: ... After remedying and when the shut down condition has disappeared switch on the voltage and press the key Reset F3 Press the keys Menu and Mainscreen to return to the Main screen and restart the compressor by means of start button 3 A shut down warning message exists A shut down warning level is a programmable level below the shut down level If a shut down warning exists LED 1 is alight The Main s...

Page 54: ...tor key 2 to select the Status data menu the option Service is blinking Scroll to this option and select it by pressing the tabulator key 2 two options may blink Inputs if the programmed service level of a component is exceeded e g the maximum pressure drop of the air filter Plan if a service plan interval is exceeded Stop the compressor and switch off the voltage In case the service message was r...

Page 55: ...he sensors is linked to a shut down service or warning function both the actually measured value as well as the corresponding shut down warning or service level can be called up by pressing key 2 3 11 Counters menu Control panel Function To call up The running hours The loaded hours The number of motor starts The number of hours the regulator module has been under tension The number of load cycles...

Page 56: ...nu F1 key Press arrow down key 1 until Test is followed by a horizontal arrow Activate the menu by pressing the key 2 To perform a display test If necessary scroll through the menu until Display Test is followed by a horizontal arrow Press the key 2 During testing the regulator will generate a series of patterns on the display which enable the operator to check that each pixel still functions norm...

Page 57: ...ms Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Modify Parameters is followed by 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 para...

Page 58: ...ck the limitations for the parameter Consult Programmable settings for the most important settings 3 15 Modifying regulation settings Control panel compressor Function To modify the low load operation mode of the dryer Procedure Starting from the Main screen 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 ...

Page 59: ...dow of an hour If the load cycle is lower than 40 the low load option is activated After the low load cycle reaches 60 the low load option will be deactivated Disabled On compressors with Low load option or compressors with IND dryer always set this option to off 3 16 Modifying protection settings Control panel Function To modify protection settings Shutdown e g for the compressor element outlet t...

Page 60: ...the limits for the parameter Use the scroll keys 1 to change the setting Press Program F1 to program the new value or Cancel F3 to cancel the modification operation The screen see example below shows a horizontal arrow indicating that the shut down warning value can be modified the procedure is similar to the description above The procedure to modify other items is similar For some settings a dela...

Page 61: ...example the compressor will be programmed as follows On Monday at 06 15 starting in pressure band 1 On Friday at 18 00 changing over to pressure band 2 On Saturday at 18 00 stopping 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 ...

Page 62: ...ram the command 06 15 Start Compressor Press the arrow down key 1 the horizontal arrow indicates that the second line is accessible Press the key Modify and modify this line in a similar way to the following command 06 15 Pressure Band 1 Press the key Menu F1 and scroll to Friday Thursday Friday Saturday Menu Delete F1 F2 F3 Programming the command to change over at 18 o clock to Pressure Band2 is...

Page 63: ...d Activated If not the programmed start stop commands will not be executed The timer can be deactivated again In this case the programmed start stop commands will not be executed but remain in the memory of the regulator Modifying a command Suppose the command to stop the compressor on Saturday 18 00 is to be modified i e stopping at 17 o clock instead of 18 o clock Starting from the Main screen p...

Page 64: ...ing the tabulator key 2 Use the arrow down key 1 to scroll until the option Clock Function is followed by a horizontal arrow Press the tabulator key following screen appears Clock Function Not Activated Menu Modify Delete F1 F2 F3 Suppose the command to stop the compressor at 18 00 must be added to the list of Monday Press the tabulator key 2 following screen appears Monday Tuesday Wednesday Menu ...

Page 65: ...until the option Modify Parameters is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 Use the scroll keys 1 to scroll until the option Clock Function is followed by a horizontal arrow Press the tabulator key following screen appears Clock Function Not Activated Menu Modify Delete F1 F2 F3 Deleting all commands Press the key Delete in the screen above A question to ...

Page 66: ...ulator key 2 In case of the option Time the second line on the screen indicates the actual setting e g 14 30 To modify this setting press the key Modify F2 the first field 14 will blink Use the scroll keys 1 to change the setting then press the tabulator key 2 to go to the next field 30 The setting of this field can now be modified using the scroll keys 1 Press the key Program F1 to program the ne...

Page 67: ... carried out previously Service plans A number of service operations are grouped called Level A Level B etc Each level stands for a number of service actions to be carried out at the time intervals programmed in the Elektronikon regulator When a service plan interval is reached a message will appear on the screen see section Status data After carrying out the service actions related to the indicat...

Page 68: ... tabulator key 2 following screen appears Next Timer Level A B 8000 hrs Back Reset F1 F2 F3 The screen shows that the next service plans to be carried out are plans A and B and that these plans are to be carried out every 8000 running hours Press the arrow down key 1 to find out which service plans were carried out previously following screen appears Previous Timer Level A 4008 hrs Back F1 F2 F3 T...

Page 69: ... data saved by the regulator These data are Last shut down data Last emergency stop data Procedure Starting from the Main screen see Main screen menu Press the key Menu F1 Press the arrow down key 1 until Saved Data is followed by a horizontal arrow Activate the menu by pressing the tabulator key 2 The first option is shown Last shutdown 1 Press the tabulator key 2 to find out the date time and ot...

Page 70: ...g pressure bar e 4 5 8 0 8 6 Unloading pressure psig 65 116 124 7 Unloading pressure bar e 4 5 8 0 9 0 Unloading pressure psig 65 116 130 5 Unloading pressure bar e 4 5 9 0 10 0 Unloading pressure psig 65 130 5 145 Unloading pressure bar e 4 5 9 0 10 4 Unloading pressure psig 65 130 5 150 8 Loading pressure bar e 4 5 6 5 7 25 Loading pressure psig 65 94 3 105 2 Loading pressure bar e 4 5 6 5 7 5 L...

Page 71: ...l F 212 437 455 Compressor element 1 outlet temperature shut down level C 226 235 235 Compressor element 1 outlet temperature shut down level F 439 455 455 Compressor element 2 outlet temperature shut down warning level C 100 210 220 Compressor element 2 outlet temperature shut down warning level F 212 410 428 Compressor element 2 outlet temperature shut down level C 211 220 220 Compressor element...

Page 72: ...imum setting Factory setting Maximum setting Service plan A running hours hr See remark 4000 See remark Service plan A running hours hr See remark 3600 See remark Service plan B running hours hr See remark 8000 See remark Service plan C running hours hr See remark 16000 See remark Service plan I running hours hr See remark 2000 See remark Remark A number of service operations are grouped Level A L...

Page 73: ... regulator will start the compressor after the minimum stop time Power 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 progra...

Page 74: ...4 Installation 4 1 Dimension drawings Dimension drawing ZR Pack Instruction book 73 ...

Page 75: ...Dimension drawing ZR Pack with energy recovery Instruction book 74 ...

Page 76: ...Dimension drawing ZR Full Feature Instruction book 75 ...

Page 77: ...Dimension drawing ZR Full Feature with energy recovery Instruction book 76 ...

Page 78: ...Dimension drawing ZT Pack Instruction book 77 ...

Page 79: ...ull Feature Text on drawing Ref Name 1 Voltage supply entry 2 Compressed air outlet 3 Cooling air outlet 4 Opening for transportation 5 4 slotted holes only for horizontally pulling unit out of container Instruction book 78 ...

Page 80: ...Water out 14 Water in 15 Automatic drain dryer inlet 17 Automatic drain dryer outlet 18 Cooling Full Feature air outlet 19 Cooling Full Feature air inlet 20 If option Prepared for MD 21 Cable box included for EC variants 22 Cable box not included for CSA UL variants 23 Automatic drain regeneration outlet 24 Low load drain optional 25 Automatic drain extra aftercooler Instruction book 79 ...

Page 81: ...4 2 Installation proposals Installation proposal ZR Pack ZR Full Feature and ZR Pack with energy recovery Instruction book 80 ...

Page 82: ...Installation proposal ZR Full Feature with energy recovery Instruction book 81 ...

Page 83: ...Installation proposal ZT Pack Instruction book 82 ...

Page 84: ...Installation proposal ZT Full Feature Text on figures Ref Name 1 Minimum free area to be reserved 2 Ventilation proposal 3 Cooling air outlet Instruction book 83 ...

Page 85: ...d ventilation capacity per compressor installed to limit the compressor room temperature can be calculated as follows On ZR compressors Qv 0 1 N dT On ZT compressors Qv 0 92 N dT Qv required ventilation capacity in m3 s N shaft input of the compressor in kW dT temperature rise over ambient in C If cooling air ducts are installed the maximum allowable pressure drop over the ducts is 30 Pa Common du...

Page 86: ...of 104 F 50Hz IEC Pack and Full Feature compressors 400 V ZT ZR55 3 x 50 25 mm2 ZT ZR75 3 x 95 50 mm2 ZT ZR90 3 x 120 70 mm2 Full Feature ND compressors 400 V ZT ZR55 3 x 70 35 mm2 ZT ZR75 3 x 70 35 mm2 ZT ZR90 2x 3 x 50 50 mm 2 Full Feature ND compressors Instruction book 85 380 V 440 460 V ZT ZR55 3 x 70 35 mm2 3 x 70 35 mm2 ZT ZR75 2x 3 x 50 35 mm 2 3 x 70 35 mm2 ZT ZR90 2x 3 x 70 35 mm2 2x 3 x...

Page 87: ...Instruction book 86 4 4 PANEL GA ZR 55 90 PACK ...

Page 88: ...Instruction book 87 ...

Page 89: ...Instruction book 88 ...

Page 90: ...Instruction book 89 ...

Page 91: ...ater that enters the cooler must be considered and not the composition of the make up water Due to the evaporative effect in the cooling tower much higher concentrations of ions can be obtained in the circulating water than in the make up water Ryznar stability index RSI The Ryznar Stability Index RSI is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonat...

Page 92: ...38 1 8 38 44 1 7 70 87 1 5 1 40 1 76 1 9 45 50 1 6 88 110 1 6 1 78 2 20 2 0 51 56 1 5 111 138 1 7 2 22 2 78 2 1 57 63 1 4 138 174 1 8 2 80 3 54 2 2 64 71 1 3 175 220 1 9 3 54 4 40 2 3 72 80 1 2 230 270 2 0 4 6 5 4 2 4 280 340 2 1 5 6 7 0 2 5 350 430 2 2 7 2 8 8 2 6 440 550 2 3 9 0 11 0 2 7 560 690 2 4 11 2 13 8 2 8 700 870 2 5 14 0 17 6 2 9 880 1000 2 6 17 8 20 0 3 0 Interpretation of the value ob...

Page 93: ... This is the sum of all the ions in the water It can be derived from the dry residue after evaporation but not including suspended solids or it can be estimated from the electrical conductivity In a closed system the following limits apply TDS 3000 mg l 3800 microS cm For an open system the following limits apply TDS 750 mg l 960 microS cm Chlorides Cl Chloride ions will create pitting corrosion o...

Page 94: ...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 4 6 Pictographs Explanation of pictographs Instruction book 93 ...

Page 95: ...ance or repair 13 Before connecting the compressor electrically consult the Instruction book for the motor rotation direction 14 Torques for steel Fe or brass CuZn bolts 15 Consult the Instruction book before greasing 16 Switch off the voltage before removing the protecting cover inside the electric cabinet 17 Oil the gaskets screw on the filters and tighten by hand approx one half turn 18 Consult...

Page 96: ...Arrow indicating rotation direction 2 Warning voltage 3 Instruction for delta P reading Purge internal impulse line before any reading of delta P on U tube close isolation valves of U tube 4 Indication for correct adjusting of the U tube water level Instruction book 95 ...

Page 97: ...e from the frame equally The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor The lifting equipment must be placed in such a way that the compressor is lifted perpendicularly Lift gently and avoid twisting 5 2 Initial start up Procedure Consult Electric cables Installation proposals and Dimension drawings A sticker dealing in short with the oper...

Page 98: ...ve support 1 at the gear casing side On ZT compressors remove bolts 1 and supports 2 immobilizing the vibration dampers of the coolers Remove support 3 immobilizing the vibration dampers of the gear casing Instruction book 97 ...

Page 99: ... Remove flange 1 and take out the silica gel bags installed in the intercooler at the condensate drain receiver side Refit the flange Instruction book 98 ...

Page 100: ...Position of silica gel bags on ZT compressors Instruction book 99 ...

Page 101: ... FF 1617 7572 00 1617 7571 00 1617 7571 00 1617 7571 00 Z 75 FF 1617 7573 00 1617 7571 00 1617 7571 00 1617 7571 00 Z 90 FF 1617 7440 00 1617 7572 00 1617 7572 00 1617 7571 00 The setpoint of the dryer heater depends on the working conditions consult the Atlas Copco Customer Centre to have the setpoint adjusted On ZR compressors fit the water drain plugs 1 DP1 DP2 DP3 that are fixed to the water p...

Page 102: ...Instruction book 101 ...

Page 103: ...he water inlet valve and outlet valve customer s installation and check for water flow On ZR Full Feature the inlet and outlet valves of the cooling water circuit of the regeneration cooler must be opened completely Check that the gear casing is filled with oil the level should be in the middle of sight glass SG Instruction book 102 ...

Page 104: ...orrespond to the local codes The installation must be earthed and protected by fuses in all phases An isolating switch must be provided Check the connections at the primary sides of transformers T1 and T2 Typical example Instruction book 103 ...

Page 105: ...nel 1 and check the rotation direction of the fan motor If the rotation direction is wrong switch off the voltage and reverse two connections at terminals 221 up to 226 of terminal strip 1X1 On ZT Full Feature compressors also check the rotation of the fan motor of the regeneration cooler Cr the correct rotation direction is indicated by an arrow on the fan motor Run the compressor for a few minut...

Page 106: ...Adjustment of the pressure difference of the dryer compartments Delta P indicator View of PDP sensor Instruction book 105 ...

Page 107: ...ve 6 slightly while monitoring the water levels in the U tube There are two possible conditions The water level in the leg marked rises Close valve 6 at once decrease the regeneration air inlet pressure see next step Do this as often as necessary until the water level drops The water level in the leg marked rises which should normally be the case If the level in this leg rises 30 mm above the leve...

Page 108: ...perator must apply all related Safety precautions In case the water system was drained close the drain valves and fit the drain plugs Procedure Step Action 1 Check the oil level which must be in the middle of sight glass SG Top up if necessary with the correct type of oil 2 Open the water inlet valve and outlet valve customer s installation Opening of the water outlet valve can be overlooked if af...

Page 109: ...Position of oil sight glass on ZR compressors Position of oil sight glass on ZT compressors Instruction book 108 ...

Page 110: ... and automatic operation LED 3 lights up 4 Regulate the water flow with the compressor running loaded See Compressor data for the cooling water temperature and cooling water consumption When the compressor is stopped and automatic operation LED 3 is alight the compressor may start automatically If the start stop timer is active the compressor may start automatically even if it was stopped manually...

Page 111: ... matched to the air consumption the compressor will start and stop whenever necessary Avoid short compressor loading periods minimum 50 load and operation at very low working pressures as otherwise the performance of the dryer will diminish Avoid operation at too low a regeneration air temperature minimum 130 C 266 F Keep all doors closed during operation Instruction book 110 ...

Page 112: ...ervice actions of the indicated plans or replace the component and reset the relevant timer Consult your Atlas Copco Customer Centre See also Preventive maintenance schedule 4 Regularly check the actual compressor status by pressing the down key from the main screen Before starting any maintenance or repairs stop the compressor wait until it has stopped Close the air outlet valve and press the tes...

Page 113: ...Procedure Position of water drain plug on LP compressor element Position of water drain plug on HP compressor element Instruction book 112 ...

Page 114: ... of oil cooler Position of water drain plugs of cooler block Frequently stopping the compressor using the emergency stop button may damage the compressor only use the emergency stop button in case of emergency Instruction book 113 ...

Page 115: ...derneath the LP compressor element El By removing drain plug 1 underneath the HP compressor element Eh By removing drain plug DP1 on the oil cooler By removing drain plugs DP2 and DP3 underneath the cooler block 1 5 7 Taking out of operation Procedure Step Action 1 Close the air outlet valve and stop the compressor 2 Switch off the voltage Disconnect the compressor from the mains 3 Shut off and de...

Page 116: ...es first The longer interval checks must also include the shorter interval checks The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the environmental and working conditions of the compressor Period Running hours Operation At initial start Check the pressure differential of the rotor compartments of the integrated dryer Adjust if necessary Daily 8 Check readin...

Page 117: ...ts to suit your needs An Inspection plan A Preventive maintenance plan A Total responsibility plan Contact your Customer Centre to agree on a tailor made service agreement It will ensure optimum operational efficiency minimize downtime and reduce the total life cycle costs 6 5 Service plan A number of service operations are grouped called Level A Level B Level C Each level stands for a number of s...

Page 118: ...tor M1 of ZT compressor Motor grease Do not mix greases of different types The recommended motor grease is KLÜBERQUIET BQH 72 102 Contact your Customer Centre for the greasing quantity and interval for the motor bearings Instruction book 117 ...

Page 119: ...Atlas Copco Roto Z oil can be ordered in following quantities Quantity Ordering number 20 l can 5 28 Us gal can 4 40 Imp gal can 0 70 cu ft can 2908 8501 01 209 l drum 55 18 Us gal drum 45 98 Imp gal drum 7 32 cu ft drum 2908 8500 00 6 8 Storage after installation Run the compressor e g twice a week until warm If the compressor is going to be stored without running from time to time protective mea...

Page 120: ...7 Servicing procedures 7 1 Air filter AF Location of the air filter on ZR compressors Instruction book 119 ...

Page 121: ...Stop the compressor and switch off the voltage to the compressor 2 Remove the filter 3 Fit the new filter 4 After carrying out the service actions of the related service plan the service warning must be reset See also Preventive maintenance schedule Instruction book 120 ...

Page 122: ...7 2 Oil and oil filter change Control panel Oil system components ZR Instruction book 121 ...

Page 123: ...contacts the seat Then tighten by hand 5 Fill the compressor sump to the middle of the oil level sight glass SG with oil as specified in Oil specifications Reinstall the filler plug 6 Switch on the voltage Unlock the emergency stop button 7 Run the compressor for a few minutes Stop the compressor If necessary top up the gear casing with oil to the middle of the sight glass SG 8 After carrying out ...

Page 124: ...r recirculation of cooling air Improve ventilation of compressor room and avoid cooling air recirculation Air filter clogged Replace filter Insufficient cooling water flow Check water temperature and increase cooling water flow Restriction in cooling water system due to formation of scale or settling down of dirt Consult Atlas Copco Condensate is not discharged from condensate traps during operati...

Page 125: ... Always be sure that the connections of the U tube are airtight Operating pressure too low Do not operate dryer at a pressure less than 4 bar e Rotor does not turn Consult Atlas Copco Rotor compartment sealing ring sealing sectors and rotor need inspection Consult Atlas Copco Aftercooler air outlet temperature too high Regeneration cooler air outlet temperature too high On water cooled compressor ...

Page 126: ...ter drains during unloaded operation and after dryer has been stopped Regeneration air cooler core tube broken Remove cooler plug broken tube or replace cooler core Regeneration air inlet temperature too low Hot air shut off valve closed Open the valve Compressor loading periods too short Take necessary action to increase duration of loading periods Nozzle of ejector partly obstructed Remove and c...

Page 127: ...utlet maximum 80 C maximum 176 F Regeneration air inlet 120 200 C 248 392 F Regeneration air outlet 55 150 C 131 302 F Dryer mix air maximum 50 C maximum 122 F Dryer water out 0 50 C 32 122 F Temperature difference dryer outlet inlet maximum 25 C maximum 45 F Temperature difference dryer regeneration air inlet inlet 100 160 C 180 288 F Temperature difference dryer mix inlet maximum 10 C maximum 18...

Page 128: ...2 Full Feature ND A Q41 A Q1 A Fuses Type 2gG A 200 V 134 10 0 10 0 13 0 4 5 2 3 315 230 V 117 8 3 10 1 15 0 4 5 2 1 315 400 V 67 4 8 6 3 8 7 2 6 1 2 160 ZT ZR75 Instruction book 127 Voltage F21 A Q25 A Q32 Pack and Full Feature A Q32 Full Feature ND Q41 A Q1 A Fuses Type 2gG A 200 V 186 14 0 10 0 13 0 4 5 3 5 400 230 V 159 12 0 10 1 15 0 4 5 3 2 355 400 V 92 7 0 6 3 8 7 2 6 1 2 200 Voltage F21 A ...

Page 129: ...lute inlet pressure bar a 1 Absolute inlet pressure psi 14 50 Relative air humidity 0 Air inlet temperature C 20 Air inlet temperature F 68 Cooling water inlet temperature C 20 Cooling water inlet temperature F 68 9 5 Limitations Limitations Value Value Maximum air inlet temperature 40 C 104 F Minimum air inlet temperature 0 C 32 F Maximum cooling water temperature at inlet at temperature rise 15 ...

Page 130: ...t at maximum working pressure ZR Full Feature hp 82 2 108 35 126 59 Oil capacity l 35 35 35 Oil capacity Us gal 9 24 9 24 9 24 Oil capacity Imp gal 7 70 7 70 7 70 Oil capacity cu ft 1 23 1 23 1 23 Cooling water consumption at temperature rise of 15 C ZR Pack l s 0 9 1 2 1 4 Cooling water consumption at temperature rise of 27 F ZR Pack l s 0 9 1 2 1 4 Cooling water consumption at temperature rise o...

Page 131: ...9 67 Power input at maximum working pressure ZR Full Feature kW 61 6 82 9 96 0 Power input at maximum working pressure ZR Full Feature hp 82 61 111 17 128 74 Oil capacity l 35 35 35 Oil capacity Us gal 9 24 9 24 9 24 Oil capacity Imp gal 7 70 7 70 7 70 Oil capacity cu ft 1 23 1 23 1 23 Cooling water consumption at temperature rise of 15 C ZR Pack l s 0 9 1 2 1 4 Cooling water consumption at temper...

Page 132: ... kW 61 3 84 6 99 4 Power input at maximum working pressure ZR Pack hp 82 20 113 45 133 30 Power input at maximum working pressure ZR Full Feature kW 60 8 84 0 98 7 Power input at maximum working pressure ZR Full Feature hp 81 53 112 64 132 36 Oil capacity l 35 35 35 Oil capacity Us gal 9 24 9 24 9 24 Oil capacity Imp gal 7 70 7 70 7 70 Oil capacity cu ft 1 23 1 23 1 23 Cooling water consumption at...

Page 133: ...g pressure ZT Pack bar 7 5 7 5 7 5 Maximum working pressure ZT Pack psi 108 78 108 78 108 78 Maximum working pressure ZT Full Feature bar 7 25 7 25 7 25 Maximum working pressure ZT Full Feature psi 105 15 105 15 105 15 Power input at maximum working pressure ZT Pack kW 64 9 86 2 102 1 Power input at maximum working pressure ZT Pack hp 87 03 115 59 136 92 Power input at maximum working pressure ZT ...

Page 134: ...ng pressure ZT Full Feature kW 65 1 89 2 104 4 Power input at maximum working pressure ZT Full Feature hp 87 3 119 62 140 0 Oil capacity l 45 45 45 Oil capacity Us gal 11 88 11 88 11 88 Oil capacity Imp gal 9 90 9 90 9 90 Oil capacity cu ft 1 58 1 58 1 58 ZT 10 bar 50Hz Unit ZT55 ZT75 ZT90 Nominal working pressure bar 9 9 9 Nominal working pressure psi 130 54 130 54 130 54 Maximum working pressure...

Page 135: ...m working pressure ZT Full Feature kW 64 9 89 8 105 5 Power input at maximum working pressure ZT Full Feature hp 87 03 120 42 141 48 Oil capacity l 45 45 45 Oil capacity Us gal 11 88 11 88 11 88 Oil capacity Imp gal 9 90 9 90 9 90 Oil capacity cu ft 1 58 1 58 1 58 ...

Page 136: ...d engineering practice Parts of category I according to 97 23 EC are integrated into the machine and fall under the exclusion of article I section 3 6 Parts subject to the Simple Pressure Vessel Directive 87 404 EEC are excluded from 97 23 EC according to article I section 3 3 The following pressure bearing parts are of category higher than I Safety valve Category IV Design code AD Merkblätter A2 ...

Page 137: ...Instruction book 136 ...

Page 138: ...www atlascopco com ...

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