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    Oil Free 132 KW ZR 3 Air Compressor made by Atlas Copco

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    Oil Free 132 KW ZR 3 Air Compressor made by Atlas Copco

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    © All Rights Reserved
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    Download as pdf
    2K views27 pages

    Air Compressor 132KW ZR 3 Atlas Copco Manual

    Uploaded by

    M Uzair Shaikh
    Oil Free 132 KW ZR 3 Air Compressor made by Atlas Copco

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Instruction book for Stationary Compressors ZR - ZR4 - ZR5 - ZR6 Pack and ZA3 - ZA4 - ZA5 - ZAG Pack Ls .. Stlas Copco *328z20 — 1989.01 Instruction book for Stationary Compressors > ZR8 - ZR4 - ZR5 - ZR6 Pack and ZA3 - ZA4 - ZA5 - ZAG Pack 2A5: 0 285: ZA6: ARP-621 000, 2R6: ATLAS COPCO AIRPOWER nv. B-2610 WILRUK - BELGIUM Printed Matter No. 2920 5970 01 This instruction book describes how to handle and operate the subject machine(s) to ensure safe ‘operation, optimum working economy and long service ie Read this book betcre putting the machine into operation to ensure corect handling, ‘operation and proper maintenance from the beginning. The maintenance schedule contains a summary ofthe measures for keeping the unit good repair. The maintenance procedures are simple but must be carried out regularly. Keep the book avatabe for the operators) and make sure thatthe units operated and tha he maintenance actions are carried out according the instructions. Recor al operating data, maintenance work eflected, ec. in an operator's logbook available at Atas Copco. Follow al appicable safety precautions, amongst others those mentioned onthe cover or onthe ist few ages of his book Repair operations should be pertormad by trained parson, avaiable at Alas Copco Senvce (utes, which shoud aso be contacted if any futher formations desired. In all correspondence always mention the unit ype and the complete seral number, shown onthe data plat. For all specific data not mentioned inthe text, consut sections "Preventive maintenance schedule" and ‘Principal data’. ‘The company reserves the right to make changes without prior notice. Contents eo Pa 1 Leading partcutars 32. Series exchange elements ” General desepon. 93. reventve mafioarceschadliraconpess'. 17 Ni F0W onssnonnnnnnnnnnnnn 34 Ol specications... 18 Ot system . 35. Oiichange 8 Cooling wate system ——- 38 Storage 8 Condensate crain system on ZR Pack. Unloading system : Adjustments and servicing procedures. 19 Blctical system. “44 Seting ofthe air pressure switch. 19 4.7.1 Operation and rouble shooting nnn 42 Aifiter... 19 42.1 Recommendations. 18 Operating instructions —— 422 Sonne 19 Compressor insialaion 4253 Cleaning the element). 20 |. 43: Unloading goar, shut-down switches and stety valves 20 23. Beloe saring = 2 Problem solving 20 25 Compression sating 26 During operation ncnnnnnnnnn a Principal data 2 27 Stopping... = 61. Readings on gauges: 2 62 Setingso shutdown switches and salty valves Maintenance ee 63. Compressor specticatons 24 ener seecomens = 64 Conversion ist of SI units ino Briish Unis. 24 1 Leading particulars 1.1 General description ZR Pack and ZA Pack are water-cooled, electric motor diven serew compressors, which deliver oi-ree, pusation-Kree ai. ZA Pack are single-stage whereas ZR Pack are two-stage compressors ‘Compressor ‘A step-up gear casing provided with an oil sump carries the ‘compressor elements). The power from the motor is transmitted {o the step-up gear shalt through a flexible coupling, Drive arrangements In Ar, the moto is fanged to the gear casing by means of an adapter housing. The compressorimotor units supported on vibration dampers onthe frame, In Ar. 1, the compressor and motor are separately mounted on a ‘sub-rame, supported onthe frame on vibration dampers, Compressor element(s) ZA have one compressor element. ZR have one low-pressure (LP) ‘and ane high-pressure (HP) compressor element. Each compressor ‘element houses two screw-ype rotors, mounted on ball and ler bearings. The male olor, driven by the step-up gear, and the female rotor are synchronized through timing gears, which maintain a slight clearance between the rotors. The male rolar has four lobes and the female rolor six flutes. Thus, the male rotor revolves at 1 1/2 times the speed ofthe female fotor. The absence of contact between the rotors and between the ‘otors and the compressor casing eliminates wear and power loss. Air and ot seating rings are fited onthe rotor shafts, The ar seals are located next tothe compression space, the ol seals next othe rotor bearings. The leak atom the air seals is evacuated to the atmosphere through vent-holes. Any ol that might gather between the oll and air seals is prevented from entering the compression ‘pace, as itis also drained through vent-holes. Oil system Oil ubricates the rotor bearings, ming and dive gears. The system includes a gear-type ol pump, an oll cooler and (an) oil fers). Cooling system ‘The compressor element(s) and the cooler(s) are water-cooled. On 2, the intercooler and aftercooler are provided with moisture vaps. Safety devices ‘On 2R, (a) relietvalve(s) and (a) HP safety valves) protect the LP and HP sides of the compressor respectively. The ZAis filed with (a) satety valve). ‘A check vale prevents blow-back of compressed ait rom the net when the compressor is unloaded or stopped. Pressure and thermal shut-down switches protect the compressor against abnormal operating conditions. Canopy ‘The motor, compressor, coolers), etc. ae enclosed ina sound: insulated canopy with an air intake silencer and doors. The front panel comprises a biparile cubicle Etectrical equipment ‘The operation ofthe units is governed by an elect reguator, in Conjunction with an ar pressure switch. The regulator comprises a blocking relay to prevent an automatic restart if the compressor is stopped through a shutdown switch, Generat The compressors furished with a data plate showing, among other things, the type, serial number and maximum final pressure, The ‘motors also provided with a data pate. 1.2 Air flow (Figs. 4 and §) Air draun through fiter elements) (AF), intake silencer (AS!) and Inet thrtle casing (IM) into compressor element (Eis ‘compressed, then discharged: + ONZR, trough outlet silencer (AS) to intercooler (Ci) = On ZA, through outet silencer (ASo) and check valve (CV) ‘The cooled air on ZR then enters HP compressor element (Eh), were itis futher compressed and discharged through outlet Silencer (ASo) and check valve (CV) to aftercooler (Ca). During loaded operation aint throttle valve (TV) i open and Lnloacing valve (UV) closed. The valves are simultaneously closed and opened respectively by oading solenoid valve (Y1) through tnloader piston (UP) when the working pressure reaches the pre sel maximum. On ZR, the pressure of HP element (Eh) i thon feleased to inlet casing (IM) upstream of throtte valve (TV) via unloading valve (UV) and bleed-off coolers) (Cb), On ZA, the Pressure ofthe compressor element s released fo the almosphere Via unloading valve (UV) and blow-off silencer (ASb). On both ZR. and ZA, this results in closing of check valve (CV) The throttle valve eaves an air passage in he closed poston. Thus, air remains drawn into the compressor to maintain a pressure rato ‘over the element (HP element on ZR). On ZA, the throttle valve has ‘small holes fortis purpose, ‘An airoperated balancing piston (BP) is fited behind the male ‘olor rear thrust bearing ofthe compressor element(s). The piston decreases the load on the male rotor front thrust bearing during loaded operation. During loading the balancing pistons is (are) actuated by: (0nZR, LP balancing piston: intercooler pressure HP balancing piston: working pressure + OnZA, balancing piston: working pressure During unloading, the pistons) is (are) in communication with the almosphere, ‘An ai fiter service indicator (Gy), a working pressure gauge (Gp), safely valve(s) and (a) high air temperature incicator/shut- down switses) (on ZR: TISHHT 1, TISHH1 and TISHH21; on ZA: TISHH11) are comprised in the system. In addition on ZR, an intercooler pressure gauge (Gpi) and an air outlet temperature ‘gauge (Gt) are installed Compressor ie ss, Aro Snor zy Reenee Sy See ene oy Bea SoD eka Stee Sseyettor Secor cn Seagate can Bela beorrale qr an) ray Sire wp Mons Se; aetna Hn aren sag ie indleatorshutdown M21) Drain ee tow rap it system eae 3.1) Cooling wator pipe, ol ‘oaling Water outst Ey ae 3, eee — 30. i cooler Gra, 1] Aftercooler cooling V ling flange, 7 ‘Semi-tlexible element Smt. Dranvate, ) aorotet connecton foe WO 23. Sensing lament, UP ‘compressor sump temperature gauge ayer Pula hoger animal re Sitio pga Sool water cutot (evi) partie (on ZA Gpo. ‘Oil pressure gauge temperature gauge 8.1) Cooling water pipe, ond ZA onty) OF. Oil filter(s) ‘Twe. Thermometer, com: bieed-off cooler to LP- FR sour eee tas 9.1) Boda ape Boned 25g Guy) inlet manifold Figs. 1 up oS. General views of 2R9 and ZA4 Pack and tow diagrams —— Process ain oatING' waren i CONTROL AMR Fig. 5. Flow diagram of ZA 1.3 Oil system (Figs. 4 and 5) Oi tom the ol sump (OT ofthe gear casing (GC) cca by aol pump (OP) mounted onthe ton ofthe ger easing. The pump i diven fom the man ive shall. Tho ols pumped trough Ai cootr (Co), ofits) (OF), compressor elements) ol pipes and ducts to lubricate te rotor bearings, cng and timing gears. ‘The ol then fows back to the oi sump. Valve (BV!) in the ol pump housing by-passes oi tothe sump whenever the maximum permissible pressure is exceeded onthe delivery side of the pump. By-pass valve (BV2) ofthe ol iter(s) opens when the pressure op over the fiter is above normal due to clogging of the element The oil is then circulated without being fiteed. For his reason it is imperative to replace te ol filters) at reguar intervals 0 pressure gauge (Go), ow ol pressure shut-down switch (PSLL49}, high ol temperature inccatorishut-down switch (TISHH44) (on ZR6 and ZA only) and oacing solenoid valve (Y1) are comprised in the system, 9) oil under pressure also opens te air int hrtte vate when loading solenid valve (Vi is energized by electric regalo (ER), Flow restrictor (Riis filed in the ol retum pipe ofthe slenoid valve. Thus, when the valve is acivated,sufcient ol pressure wil prevail upstream of the restrictor or operating the unloading mechanism. 1.4 Cooling water system RG have three circus (Fp. 4): ‘one for compressor elements (El and Eh) and ol cooler (Co) ‘ne for intercooler (Ci) and the two bleed-of coolers (Co) ‘one for aftercooler (Ca) which has the elements Each circuit is provided witha valve (Vic, Vil and Via for regulating the water flow. The two fist mentioned circuits have a thermometer (Twe and Twi) ited inthe outlet piping PYZPG, 4,5 have bo circuits: ‘one far cil cooler (Co), intercooler (Ci), bleed cooler (Cb) ‘and compressor elements (Eland Eh) = one for aftercooler (Ca) Each circuit hasa valve (Vii and Via for regiatng the wate flow. The allercooler of ZR3, -4 has one, tat of ZFS two elements ‘The compressor and atercoole cooing water circuits comprise a BR. Connection, ol Ra. Orain receiver, breathing pipe atorcoolor Daa, Automatcrain outlet, DRL Drain recover, ‘attorcooler intoreooter Dai Automate dain outlet, 1.-—-Cooling water inlet pipe intercooler 2 Gaaleg water outlet Dia. Drain valvo,atercooter Pipe ‘rain receiver 3, Compressor data plate Di, Drain valve, sntococler 4. Ar owlet ipo rain recover 5. Motor compartment Fig. 6. Condonsate drains of 273, -4 temperature gauge (Gite and Gla), the sensing elements of which are fited in he drain pes, ZA have one circu (Fig. 5): ‘The cooling water fist passes regulating vale (Vic) and ol cooler {Co}. The waler then flows through the cooling jacket ofthe Compressor element, rom where its drained, ‘The circuit comprises a temperature gauge (Gie), he sensing clement of whichis ited in the dain pipe. General The cooling jackets) ofthe compressor elements) consists) of ‘wo interconnected compartments, the lower parts of which are commiected extemaly by a pipe for draining, On ZR, other crn Points are also provided. ‘Adrain cock should be filed by the customer inthe ower part of the main cooling water inlet and outlet pipes. When the unitis stopped and freezing temperatures are expected, the cooling system must be drained completely. The coating water shal be tee fom solid impusies. The contot of calcium compounds shouldbe as law as possible and not exceed 120 img ot calcium exide (CaO) per ie to avoid te formation of sale 1.5. Condensate drain system on ZR Pack (Figs. 4 and 6) To prevent condensate from entering the HP element from the intercooler and the air outlet pipe from the aercocler, both coolers are equipped witha moisture tap (MT) and (Ma). Each moisture trap is connected to a drain receiver (DRI and DRa), provided with an automatic float valve, and a manually operated valve for draining condensata after the unit has been stopped. 1.6 Unloading system (Figs. 7 and 8) The on-off unloading system is operated by air pressure switch (PSR28), which senses the pressure variations inthe ai cischarge system. The pneumatic side ofthe ar pressure switch is connected to the air outlet, the electrical side tothe regulator. PER 1 2 $ Da DiRa Daa Oni DRI Dai eR COMPRESSOR LOADED f | sR 4 er : 1 5 Fle 7 | {tM UF 8 ov a Ga | LULU & “2 ont isis ' En RF ae { AS yee svt Mra} id t l-Oe cd : > risus T J Let Lsve & ww ' F.7.Artowdagom ad adgo}2R “The system contol the air output in relation othe ar consumption + and maintains the pressure in the ai net within the pre-selected Upper and ower iis of the working pressure (unloading and loading pressures). The uniading and loading pressuces ae the ‘opening and ciosing pressures ol he aipressure switch ‘The air outputs stopped (0% output) by unloading the ‘compressor and simultaneously closing the air inlet. Compression is resumed to ful capacity (100 % output) when the compressor is reloaded. Unloading/oading Ifthe air consumption is less than the capacity ofthe compressor, the net pressure increases. 8 \Wnen the net pressure reaches the unloading pressure, the conact of ai pressure switch (PSR29) opens and de-energizes loading solenoid valve (V1). This causes unioacig vale (UV) fo open ard thro valve (TV) to close. The air outputs stopped, the ‘compressor runs unloaded. On ZR, a vacuum prevails in the intercooler. ‘When the net pressure decreases tothe loading pressure, the contact ofthe air pressure switch closes, so that the loading solenoid valve is energized again. The throttle valve opens, the Unloading valve closes and the air output is resumed to fll capac. ‘The unloader cylinder (UA) comprises shutle valve (7), one side of which is actuated by ol pressure admitted to chamber (10) from the oil circuit. The other side is spring-loaded. SE a a TISHH it ae Air fitor Blow-off siencor Airinsakesiloncor ‘Aroutet siencor LP ‘eoment ir outlet sioncer Air outlet valve Balancing piston Altereoclor Blood of cooler interecoler Gheck vave HP compressor flement Compressor element (UP etement on ZR) lecric regulator Gear easing Working pressure gauge Intercooler pressure gauge Air out omporaturo gauge Ai titer vacuum gauge Bir io ott casing Fig. 8, Air ow aiagram and unloading gear of ZA Mra. 1) Moisture wap, ua. Unioadereylinder aftercooler uP, Unloader piston MT.1) Moisture tap, uy Unloading valve intorcooio vt Leading soloncid PsA2o. —_Arpressure switch valve Br Oil fow restrictor 1 Chamber, piston SV1.1) Intercooler relot spring ade vale(s) 2 Chamber, piston sve Satety valves) (HP protoure ede onzR) 3 Biaphragm-typ0 TISHH11.2) Compressor element swtening valve ‘ute temporatore 4 Chamber, Indeatorshutdown ltmospherc pressure switch 5 Unloader plunger TISHH11.1) LP element outet 6 ‘Air prossuro part temperature 2 Shuto valve Indieatorishut down 8 Vacuum port switch 8 Starting plunger TISHH18. 1) HP eloment inlet 10. ‘Chamber, ol from temperature workating creat Indeato/shut-down 1 From ol sreut switch 12 Tool sump TsHH21.1) HP element outlet temperature indeatorshutdown 1) On ZA ony switch 2)On ZA only Ww. Air inot tote valve 3) Tobe installed by the customer Figs. and 8. Ai low diagrams and unloading gear / Loaded operation The net pressure is less than the unloading pressure and the contact, of air pressure switch (PSR28) is closed. 41. Loading solenoid valve (¥1) is energized; ol under pressure is present in chamber (10) 2. ‘Starting plunger (9) and shuttle valve (7) have maved against the spring force of plunger (5). Port (8) is closed and port (6), open. 3. Switching valve (2) admits: (0nZR, inlrcooler pressure On ZA, air at working pressure to the balancing piston ofthe (LP) compressor element and to ‘chamber (2) of unioader piston (UP) via port (6). The atmospheric pressure inet por of the switching vavo is closed 4. Atmospheric pressure is present in chamber (1) of unioader Piston (UP). The pressure diference between chambers (1) and (2) keeps throttle valve (TV) open and unloacing valve (UV) cosed The compressor deliver its maximum output. Check valve (CV) isin its open positon. Unloaded operation ‘The net pressure has reached the unloading pressure. The contact, ofthe ai pressure switch opens. 1. Solenoid vai (Y1) i de-energized and the oil pressure ‘leased trom chamber (10). 2, Plunger (9) and shutle valve (7) are moved by sping force; ort (6)is closed. Port (8) is opened 3. The pressure is released from chamber (2) and replaced by atmospheric pressure. This causes spring loaded unioader piston (UP) to close throttle valve (TV) and to open unloading valve (UV) 4. On ZA, the compressed air between the HP element and the Unloading vale is blown off through bleed-off coolers) (Cb to inet casing (IM); check valve (CV) closes and prevents biow- back of compressed air fom the net. Wit the throttle vale closed, a vacuum prevails in unioader piston chambers (1 and 2) and in the intercooler. This causes swchingvaive (3) 0 operate, so that atmospheric pressure now operates the balancing piston ofthe LP element ‘On ZA, compressed ai is blown off tothe atmosphere through the open unloading valve and blow-off siencer(ASb); check valve (CV) closes and preven bow back of campressed alr from the net. With the throttle valve closed, a vacuum prevail in unioader ison chambers (1 and 2). Switching valve (3) admits air al almost atmospheric pressure to the balancing piston of ‘he compressor element instead ofa at woking pressure This condition wil prevail unti the net pressure has decreased to the loading pressure, The compressor can at all imes be manually unloaded by means of a toggle switch ted on the control pane Note: The unloader cyindor is a standardized component for single- sage (ZA) and two-stage (ZR) compressors. On ZA, the saphragm switching valve (3) has as such no function, a it always, remaing inthe same positon whether the compressor runs unloaded ornat. 10 1.7 Electrical system ‘Arrangement E units are normally completely equipped and wired, and recuie only connection tothe mains. The elecical systom comprises: Motor Motor starting equipment + Transformers for contol and lamp circuits Electric regulator + Shut-down switches Motor starting equipment The stating equipment and circuit diagram ofthe mole are not clealt with, as they depend on the type of molar insialled. The Circuit cagram is stuck on te inside ofthe regulator cabinet door Regulator and shut-down switches All the components ofthe regulator are housed withthe voltage transformers and motor stating equipment in tne “regulator cabinet” ofthe cubicle (Fig. 10), the door of which caries the ‘contol and incicator panel (Fig. 14), ‘The of pressure shut-down switchs fited together wih the air Bressure switch inthe “compressor cabinet ofthe cubicle (Fg 9). ‘The door ofthis cabinet cates the instrument panel (Fig 15), which is provided wih gauges and temperature indicatorishut- down switches. The temperature shut-down switches are incorporated inthe respective temperature indicators. PsLtsg Psroa PsLias, PSR29. i pressure shut-down switch ‘A pressure switch Fig. 9. Compressor panel ‘See lagend of Fig. 11 for denomination af components Components of starting equipment Fe tnermal overload relay Ket, Line contactor kez Stareontactor Kea Dolla contactor Koa. ‘Tmo relay, stavieta switching over x3, Earthing stip Fig, 10. Regulator cabinet of unit with Siomens star-deta starting ‘equipment ‘The shut down switchos are connected to the regulator. The sensing elements ofthe switches are fied to various points ofthe ‘compressor. Ian abnormal operating condition arises, the operative switch breaks the ict tothe regulator, causing the motor to stop and the faut ngicator lamp ofthe switch concerned to igh up. ‘Shut-down switches (Figs. 9 and 15) Ret. TISHHI Designation Air outet temperature on ZA, LP air outlet temperature on ZA Connected to Outlet pipe of (LP) compressor element Tripping cause Air oul temperature of (LP) compressor element 00 high Contacis. Normally alvays closed Ret, TISHH18 1) Designation HP airinlet temperature Connected to Intorcooler air outlet manifold Trpping cause Inlercooler aout temperature too high Conlacis” Normally always closed Ret. TIsHH44 2) Designation Oil temperature Connected to Oil cooler outlet piping Tripping cause Oil temperature to high Contacts Normally always closed Ref. SLAG Designation il pressure Connected to Outlet piping of oi itr(s) Tripping cause Oil pressure too low Coniacis Open when unitis notin operation, Normally closed i «uring operation Ref. TISHH21 1) Designation HP air oulet temperature Connected to Outlet of HP element Tripping cause Air oubet temperature of HP element 100 high Contacts” Normally alvays closed 1) On ZRonly 2)On ZR6 and ZA only Regulator cabinet ‘The regulator isan or-of control equipment with dela circuits for Jiming the interval before the compressor is loaded when started up (loading delay), and betore the motor stopped ater uninterrupted Unloaded operation (delayed motor stopping). ‘The reguator adap the operaton, ie. loading, unloading, stopping and restarting, according tothe ar consumption and protects the compressor and motor from overioads. When the voltage is, switched off or after a power falue, it automaticaly unloads the compressor. The regulator consists ofa relay panel and a control and indicator panel Relay panel (Fig. 10) ‘The panel comprises relays, transformers, fuses and a terminal stip. olay (K11) breaks the cicut to loaing solenoid valve (¥'-Fgs. 13) via relay (K14) and overrides ol pressure shut-down switch | (PSLL48-Fig. 9) during stating. Approx. 20 seconds from startin, relay (Kis energized by time relay (K42) and then makes the circuit othe solenoid valve via relay (K14) and stops verging switch (PSLLA9). By this time, the motor shouid have reached is normal speed and the ol pressure switch should have closed is contact. } Time relay for delayed motor stopping (K10) mits the requency of automatic mator stats by stopping the motor only after a pr sel tie of approx. 20 minutes of uninterrupted unloaded ‘operation. The motor wil restart when the net pressure drops to the loading pressure. Ifthe net pressure drops to the loading pressure within the pre-set unloading time, the compressor wil be loaded again without the motor having topped. The setting ofthe timers limited by he ‘maximum permissible numberof motor stats per hour. Control and indicator panel (Fig. 14), comprising: IL PRESSURE (Hi): Lights up fol pressure shutdown ‘witch eacts to too low a pressure. The regulator stops the motor = OIL TEMP. (HS) (on ZR6 and ZA only: Lights upif oi temperature shutdown switch reacts due to too high an ol temperature. The regulator stops the motor. + (#8) (on ZR, A FAULT INDICATOR LAVPS, MARKING/FUNCTION 5) Spare lamp for adaional safety : t ‘ovice, Lamp is connected oreguito 1) MOTOR OVERLOAD (H6): Ligh up if overload ely tps, ie when the motor current exceeds the permissible maximum. The ‘equator stops the moter. ~ TEMP. LP OUTLET (H7: Lights up a outet temperature shut-down switch reacts due lo temperature of ar leaving compressor element (on ZA) or LP elent (on ZR) being too high. The reguator sips the motor ‘TEMP. HP INLET (H8) (on ZR only): Lights upt ai temperature shut down switch reacs due to temperature ol air entering HP element being too high. The reguaor stops the mote ~ TEMP, HP OUTLET (Hs) (on ZR only: Lohts up ar . temperature shutdown sich eacs de io temperature of ar eekgs leaving HP element being to high. The requatr stops be ‘motor. = (HB and Ho) (on 2A): Spare lamps for adstonal safety ‘eve, Lamps ae connected to regulator 1) + (H9, H10 and 11) Lamps for atonal safety device. Lamps ate connected to regulator 1). = MD ON (H12) (on 2R only: an MO dryers installed and (312) is electcaly connected, lamp lights up incicating tat ‘lage is supplied to MD dryer, = (H12}(on ZA only: Spare lamp or adlonal safety device Lampis connected to regulate 1). temperate ‘Toggle switch, UNLOADad NOR. [P element air outer temperature Hourmeter, meter RUNNING. ‘shuteown switch (ZR) TIME Push buon, RESET-STAAT Hovtmeter, compressor LOADING TIME Push bution, STOP shut down sich (ZA) HP element a cute tomperatire shutdown switch Terminal stip Earhing s9 Lacing eoloned vale TISHH18, HP element TisHHN TishHat, p Pa, st 82 se P B. INDICATORS AND SWITCHES, MARKINGIFUNCTION ‘Shutdown relay, (LP) element temporal ewiich Shutdown flay for extra safety eves and lamp (H3), Time relay, colayod lading (20 out Shutdown relay, HP clomont (isnt) Sime relay, delayd motor stopping (20 minutes) ‘anlar relay loading dek ‘unary relay for loading indleaton Compressor motor Gilpreseure shut down switch Ie pressure switch RUNNING TIME (Pt): Hourmeter indicating total running time ol motor UNLOADINORMAL ($3): Toggle switch for unloaded or loaded operation LOADING TIME (P2): Hourmeter indicating total loaded running time of compressor. RESET-START (St): Push button to reset blocking cut and start the motor. STOP ($2); Push bution to stop motor. = VOLTAGE ON (Ht): indicator lamp for signaling that voltage is supplied to starting and contra equipment. AUTOMAT. OPERATION (H2): Indicator lamp which Eghts up ‘when RESET-START bution is pressed, showing that regulator is operative. Goes outta shut-down switch tips. 7, a, ka, ko, Ko, kro. Ki Ki2 Kia ™ PSLLA9, PSReo. Fig. 11. Circuit gram of regulator and switches INLET faut 1) The spare lamps always light up when the voltage is switched on (Camp test. 41.7.4 Operation and trouble-shooting TEMPoraturo LP OUTLET faut, Indeator amp (24) ‘Shutdown relay, oll pressure twitch (PSLLAG) ‘TeMPeratuo HP Blocking relay ‘usar relay Reset relay Shut down relay ‘Shutdown relay, motor overioad way (£21) €, Ww. He He, He, He ge ¢ An ASB (Service Bulletin) dealing with the operation and trouble- shooting of he regulator is available on request. pee 2 3 acy 5 3 BEL Evia 3 eas 23 3 eg a 3 3.89 £_ — pat Zs8$o 26 3 E ae 2 83ec 3% & a3 2S ebibege Z Hee a3 geessis 6 E ie BE SSS 222 = 39383 geet e85sss 2 2853 355 532202 5 = 2 13 1. Transport bolt wih bush on moter side 2. Sublrame 3. Vibration damper 4 Motor beam 5. Compressor boam 6. Transport bolt mith bush on compressor sido 7 Central bolo vbraton damper Fige. 12. Teansport bali 2 Operating instructions Safety precautions ‘The operators expected to apply al elated safely precautions, ‘among others, those mentioned on the inside ofthe cover (or onthe frst few pages) ofthis book 2.41 Compressor installation ‘An AXB dealing withthe compressor instalation is avaliable on request It the compressors installed outdoors or ifthe ar ilet temperature may be below 0°C/32°F, necessary precautions ar to be taken, Consult Atlas Copco, 2.2 Preparation for initial start-up 1. Onan Ar.€ ur, ascertain at the wedges are removed from between the motor and compressor coupling anges. 2. The motoricompressor supports are secured tothe frame immobilizing the vibration dampers during transport (Figs. 2) Remove the two long transport bols (1) (one a each side the motor) and bushes which fx the beam (4), supporting the motor, and the sublrame (2) Fit short bots, delivered wih the unit, ito each vibrabon damper pate andthe frame and tighten them, ‘Remove the four transport bolts (6) and bushes which fix the beam (6), supporting the compressor, andthe frame, It the breathing pipe (BR-Fig. 6) is ducted aw instalation proposal), 5 mm water column (05 mbar 4, OnZR, make sure that al the bags with sca gel piaced inthe ‘moisture trap (MTi-Fig, 2) ofthe intercooler have been removed. The bags are accessible after removal of the tape closing ofthe manifold flange botiom orifice. instal the ‘moisture trap flange and connect the pipe ofthe drain receiver (17-Fig. 2) tothe flange after removal ofthe slica gel bags 5, Refit the drain pugs ofthe LP element water inlet pipe (D2 Figs. 13) and ofthe intercooler (OP-Fig. 2). The plugs are delivered loose in a small bag. 6. Refit he interconnecting pipe (4Figs. 13) ofthe element cooling jacket compariments of each compressor element, Motor se 87 Compressor side (On Arr. 1 nits supplied ex factory wih a motor, check the motor aignment, as it may have been disturbed during vanspor. (On ZA Arr. 1 units supplied ex-factory without motor, aosen the bolts ofthe semi-lexibe element (22-Fig. 1 and 3-Fig. 18) to make the safety valve pipa (7-Fig. 1 tension ree. Retighten the bol atenwards, ‘On 2R, check the condensate dain piping. The lines shouid pitch ‘downwards, away from the compressor. The open ends must never dip into the water ofthe sewer. Check thatthe cooing water drain cocks (customer's installation) n the inlet and outlet tines are closed. Check for water ow. zr cp AF OUP UA AF SEC AF DP! Vic DRa/DRI 26 10. Fillthe compressor sump to the MAX. mark on the dipstick (DS: Figs. 1 and 3) with oll as spectied in secbon 3.4. Fil the oll Cooler after removing the vent plug or ol temperature sensing clement on top ofthe cooler. Reistall the pg or element 11, Check the voltage selecting wires at ransiormer(T1-Fig. 10) for corect connection. Check the setting of overload relay (F21-Fig. 10) and thatthe relay is set for automatic resetting 12, Remove he bridge between terminals 18 and 20 on terminal sttip (1X1-Fig, 10) itis not desired thatthe motor stops aulomatically after an uninterrupted unloading period of approx. 20 minutes AF Ai fitor elements) [ASb, Blow of siencor ASL. Airintake sloncor 1ASo, A aut slancer (HP) ‘compressor element BP, Balancing piston BBV1_ Bypass valve, oll pump Ca Atercooloe Cb. Blaod of cooler Ci lntereaoier Co Gileosior OV. Check vale mt. Bran valve. compressor somo DP1. Brain plug, ol coolr ot se DP2, Drain plug, LP eloment Cocling water jackot and bioed-o cooler Ra, Altoresoler sain receiver Intercooler dain receiver Gillove epstck Expansion compensator HP element (Peoment Otter pipe Moisture tap, intercooler OP Ol pump ua, up. Vie vie va UP AF UA Unioadereyinder Unioader piston Regulating valve, steroacor casing water fow Fogulating valve, comprotorconing water Regulating vale, imeregoler (on 283-4, also compressor elements) oaling water flow Loading solenoid val ‘ir ipo, chock valve 0 ooking water pipe, of cooler to inereoole Breathing pe Interoannecting pipe(s) (UP) element ecsing Iacket comparments bir proseure fed pipe, HP balancing piston Air prassure toed pipe, balancing pistons Sensing element, il temperature (On 2R6 and Zh eniy) Figs. 19. Non chive ond vows of ZA6, ZR and ZRS 13. Check thatthe electrical connections corespond tothe lacal codes. The installation must be earthed and protected against short cuits by fuses ofthe inert type inal tree phases, An isolating switch must be intaled near the unit 14. Switch on the voltage. Start and stop the motor immediately alter the slightest rotaton. Check for correct direction of Totation 2s indicated by the arrow on the motor housing. On ‘Art E units, the coupling can be observed through the openings in the motor-o-compressor adapter housing, the rotation direction is wrong, switch ofthe votage and reverse two of the input ine connections. Hi M2 He HS Mb OH He HO ato HIT HZ Faultindiostor lamps. Indicator amps Hi LowOILPRESSURE — HI, VOLTAGE ON HS High OL He| AUTOMATic TEMPorature (2R6 OPERATION ‘and ZA) ta, MO etyer ON (2A) HS, Spare iam 2R3,- 45) Controt devices 6 MOTOR OVERLOAD Br. Hourmeter, motor H7 High TEMPerature RUNNING TIME LP'STAGE (2h) 2, Houmeter, compressor 7 High TeMPerature LOADING TIVE LPOUTLET (za) ‘St, RESET-START puch He High TEMPerature button HPINLET (2A) $2. STOP push button He. Spare lamp (2A) $3, UNLOADod NORMAL Ho High TEMPeratie ‘operation toggle switch HP OUTLET A) Ho. Sparo lamp (2A) Hromt1. Spare lames. Fig. 14, Conto! and ingicator panel 2.3 Before starting 1. Check the ol level. Top up, it necessary, tothe MAX. mark onthe Spstck (DS-Figs. 1 and 3). 2. OnZR, cose the drain valves (Omi and Dma-Fig, 6) ofthe intorcocier and atecooler drain recovers. 3, Check thal the cooling water drain cocks (customers installation in the inlet and outet nes are closed. 4. Check that toggle switch ($3-Fig. 14) is in the UNLOADed 5, Open the cooing water inet valve, 6. ONZR, open the water ow regulating valves (Vi and Ve Figs. 1, 2 and 13) ‘On ZR6, aso open valve (VioFigs. 13) ‘On ZA, open the water fow regulating valve (Vic-Fig. 19). ‘Opening ofthe water flow regulating valves can be overlooked if, alter previous operation, the setting ofthese valves has not been disturbed. 2.4 Starting (Fig. 14) 1. Switch on the voltage and check that VOLTAGE ON lamp (Ht) lights up. All other ingicator lamps (+4 up to H42) also ight up (amp tet), except AUTOMATic OPERATION lamp (H2). 2, Press RESET-START bution (S1). After starting, check: thatthe AUTOMATic OPERATION lamp (H2] is alight that all the fault indicator lamps are out =the ol pressure (Gpo-Fig. 15) te intercooler vacuum (Gpi-Fig 16) (not on ZA) 3. Check fr water oral leaks. Number of starts: The temperature ris inthe motor windings limits the number of nocmal motor starts to tee per hour (Observe an interval of 20 minutes between each start. The setting ot relay (K10) should never be less than 20 minutes. Never aust the satin wit the voltage switched on. 16 2.5 Compression starting 1. Open the ai outet valve. 2. Move UNLOADed/ NORMAL toggle switch ($3) to NORMAL to load the compressor 3, With the compressor running loaded (Figs. 13): onzR a. Regulate the cooling water flow through the compressor and intercooler circus (2R6) or compressorintercooler cic (ZR, -4,-5), i necessary. For optimum operation, tne cooling water outlet temperature(s or the dtlerence between the init and cutlet water lemperatures should be as shown in secon 6.1 (On ZR3, 4, -5, the waler out temperature is controlled by valve (Vi; ZR6 has two valves (Vic and Vi). The cooling water oulet temperature is indicated on gauge (Gtc Fig. 18), and on 2R6 also on thermometers (Twe and Twi) ros tioun Gn Zhe as. wo abe nie sametenpetuce opr one gage ardon be No bemonetes v. Att cong water tough Beata by reas va a) obame mos sate wat 2d Speer umpc (eens63PG Sk God. Air dscharge pressure TISHHI1, Aicoutet temperature saug0 indieatorshut sown pi, Intercooler pressure sch (on 28) gauge (on ZR) TsHHt1, [Paroutet po. Si pressure gauge temperate Gla. Alteroalereaaling incleatrshut down water outlet swten (on ZR) temperature gauge (on TISHH8, HP ait ret tomporature 2h) incfeatorishut own Gre. Compressor cooling Switch (on ZA) water outlet, TisHH21, HP airoutot Temperature gauge temperature Sid, Air outlet temperature Incleatshutdown incieator on ZR) swteh (on ZA) Gy. Aifiter vacuum Tishiss, Oltemperature Indicatrshut down Switch (on ZR and ZA) Fig, 15. Instrument panel gauges onza Feegulate the water low through the cooling circuit. For ‘opium operation, the cooling water out temperature or the difference between th inlet and outlet water temperatures shouldbe as shown in section 6.1. The waler outlet temperature is controled by valve (Vie-Fig. 3) and indicated on gauge (Gte Fig. 15) (On ZRZZA, as soon asthe unloading pressure registers on gauge (Gpd-Fg. 15), the ar pressure switch unloads the Compressor. 2.6 During operation Check the readings on the gauges (section 6.1) othe instrument panel (Fig. 15) and consult section 33, under “Daly” 2.7 Stopping 1. Close the air outlet valve. 2. Move toggle switch (S3) to UNLOADed. 3. Press STOP button (S2). The AUTOMATic OPERATION lamp ‘goes out and the compressor stops. The VOLTAGE ON and the fault indicator lamps will remain alight, as long as the voliage has nol been switched of 4. On ZR, open the drain valves ofthe intercooler and atercooler drain receivers, Wait untl al of the condensate has drained from the receivers. i waler continues owing from any ofthe drains, consult section 6. 5. Close the cooing water inet valve, 6. When freezing temperatures are expected, crain the cooling system completely by opening the main drain cocks (customer's instalation) and ‘On ZR: By removing the drain plugs rom the intercooler, LP element water inlet pipe (i provided), the vent plug ontop of the intercooler and the wo pipes (4-Figs. 13) that interconnect the cooling jacket compartments ofthe LP and HP elements. Period) Running ours 1) Operation ‘On ZA: By removing the pipe (21-Fig. 3) thatinerconnects the cooling jacket compartments ofthe compressor element. 3 Maintenance 3.1 Motor Refer to the motor manufacturer's instruction leaflet and data plate. ‘The greasing interval and the corect type and quantity of grease {or lubricating the bearings are stressed. Stick tothe motor air path cleaning interval 3.2 Service exchange elements ‘Alas Copco Service Outlets have available compressor elements fr ‘immediate replacement. Down-time is reduced toa minimum wile major repair in the field eliminated. Compressor elements are not to be dismantled by Customers. After an element has been taken off the ‘compressor, it should be returned to Atlas Copco to benefit the customer witha “service exchange system". 3.3. Preventive maintenance schedule for the compressor ‘The schedule contains a summary of the maintenance instructions. Read the related section betore taking maintenance measures, In servicing, replace all removed gaskets, O-rings and washers, ‘The "longer interval” checks must also include the “shorter Interval” checks. Consut See section note Before starting Check ol level During operation CCheck readings on gauges. 61 ‘On ZR6, check cooing water autet temperature on (Twc) and (Twi) 25 (Check unioading and lading pressures, 43 CCheck that hourmeters RUNNING TINE (P1) and LOADING TIME (P2) are operative. (On ZR, check that condensate is discharged trom intercooler and altercaoler cain receivers dung loading, 2 After stopping (0n.ZR, drain intercooler and atercooler dain receivers. 27 (lean nit - Drain condensate rom ar receiver, installed : CCheck for water or oll leaks. Inspect al air pipes and hoses. Replace damaged gaskets, or tbes 4 6-monthly 4000 a Check pressure drop of breathing extension pipe 22 Remove ar fiter elemenls; clean by airjet and inspect 42 Periods) Running Operation consut see pours} Secton nae Yeaty 00 Ctageoda 2435 : Eanes 3s “ _ On ZR, dismantle and clean float valves of drain receivers. 7 Replace air filter element(s). 42 a : Pepe rang Satan of ona son oo 5 : Desart and spac pats lunes of so : Removed rape dapragm fear past i : Fenor andneped owas mm ; : Tessa), On2hy ass lih il rn : Testsuttown ses ee : nzncwek coy ca al ial an ahs. Bassas al Pecosers : we UG : nan esis ssa le oleae oe Dt : Pawnee cs not ese, yan : Gee nt egret 7 Chest cndlon fee ong ; : Favepesucandianpeniedajossivalavisionneaarenansersiad. 2 un Mtr 1) Whichever interval comes first. The ocal Atlas Copco Sales Company may overrule the maintenance schedule, especially the service Intervals, depending onthe enviconmental and working conditions ofthe unit ‘Notes 1. Maintain the level near the upper mark on the dipstick. 2. Take immediate remedial action ithe automatic dain othe intercooler does not discharge condensate. Ifthe unit cannot be stopped, sigily open the manual drain of the intercooler crn receiver to prevent the condensate from entering the HP element. Note that whether condensate Is @scharged or not, depends on the moisture content of the intake air and the degree of cooling, 3. Pressure and temperature measuring points that enable quick connection of precision instruments are provided onthe unt. In adiion, ‘he housing(s) ofthe compressor elements) has (have) SPM (Shock Pulse Meter) adapter plugs to receive the sensors ofa vibration ‘meler. The dagrosis can be carried out without turing the normal operabon of the machine and may be made at shorter intervals, as required 4. Especialy check the balancing piston pipe(s). Repair the slightest leak. Replace damaged pipe) 5. The difference in perature between the incoming water and the outgoing ar ofthe intercooler and attercooler should never exceed 25°C (45°F) during loading. Use a thermometer of the contact type fo measuce the temperatures atthe various points. Have the Cooling system cleaned if the cooling efficiency is insufficient 6. Special gauges are to be used and a record ofthe measured values should be kept over the years of operation. Based on this record, the Condon ofthe compressor elements can be judged. 7. Preferably tobe carried out by an Alas Copco Service representative. 3.4 Oil specifications ‘Ahigh-qualty mineral ol for bearings and gears, with rust and ‘oxidation inhibitors and water separation properties is recommended. The viscosity grade for operation in ambient temperatures above -10°C (14°F) should be ISO VG 68, in ‘conformity with ISO 3448, Consult Atlas Copco forthe recommended olls. Once a brand hhas been adopted, keep to It. Never mix different oll, 35 Oil change The normal ol change interval i year, 1a lnger change intervals requited, the ol canbe analysed ina laboratory oestabish the oplimum interval Change the oil as follows: 1. Drain the compressor sump and oll cooler wile the units stopped but stil warm. A drain valve (Omg. 1) is provided 18 ee on the sump and a drain plug (DP Fig. 3) onthe cooler. Close the valve and reinstall the plug ater draining. 2. Remove the ol fiter(s). Catch the oiln a drain pan. 3. Clean te filter seat(s) onthe adapter head. Fill the new filter(s) for about two thirds withthe corect ol. Oil the .gaskal(s) and screw th fits) into place uni the gaskets) Contact(s) ts (het) seals). Then ighten one half turn only. 4. Remove the filer cap (FC-Fig. 1). Refi he sump tothe upper mark on the dipstick (OS-Fig. 1) with the correct ol, Remove the vent plug or sensing element ontop ofthe ol coler and fi it Reinsal the plug or sensing element. ‘5. Run the unit unioaded fora few minus; check the oll level. Top up, ifnecessary. 3.6 Storage |An ASB (Service Bulletin) dealing wih storage betore instalation, as well as with slorage ater operation is avaiable on request. 4.2.1 Recommendations 4, Te elements) must be serviced as soon as the pointer of the vacuum gauge (Gw-Fig. 15) reaches fe redline or fel, i.e. coresponds to 45 mbar (1" wo) during loading Wen te elements) is (are) new, the pressure dop is betnean 7 mba, depending onthe compressor ype. Tis i hardy noticeable on he gauge. However alter some tine of operation, the pressure drop should cleat show on the gauge dung loading. Hi ator sometime of operation, the pointers does not show a aor drops back o an imprabably ow va, points oa Weak ine aril sytem Nevor remove the elements) whi the compressor i ring The elements) may be washed nat more than te ines 'ndusty operating conditions whereit wil be necessary a seni or eplace he elements) oo trequenty, an appropiate prectter of the dry type shoul be ins 5. For minimum compressor down-ime, replace the diy elemeni(s) by (a) new o leaned on 8, New elemenis must also be inspected fr tears or punctures before instalation. 7. Discard he elements) whon damaged 4.2.2 Servicing 1. Remove the titer housing cover. 2. Using a damp cloth, clean out any dust from the fiter chamber. Acjustng srow, Unloading pressure icaeh ies ones ; i 4. Bont be Senen(), Ceo rdinepec een sang ‘surface(s) of the filler chamber. Take care that no dirt drops 4. fl ewer ane denen) and be coe 4 Adjustments and servicing procedures 4.1 Setting of the air pressure switch (Fig. 16) The switch afows to select the unloading pressure and the pressure difference between the unloading and loading pressures. Before adjustment, ascertain thatthe switch breaks the circuit to the loading solenoid valve (Y1-Figs. 13) when the working pressure has reached the unloading pressure, and thatthe contol oom the tnloader cylinder is drained, as otherwise the compressor wil nt Unload (see Figs. 7 and 8). Also ascertain thal te loading solenoid valve is energized al the loading pressure and that contol ois admitted to the unloader cylinder. ‘The unloading pressure is controlled by adjusting sorew (2). Turn the sorew clockwise to raise the unloading pressure or ant clockwise to ower i ‘The pressure difference is controled by adjusting sore (4) Turn the screw clockwise to reduce the pressure diference or ant Clockwise to increase it. Recommended minimum pressure sierence: 0.8 bar (8 IM. Aeitet ott cating 3. Pip: Ok OnbacerCindee On ER trcookr ott 42 Air filter 1 Pipe to cmpressor ou on 2A sir outet sloncor * Se taan) 4. Boots teen sono Alairpasses trough the dyype paper elements) remove «2 ——Pipeto (Balancing wae dust bore entering the compressor. The elmer) (are) tbe piston 8, Pre to tone casng Serviced oroplaced at requ inva. Fg, 17 Unload pind wt sir aro conoctons Mi. Motor SSVI. Intrcooter rot valves (ony one on ZR3) 1 Hor terminal box 3. Semiftexble element Fig. 18. Motor compartment of 2R4 4.2.3 Cleaning the element(s) Caretuly knock the end laces ona flat sutace fo remove the heavy conlaminant. Never krock ona hard surface. Then bow dry ar up and down he plats inthe reverse direcon of normal fow wih the et obique la the surlace in the direction ofthe folds; subsequentiy Bow up and down the pleas on bth sies ofthe elements). The ac pressure(e) may not exceed 5 bar (73 ps). Itthe contaminants sooty, soak the elements) for 10 minutes in lukewarm water in which anon foaming detergents dissolved. A recommended detergents MANN 053, Then move tne elements) to and fo inthe solution for 5 minutes. Finse with soft water until the drain watris clear. Let the laments} dry. Never use compressed air or heat to hasten drying Inspect each element by placing a lamp inside i. Thin pots or «uptues ofthe paper render te elements) uni or fuer use 4.3. Unloading gear, shut-down switches and safety valves ‘The main components ofthe unloading gear are the thrtte vaWe, the unloader piston and the unloader cyinder. ‘The throttle valve is mounted on sealed ball bearings and the Lnloader piston on drytype bushes. This ensures long service ile ‘without lubrication or adustment, The unloader piston is sealed by a roling Gaphvagm, 2 The setting of each temperature shut-down switch can be adjusted bby means ofa key fited atthe rear ofthe switch housing ater unscrewing the cap inthe centro of the indicator scale. The red pointer indicates the set ofthe switch. ‘An ASB (Service Bulletin) dealing with the renewal ofthe roling ciaphragm is available on request. An ASB dealing wit testing ot the shut-down switches, relia and safety valves may also be obtained, 5 Problem solving ihe moor has stopped de oa aut, sith of the valage anc remove the man tses belo attempting repro ave he Dossy ofacisentl restart. Always race and remedy the fault balore a new sarngatompls made ‘The fault indicator lamps help in tracing operating faults. During starting, tse lamps should light up and any tht are detective should be replaced, which requires removal a the front panel ‘An electrical fault must be traced by an electrician. Make sure that the wires are not chafed, damaged or broken and that they are clamped tight to theic terminals Mechanical faults and their suggested remedies Explanation about the table boiow: = Conditions ofthe unit, always preceded by a number, are printed in bold. Each possible faut is followed by its related suggested remedy ‘and both are preceded by the same leter. 1. Motor cuts out after starting (within approx. 20's) and OIL PRESSURE fault lamp (H4) lights up a. Oilpressure too low a Sees . Oi pressure shut-down switch remains suck in open poston . Remove and tes switch . Time relay (K12) for delayed loading trips oo soon ©. Set lay to cut out approx. 20 seconds after starting 2. Toggle switch ($3) moved from UNLOADed to NORMAL, but compressor does not load (hourmeter LOADING TINE. ‘and loading solenoid valve are inoperative) Pressure in air nets above pre-set loading pressure, ie. at pressure switch (PSR2S) is open a, Wait unl pressure in air net is lower than pre-set loading Pressure of air pressure switch 3. Toggle switch ($3) moved from UNLOADed to NORMAL; hhourmeter LOADING TIME operates but compressor does, ‘ot load. Air inlet throttle valve does not open due to: Loading solenoid valve (Y1) inoperative Remove and check solenoid valve Throtle valve operating mechanism jammed or unloader eyinder cetecive . With unit stopped, proceed as follows. Disconnect ol pressure feed pipe (¢Fig. 17) rom unloader cylinder and connect port to.a compressed air source of approx. 2 bale) (29 psig) Disconnect air pressure feed pipe (3-Fig. 17) and Intermitenty admit air at a pressure) of 2 bar (29 psi to unloader cylinder. This should cause teotle valve o operate, which is audible e = thro valve is operative: remove unloader cylinder, dismantle and inspect pats - thro valve remains inoperative: remove unioader piston ‘cover and inspect roling diaphragm of piston. fin order, ‘check piston for ree axial movement by hand. jammed, remove thro casing, ismante and replace defective parts 4. Compressor capacity ot working pressute lower than normal Ar consumption exceeds capacty of compressor Check pneumatic plant ‘pressure switch opens to soon See secton 4.1 Thro vave does not uly open o unloading valve leaks Inspect unloader cynder, pipes and connections; repair sightest leak. Remove pipe from between ar outlet slencer andar inlet casing; move vave seat and valve cone, ean and inspect , Salty valves) or, on ZR, intercooler reli valves) leaking Remove leaking valve, clean and inspect. Replace i not atight ate renstaling e. Compressor elemeni(s) out of oder Const an Alas Copco Senice representative 5. Compressor does nat unload; safety valve(s) blow(s) Air pressure switch opens too late Check seting. See section 4.1 Ar leak at connections of a pressure switch feed pipe Inspect connection(s) “Thvottle valve remains stuck in open postion Inspect unloading gear Wrong motor stopping delay Time relay (K10) out of adjustment CChange to corect sting. corect sting cannot be obtained, replace relay pee 7. Unloading pressure or pressure difference cannot be adjusted a. Airpressure switch out of order Test swilch at varous setings, Replace switch tit does not respond 8 Low compressor oll pressure or oil pressure switch {PSLLAS) tips, OIL PRESSURE fault lamp (H4) lights up and motor stops Oillevel co ow Top up evel to upper mark on dipstick i ites) Cogged epace fits) By-pass valve in oll pump stuckin open postion Remove valve, clean and inspect i pump fare Remove pump and inspect pats for wear pa pegsee Excessive oil fumes or alt flow coming from breather pipe Balancing piston ciaptragm of (a) compressor elements) cracked Remove balancing piston cover from timing gear covers) and Inspect diaphragms). Replace diaphragm if detective ee 410, Water droplets show on dipstick a. Oting or pipes) of ol cooler leak a. Remove and dismantle il cooler. Pressures core. Repace (ings and change ol 11. Alfitr vacuum gauge does not indicate or pointer suddenly drops to low value during loading CConnecon of gauge pipe leaking Check and correct, a necessary Fir element not properly nstaled Check seating Fiter element ruptured Remove andinspect. Repiace iin doubt about condton Leak n inet system Inspect and tighten system connections ONZR ONLY. 412, Gauge (TISHH11) shows too high an air temperature ots ‘switch trips, TEMP. LP STAGE fault lamp (H7) lights up ‘and motor stops Inet temperature to high due to too high ambient temperature ‘or bad compressor room ventilation ‘Improve ventilation of compressor room ». Inlet temperature oo high due to inefcient cooing of bleed off air at unioading (caused by too low cooling water flow or by improper operation of throttle valve mechanism, leading to ‘overcapacity of ar through bleed of cooler) . Check operation of throte valve mechanism or adjustment of cooling water ow Pressure ratio too high due to low eficency of HP element, leading to too high an intercooler pressure ‘Consult Alas Copco LP element not in order Consult Alas Copco ‘Switch incorrety set ‘Set switch to trip at specified temperature esaae 13, Gauge (TISHH18) shows too high an air temperature or its switch ips, TEMP. HP INLET fault lamp (H8)Ights up and motor stops a. Insufient cooing water fow or wate inlet temperate too tigh ‘a. Check and increase water flow or decrease water inlet temperate, if possible ». Reston in cooing system due to formation of sale or satin down of dit . Glean cooing system. Consult las Copco . Switch incorecty set ¢. Set switch to trip at specified temperature 14. Gauge (TISHH21) shows too high an alt temperature or its switch trips, TEMP, HP OUTLET fault lamp (H9)ights up ‘and motor stops 2. Inet temperature too high duet insufcient intercootng \tomperature indication on TISHH8 aso loo high) a. See t3aand 130 Pressure rato to high during loaded operation due oto high a working pressure or loo low an intercooler pressure (caused by low efficiency of LP element or inlet pressure at LP element too ro) . Decrease working pressure or replace ar iter element). Check if compressor air inlt is ee. Consult Atas Copco LP ‘elements not inorder Pressure rato too high during unloaded operation duet leaking check valve orto high a pressure cop over bleed system Inspect check valve or blead-off coolers and operation of throttle valve mechanism HP element notin order Consult Alas Copco ‘Switch incorrectly set ‘Set switch fo trip at spected temperature at 15. Leakage between air and water systems. 1.Discharge cooling water is miky during loading (water Pressure is less than intercooler pressure) ‘Oring o pipes) of aftercooler or intercooler leak ‘a.Unioad compressor and watch discharge cooling wate. tt ‘waler remains miky,allercooler defective; i water becomes: ‘lear, intercooler detective. Stop unt, dismante and inspect Cetectve cooler. Replace parts where necessary ‘Automatic intercooler drain discharges excessive or more condensate than normal during loading (water pressure is. higher than intercooler pressure) ‘O-ring or pipes) of intercooler leak Stop compressor immediately. Dismante and inspect cooler. Replace parts where necessary 16. Water flows from intercooler manual drain after ‘condensate has been drained from drain recelver after stopping Oring or ppe(s) of intercooler leak ‘a. Dismantle and inspect cooler. Replace pars where necessary 17. AS above, but water flows from aftercooler manual drain (ing or pipe(s) of atercooler leak a Dismante and inspect cooler. Replace parts where necessary 18. Condensate is not discharged from intercooler and/or aftercooler drain recelvers during loading Discharge ppe(s) clogged or pinched CCheck and correct, as necessary Float valve(s) maifunctoning Remove fat valve assembly, clean and inspect 8 Intercoote pressure below normal Choked ai iter elements) Replace itr elemeni(s) Intercooler ee valves) leaking Remove valves) Clean and inspect ‘Airleak al gastesin cru between LP and HP elements Tighten screws of leaking comeston. Replace gasket, necessary 4. Pipe between intercooler and unioader cylinder or LP balancing Dison leaking or broken (vote valve does not ly open}. ‘Ths faut might also cause air temperature switch (ISH 1) to rp de to leaking of compressed air through open HP ustoading valve (Chock and comect as necessary LP element notin order Consultan Atlas Copco Service representative Intercooler pressure above normal Insufficient cooling water flow Check and increase water fow Cooling water inet temperate too high Decrease inlet water temperature, it possible Scale deposits on pipes and internal walls of intercooler See 130 HP element notin order See 4d aeeosspeny ON 2R6 AND ZA ONLY 21. Ol temperature switch (TISHH4S) trips, OIL TEMP. fault amp (H8) lights up and motor stops 2 Insutcient cooing water tow ‘2. Check and increase water flow . Cooling water inlet temperature too high 22 b. Decrease inlet water temperature, if possible ¢. Oil temperature swich incorectly set ©. Set switch to trip at the spectied temperature. Never set ata higher temperature 4, Restrcion in cooling system due to formation of scale or setting dow of dit 4d. Clean cooling system (consult Alias Copco) ONZAONLY 22, Gauge (TISHHt1) shows too high an air temperature or Its temperature switch trips, TEMP. LP OUTLET fault lamp (H7) lights up and motor stops See 12a and 13a See 128 and 138 Pressure rato above maximum (see section 6.3) due to oo high a working pressure or low inet pressure (caused by clogged air fiter or operation at high ait) . Decrease working pressure or replace ab iter. Check ar ines tee Compressor element notin order Const Alas Copco Switch incorecty set Set switch o tip at specified temperature 6 Principal data 6.1 Readings on gauges (Fig. 15) Marking DISCHARGE PRESSURE Reading Depending on seting of air pressure switch Unit barle) Remarks Modulates, depending on ar consumption, between Unloading and loading pressures Ret Gpd Marking Oil PRESSURE Reading Approx. 2-22 Unit barle) Remarks Should nat be allowed to drop below 1.4 bare) on 2A, 1.2 bare) on ZR Ret Spo Marking FILTER INDICATOR Reading During loading: less than 45 Unit mbar Remarks When pointer comes upto red tne or field during loading, service air fiterelemeni(s) Ret, Gv Marking WATER TEMP. COMP. Reading Approx. 53) Unit C Remarks Or 15°C above tat of incoming cooing water ding loading 2) Ret. Gite AIR TEMP. OUTLET (OnZR: approx. 30-35, (On ZA: approx. 1653) Unit °c Remarks On ZA: Or 10-- 15°C above that of incoming cooing water during loading 3) (On ZA: 185 °C at 3 barle) normal working pressure Ret Gidon ZA TISHHit on ZA Marking Reading IN ADDITION ONZR Marking INTERCOOLER PRESSURE Reading During unloading: 0.7 bar(e), coresponds to 0:3 bara) Belang: 2251) Unit bare) Remarks Al normal working pressure Ret Goi Marking WATER TEMP. AC, Reading —_Approx.953) Unit °C Remarks Or 15°C above that of incoming cooling water ring toading 2) Ret Ga Marking AIR TEMP. LP QUT Reading Approx. 150 160 Unit Bd Remarks _Attelerence conditions 3) Ret TISHHTY Marking AIR TEMP. HP QUT Reading Approx. 140-150, Unit °C Remarks Alreference conditions 3) Ret, TisHH21 Marking AIR TEMP, HP IN Reading Approx. 35, Unit °C Remarks _Atreference conditions 3) or approx. 15°C above Cooling water inlet temperature Ret TSH. ‘ONLY ONZR6 and ZA Marking Ol TEMPERATURE Roading Approx. 35, Unit °C Remarks _Atteterence conditions 3) Ret, TISHHA4 1). This pressure varies in crect proportion tothe barometic, pressure and oa lesser extent tothe working pressure, ‘ambient temperature and cooling water iat temperature. 2) Never set the cooling water flow regulating valves for a water ‘outlet temperature exceeding 50°C without authorization of an ‘tas Copco Service representave 3), Reference conditions: ‘Absolute inlet pressure... bar Relative airhumidity ons Oe Ar inlet temperate 200 Cooling water init temperature... 20°C Normal working pressure: ZR...» 79.5 bar(e) ZA 25 bare) 6.2 Settings of shut-down switches and safety valves ‘Shut-down switches 1) Breaks at Unit Ref. Air outlet temperature (on ZA) 235°C TISHHIY LP air outlet temperature (on ZR) ZR BIB.6 bat an 200 °C TISHH 7A 105 bar. 235 °C TISHHIY HP airinlet temperature (on ZR).......70 °C _—‘TISHHI8 iltemperature (on ZR6 and ZA)......70 -°C_—_TISHH44 (il pressure(e) 2) (on ZA). 14 bar PSLLED (Oi pressure(e) 2} (on ZR). 12 bar PSLLAS HP air outlet temperature (on ZR) ZR 818.6 bat 0 °C TISHHRt ZR 1065 bar. 235 °C TISHH2t Safety valves Opening Unit Ret. pressure(e) Intercooler relief valve(s) (ON ZA). 3.7 bar SMA HP safety valve(s) (on ZR): - Units with max, working pressure(e) up to 86 bar. 93 bar Sve Units with max, working pressure(e) OF 10.5 Ba nn 1 bar Sve Safety valve (on ZA) 37 bar Sve 41) tis recommended to adjust the air outlet temperature svitches (TISHHI and TISHH21) 20°C-80°C above the normal ‘working temperatures which ae indicated by the white pointers of the gauges. Never set the temperature shut-down switches to open their contacts at a higher lemperature than spected in the table above. Ifthe unit has stopped through a shut-down sich, the fault should be remedied before a new staring attempt is made. 2) Pressure diference setting must be minimum, ie. pressure illerence serew must be turned fuly clockwise, 2 6.3 Compressor specifications 1) Maximum working pressure(e) ‘ZX all units (except those mentioned below)......bar + 283 $363 oo bar 205 52,62 20652,63, 77: Unt loving sts np ae 50,51,52,53,54 at 00,61,-62-63 As. Att $5,56,57,58,-65,06-67 Art. AA. Normal working pressure(e): ZA ZR - Units with max. working pressure) of 8/8 6 ba. 7 + Unis wth max. working pressue(e) of 105 bar -bar 95 Free air delivery a fuilioad: Const data pale on unit Recommended cooling water niet pressure)... bar 3 Maximum cooling wate inlet pressure(e) bar 55 Maximum cooing water inlet temperature 8 ‘Maximum cooling water outlet temperature. 50 Ot capacty, aprox 0 6 5 40 4% - ZA, C165 + MZRunis cet tase menored BW? $0 + 2R353,54,58,63,67 C34 22657 41) At folowing reference condions: + Absolute inet pressure 1 bar = Relative ai humidity | 0% + Air inet temperature 20°C Cooling water inlet temperature 20°C + Normal working pressure: ZR... 7195 bar(e) ZA 25 bare) 2 6.4 Conversion list of SI units into British units 1 bar= 14504 ps 19= 0038 a2 1 kg = 2.205 ib 1 kav 0621 mile 1 KW = 1.341 hp (UK and US) 11 = 0.264 US gal 110.220 imp gl (UK) 11-0035 cu im=3.26tK 1mm = 0.039 in 1 mmin =35:315 cfm J 1 mbar = 0.401 inwe 1N= 0225 bt 1 Nev = 0.738 tt °C = (32 +1.8.x)°F 1) 1) Atemperature difference of 1°C =a temperature ditference of 18°F od SAFETY PRECAUTIONS FOR STATIONARY COMPRESSORS AND EQUIPMENT (continued) 6. Argo at wate oat a ingot caren 8. Donotonoe tere wth sone ma 7 suet hecetage potenibecenpena tne Maintenance Hocelras ne ot enpd delat aoa strntera nie onli Menezes nao sso 8. No external force may be exertad an the ai oufet vate; the connected imecnecist * Poorata fetes 1. een coe mst nw 4 roo corrls rl. si erent 2. ory genesepe Lp 3. Allmainienance wark, other han routine attention, shallonly be DANGER: Ths achie eeycna and ny si tronlanriar hon sydd te mapas oe 8 whoa wane mised tna psmepecaa meme tate en cs [As a furthor safeguard, persons switching on remotely contraiod be staried inadvertent, tna Sitdaclanelnenson wteuetalbet rte 6 or Chock orwekrgon te mache, Ths ena aul worced tinvonal ood peau nd iow by onsen a Senthaldoches no satonamert pose 10, mtg conpese sens naval wes tle lea Sete eee ‘solato each compressor. Non-return valves {check valves) shall not be dy ~ +2 Seanee ‘hes ptactrapuntice mpc ocean Sheds er coug pus eure, i, Teter pecans aero we feo @ ovrrenove er anew bo sy coves. gare eusns ‘ Menu Evy poe ward o astioy ruled sae ‘ovsio sonia lve tvspane pene lbs pce Sapte ig connar Sven ond 12, Pawskor ahr pons wih atonpeaie inencss 50° ‘Supls obsee ceaninss dung minarane ané ep. Kreg

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