2.

4 Cooling water requirements

The cooling water quality must meet certain minimum requirements.

No general recommendation can encompass the effects of all combinations of the various compounds,
solids and gases typically found in cooling water in interaction with different materials.

This recommendation is a general guideline for acceptable coolant quality.

2.4.1 Type of the system

Closed system
In a closed system, the same cooling water is circulating through a system without contact with air.

Open system
An open system is a pass-through system, or a circulating system with a cooling tower. In the latter
case, the composition of the water that enters the 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.

2.4.2 Cooling water parameters

The Ryznar stability index (RSI)

The Ryznar Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitate
calcium carbonate. The adhesion of scaling deposits and their effect are different on different
materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH
value and by the saturation pH value (pHs).

The saturation pH value is determined by the relationship between the calcium hardness, the total
alkalinity, the total solids concentration and the temperature.

The Ryznar Index is calculated as follows:

RSI = 2*pHs - pH

Where: pH = measured pH (at room temperature) of water sample

pHs= pH at saturation

The pHs is calculated by using:

pHs = (9.3 + A + B) - (C + D)

A: depends on the total solids concentration (mg/l).

B: depends on the highest cooling water temperature (°C).

For ZH units take: T = 65 °C

C: depends on the calcium hardness (ppm CaCO 3).

D: depends on the HCO3- concentration or M-alkalinity (mval/l).
 The values from A, B, C and D are found in the table below.

Total
Dissolved
solids (mg/l)

The interpretation of the values obtained is:

RSI < 6 boiler scale formation

RSI 6 - 7 neutral water
This table indicates that distilled or demineralised water should never be used, as their RSI is > 11.
RSI > 7 corrosive water

A more detailed interpretation follows below:

RSI Tendency of the water Action

The RSI only indicates the equilibrium of scaling _ descaling. Cooling water showing good RSI
conditions can still be unsuitable due to other factors.

From the table above, the RSI index should be between 5.6 and 7.5; otherwise, contact a specialist.

pH

The effect of pH is already calculated in the Ryznar index, but the pH itself has some additional
limitations:

6.8 < pH < 8.5

Total Dissolved solids (TDS)

This is the sum of all 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 µS/cm)

For an open system, the following limits apply:

TDS < 750 mg/l (< 960 µS/cm)

Chlorides (Cl-)

Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited:

Closed cooling system: Chlorides < 500 ppm

Open cooling system: Chlorides < 150 ppm

However, if the water is scaling, lower limits should be used. (See The Ryznar stability index (RSI)).

Free chlorine (Cl2)

Continuously, a level of 0.5 ppm should not be exceeded.

For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies.

Sulphates (SO4--)

Closed cooling system: Sulphates < 400 ppm

Open cooling system: Sulphates < 150 ppm

Carbonate hardness

Closed cooling system: 50-1000 ppm CaCO3

Open cooling system: 50-500 ppm CaCO3

HCO3- / SO42- should be > 1

Ammonia

< 0.5 ppm

Copper

< 1 ppm
Iron and manganese

< 1 ppm

Organics

No algae.
No oil.

Suspended solids

Non-soluble particles, size < 1 mm.

< 10 ppm

Remark
- Chloride and sulphate are interactive. In open systems the sum of the squares of these
values must not exceed 85,000. For recirculating systems with proper controls and treatment,
the sum of the squares may be up to 520,000. Note that the sulphate value must include any
sulphite present.

2.5 Pictographs

1 Condensate drain, blow-off silencer

2 Manual condensate drain, aftercooler
3 Automatic condensate drain, aftercooler
4 Manual condensate drain, second intercooler
5 Automatic condensate drain, second intercooler
6 Manual condensate drain, first intercooler
7 Automatic condensate drain, first intercooler

Fig. 2.9 Pictographs, condensate drains

 1 Cooling water outlet
2 Cooling water inlet

Fig. 2.10 Pictographs, water

1 Warning, under tension

2 Heated surface
3 Consult the Instruction book
before greasing
4 Switch off the voltage and
depressurise the compressor
before maintenance or repair
5 Before connecting the
compressor electrically,
consult the Instruction book
for the motor rotation
direction
6 Torques for steel (Fe) or
brass (CuZn) bolts
7 Disconnect from electrical
supply before opening
8 Read Instruction book before
starting the compressor

Fig. 2.11 Pictographs, other locations

15. Check that the auxiliary oil pump (6-Fig. 3.3) starts running (see section 1.9.4 to find the message
Auxiliary oil pump on). The pump may start after a period of time, controlled by the Elektronikon
3.3 Before starting
regulator.
Check the rotation direction of the motor (5-Fig. 3.3) of the oil pump: the correct rotation direction
isAttention
clockwise when looking at the drive end shaft of the motor; if wrong, switch off the voltage and
reverse
Before3 OPERATING
two incoming
starting INSTRUCTIONS
electric
the compressor, lines
theatoil
overload relay must
temperature (F25-Fig.
exceed 1.9).
25 °C; immediately after pressing the
16.start
Check the rotation
button, of fan motor
the oil pressure must(1-Fig.
exceed5.5)0.2 of the demister:
bar(e). the correct are
If these conditions rotation directionthe
not fulfilled, is
Safety
clockwise precautions
when looking at the drive end shaft of the motor. If wrong, switch
compressor will not start and the alarm LED (9) will light up after the permissive start time (30off the voltage and
reverse The
seconds). operator must apply all related safety precautions,
two incoming electric lines at overload relay (F27-Fig. 1.9). including those mentioned in this book.
17. Have the tuning of inlet guide vanes (3-Fig. 3.3) and blow-off valve (9-Fig. 3.3) checked by an
It is Operating
Atlas conditions
Copco representative.
recommended to keep the voltage to the compressor on in order to keep the oil heater energized
18.and
Have If
thethe
the ambient orpump
settingsoil
auxiliary air inlet
programmed temperatures
in the(started
operative can bestopped
Elektronikon
and beyond thethe
regulator
by limitations
checked by stated in section
an Atlas
Elektronikon Copco See
regulator). 7.4, section
precautions
must
representative.
1.7.5. be taken. In this case, and also if operating in other extreme conditions, consult Atlas Copco.

Moving/lifting
The compressor
3.21.Compressor
Check levelcan
the oilcontrol be moved
modes
(3-Fig. by a lift
3.2) which truck
must be using
in thethe slots
green in the
range orframe.
above. Make sure
Top up, if that the forks
necessary,
protrude
with from type
the correct the other
of oil.side
Seeofsection
the frame.
4.3. The compressor can also be lifted after inserting beams in
the slots.
The2.Elektronikon Make
Close condensate sure
drain
regulator that the
valves
allows beams cannot
the(5,operator
7 and 9-Fig. slide
to select and
3.1).threethat they protrude
control modes: from the frame equally. The
chains
3. Open
- Local must
the air
control mode be held parallel
outlet valve. to the bodywork by chain spreaders in order not to damage the
compressor.
4. If thecontrol
- Remote cooling The lifting equipment must
water was drained (see section 3.7):
mode be placed in such a way that the compressor will be lifted
- Local perpendicularly.
- close
Areathe drain valve
Network Lift(1-Fig.
(LAN) smoothly
control3.4)and avoid
in the
mode twisting.
water inlet pipe and fit the drain plug (2)
- fit the drain plugs (8-Fig. 3.3) underneath all coolers
5. Open the water inlet valve and outlet valve.
1 6.
Local3.1control
Open Preparation
the water
mode flow for
(remote initial
regulating start-up
valves
control mode(1, is
2 and
made 4-Fig. 3.3). Opening of these valves can be
inactive):
overlooked if, after previous operation, the settings have not been disturbed.
1. Consult section 2 for the dimension drawings, installation proposal and voltage supply
connections. Consult section 7.3 for the values of the fuses, electric supply cables, overload relay
and motor types.
2. If not provided, stick warning labels next to the control panel and also on both sides of the
compressor in an obvious place inside the bodywork, indicating that the compressor is
automatically controlled (started and stopped) by the Elektronikon regulator.
3. A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect
the compressor against corrosion. Remove the plates.
4. Check the voltage selecting wires at transformer (T1-Fig. 1.9) for correct connection (a label is
stuck on the transformer). Check the setting of overload relays (F25/27/29-Fig. 1.9). See section
7.3.
5. Remove the centre part of the drive coupling (4-Fig. 1.1).
6. Have the drive motor alignment checked by an Atlas Copco representative.
7. Start the drive motor and stop it immediately. Check the rotation of drive motor (1-Fig. 1.1) while
the compressor is coasting to a stop: the correct rotation direction is counter-clockwise when
looking at the drive end shaft of the motor. If wrong, switch off the voltage and reverse two
Remark
incoming electric lines.
8.When thecentre
Fit the electrical
part power to thecoupling
of the drive compressor is switched
(4-Fig. 1.1) usingoff,new
the bolts.
Elektronikon regulator will not
9.react to any
Check thatstart/stop command
the oil reservoir and the
is filled withoiloil
willto not
the be
fullheated
mark nor circulated.(3-Fig. 3.2). See section
of sight-glass
4.3. For drive motors equipped with sleeve bearings, check that oil is visible in the bearing sight-
glasses.
10. The outlet of the demister may be ducted outside of the bodywork. The maximum pressure drop
over this pipe is 0.5 mbar. Never install valves in this pipe. Avoid any obstruction or liquid lock by
sagging of the pipe.
11. Check that the cooling water drain valves (customer's installation) in the inlet and outlet piping are
closed. Check that the drain valve (1-Fig. 3.4) in the water inlet pipe is closed and the drain plug
(2) is fitted.
12. Open the water inlet and outlet valves (customer's installation), as well as the flow regulating
valves (1, 2 and 4-Fig. 3.3). Check for water flow.
13. Close the condensate drain valves (5, 7 and 9-Fig. 3.1).
14. Switch on the voltage.
On compressors provided with a reset button (5): the control panel will indicate an emergency
stop. Press reset button (5), then press key Reset (F3).
Check the oil reservoir temperature: if below 38 °C, the oil heater will be activated (see section
1.9.4 to check the oil temperature and to find the message Oil heater on).
 1 Air outlet
2 Water outlet
3 Water inlet
4 Automatic drain outlet, first intercooler
condensate drain
5 Condensate drain valve, first
intercooler condensate drain
6 Automatic drain outlet, second
intercooler condensate drain
7 Condensate drain valve, second
intercooler condensate drain
8 Automatic drain outlet, aftercooler
condensate drain
9 Condensate drain valve, aftercooler
condensate drain
10 Condensate drain, blow-off silencer

Fig. 3.1 Air, water and condensate drain connections

3.4 Starting

3.4.1 Routine starting

1. Switch on the voltage. Check that voltage on LED (8) lights up.
2. Normally, the main screen is shown. See section 1.9.6.

The menu shows:

- the compressor outlet pressure
- the percentage of open position of inlet guide vanes (IGV)
- the percentage of closed position of blow-off valve (BOV)
- the compressor operation status

By pressing the “ key, other conditions are shown (amongst others):

- the conditions of the auxiliary oil pump and oil heater
- whether the compressor is controlled locally (start/stop and manual load/unload commands
only possible by means of the buttons of the control panel), controlled remotely (start/stop and
manual load/unload commands only possible by means of external switches) or controlled by
Local Area Network (LAN)
- the status of the Week timer (if activated, the programmed time-based start and stop
commands will be executed; see section 1.9.15)

3. Press start button (1). The compressor starts running in unloaded condition. Automatic operation
LED (10) will light up. Auxiliary oil pump (6-Fig. 3.3) should automatically turn off after the
compressor has reached full operating speed.
4. After 20 seconds (programmable), the compressor starts running loaded.
5. If necessary, regulate the water flow with the compressor running loaded, using valves (1, 2 and
4-Fig. 3.3). Consult section 7.4 for the cooling water temperature and pressure, and for the
cooling water consumption.

3.4.2 Starting after emergency stopping or shut-down

Press emergency stop button (7) (if not yet done so), switch off the voltage and depressurise the
compressor. After remedying the fault, unlock the emergency stop button by pulling it out and push
reset button (5) if available. Push key Reset (F3) on the regulator. Restart the compressor as
described above.