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ZR45 Пример
ZR45 Пример
Instruction book
This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines
2004-05 www.atlascopco.com
2920 1472 03 1
Instruction book
This instruction book describes how to handle and operate the subject machine(s) to ensure safe
operation, optimum working economy and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and
proper maintenance from the beginning. The maintenance schedule comprises measures for keeping
the compressor in good repair.
Keep the book available for the operator(s) and make sure that the compressor is operated and that
maintenance is carried out according to the instructions. Record all operating data, maintenance work
effected, etc. in an operator's logbook available from Atlas Copco. Follow all applicable safety
precautions, amongst others those mentioned in this book.
Repairs must be carried out by trained personnel from Atlas Copco who can also be contacted for any
further information.
In all correspondence mention the type and the serial number, shown on the data plate.
For all data not mentioned in the text, see sections "Preventive maintenance schedule" and "Principal
data".
The company reserves the right to make changes without prior notice.
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Instruction book
1 LEADING PARTICULARS................................................................................................................... 5
1.1 General description........................................................................................................................ 5
1.2 Air flow (Figs. 1.6/1.7) .................................................................................................................. 10
1.3 Condensate drain system (Figs. 1.6/1.7)..................................................................................... 10
1.4 Oil system (Figs. 1.6/1.7) ............................................................................................................. 10
1.5 Cooling system (Figs. 1.6/1.7) ..................................................................................................... 10
1.6 Air dryer on Full-Feature .............................................................................................................. 17
1.6.1 Compressors with an ID dryer (Figs. 1.6) ............................................................................. 17
1.6.2 Compressors with an IMD dryer (Figs. 1.7) .......................................................................... 17
1.7 Electrical system .......................................................................................................................... 18
1.8 Elektronikon control system......................................................................................................... 19
1.8.1 Automatic control of the compressor..................................................................................... 19
1.8.2 Protecting the compressor .................................................................................................... 19
1.8.3 Service warning..................................................................................................................... 19
1.8.4 Automatic restart after voltage failure ................................................................................... 19
1.9 Control panel................................................................................................................................ 20
1.9.1 LEDs/buttons/keys ................................................................................................................ 20
1.9.2 Display................................................................................................................................... 21
1.9.3 Function keys (5-Fig. 1.10) ................................................................................................... 21
1.9.4 Emergency stop button (S3-Fig. 1.10) .................................................................................. 22
1.10 Menu-driven control programs................................................................................................... 22
1.10.1 Function of control programs .............................................................................................. 22
1.10.2 Main screen......................................................................................................................... 23
1.10.3 External compressor status indication ................................................................................ 23
2 INSTALLATION ................................................................................................................................. 25
2.1 Dimension drawings..................................................................................................................... 25
2.2 Installation proposal (Figs. 2.6/2.7).............................................................................................. 30
2.3 Electric cables.............................................................................................................................. 34
2.3.1 ZT15 up to ZT22 IEC............................................................................................................. 34
2.3.2 ZT15 up to ZT22 CSA/UL ..................................................................................................... 34
2.3.3 ZT/ZR30 up to ZT/ZR45 IEC................................................................................................. 35
2.3.4 ZT/ZR30 up to ZT/ZR45 CSA/UL.......................................................................................... 35
2.4 Pictographs (Figs. 2.9 and 2.10).................................................................................................. 38
2.5 Cooling water requirements......................................................................................................... 39
2.5.1 Type of the system ................................................................................................................ 39
2.5.2 Cooling water parameters ..................................................................................................... 39
3 OPERATING INSTRUCTIONS .......................................................................................................... 43
3.1 Initial start-up ............................................................................................................................... 43
3.2 Starting (Fig. 3.4) ......................................................................................................................... 48
3.3 During operation (Fig. 3.4)........................................................................................................... 48
3.3.1 Checking the display (2-Fig. 3.4) .......................................................................................... 48
3.3.2 On compressors with an IMD dryer (Fig. 1.5) ....................................................................... 50
3.4 Stopping (Fig. 3.4) ....................................................................................................................... 50
3.5 Taking out of operation ................................................................................................................ 50
4 MAINTENANCE ................................................................................................................................. 51
4.1 Preventive maintenance schedule for the compressor................................................................ 51
4.1.1 Regular service operations ................................................................................................... 51
4.1.2 Service kits ............................................................................................................................ 51
4.1.3 Service agreements .............................................................................................................. 51
4.1.4 Service plan........................................................................................................................... 52
4.2 Motor greasing ............................................................................................................................. 52
4.2.1 Fan motor (ZT) ...................................................................................................................... 52
4.2.2 Drive motor (M1-Fig. 1.2) ...................................................................................................... 52
4.3 Oil specifications .......................................................................................................................... 52
4.4 Storage after installation .............................................................................................................. 52
4.5 Service kits................................................................................................................................... 52
5 SERVICING PROCEDURES ............................................................................................................. 54
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Instruction book
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Instruction book
1 LEADING PARTICULARS
1.1 General description
ZT15 up to ZT45 and ZR30 up to ZR45 are two-stage tooth compressors, driven by an electric motor.
The compressors deliver oil-free air. ZT are air-cooled and ZR are water-cooled.
The compressors are enclosed in a sound-insulated bodywork and include mainly (Figs. 1.2 up to 1.4):
- Air filter (AF)
- Load/no-load valve (TV)
- Low-pressure compressor element (El)
- Intercooler (Ci)
- High-pressure compressor element (Eh)
- Aftercooler (Ca)
- Electric motor (M1)
- Drive coupling
- Gear casing
- Elektronikon® regulator (1-Fig. 1.2)
- Safety valves (SVh/SVl)
Full-Feature compressors are additionally provided with an air dryer (Figs. 1.3/1.5), which removes
moisture from compressed air. See section 1.6.
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Instruction book
Ca Aftercooler
Ci Intercooler
Co Oil cooler
Eh High-pressure compressor element
FC Oil filler plug
FN Fan
M1 Drive motor
M2 Fan motor
OF Oil filter
SG Oil level sight-glass
SVl Low-pressure safety valve
S3 Emergency stop button
1 Elektronikon regulator
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Instruction book
AF Air filter
Ca Aftercooler
Ci Intercooler
Co Oil cooler
Eh High-pressure compressor element
El Low-pressure compressor element
FN Cooling fan
MTi Condensate trap, intercooler
M2 Fan motor
TV Load/no-load valve
1 ID dryer
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AF Air filter
Ca Aftercooler
Car Cooler, regeneration air
Ci Intercooler
Co Oil cooler
Eh High-pressure compressor element
El Low-pressure compressor element
FN Cooling fan
MTi Condensate trap, intercooler
M2 Fan motor
SVh High-pressure safety valve
TV Load/no-load valve
1 IMD dryer
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Instruction book
1 Safety valve
2 Shut-off valve, regeneration air
3 Safety valve
4 Inlet regeneration air
5 Inlet pipe, wet compressed air
6 Condensate trap, aftercooler
7 Dryer inlet valve
8 Manual drain valve
9 Dryer by-pass valve
10 Dryer outlet valve
11 Moisture indicator
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Instruction book
For Full-Feature compressors with an ID dryer (Figs. 1.6), the condensate trap downstream the
aftercooler is replaced by a condensate trap (5) in the dryer.
Full-Feature compressors with an IMD dryer (Figs. 1.7) have three additional electronic water drains:
- One on the IMD
- One upstream and downstream the regeneration air cooler
The oil system is protected by a valve that opens if the oil pressure should rise above a given value.
The valve is located in the oil filter housing.
ZR compressors
The oil cooler, intercooler and aftercooler are water-cooled.
The water system includes three parallel circuits:
- One for the oil cooler and intercooler.
- One for the aftercooler.
- One circuit is only for compressors with an IMD dryer and contains the regeneration cooler.
Each of these circuits has a separate regulating valve (see section 3.1)
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Instruction book
AV
8
12
13
10
9
M3
FN2
M2 FN1
15
SVh
16 11
Y1
UV TV UA 2 3 CM
1
AF
Elektronikon
F1 F2 F3
4 AS
US
OP
55347D
EWDi
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Instruction book
AF
CM 3 2 UA TV UV
1
Y1
Elektronikon
17 19
F1 F2 F3
16
4 US OP
OF
AIR INLET (1)
AIR FLOW (2) El
SVl
11
EWDi 15
18
14
AV
SVh
12 8
13
10
9
55346D
M3
FN1
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Instruction book
AF Air filter
AS Pulsation damper
AV Air outlet valve (customer’s installation)
CM Control module
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
EWDi Electronic drain, low-pressure element
FN1 Fan, compressor coolers
FN2 Fan, condenser
M2 Fan motor, compressor coolers
M3 Refrigerant compressor
MTi Condensate trap, intercooler
OF Oil filter
OP Oil pump
SVh Safety valve, high-pressure element
SVi Safety valve, low-pressure element
TV Load/no-load valve
UA Unloader
US Silencer
Y1 Loading solenoid valve
1 Chamber
2 Plunger
3 Chamber
4 Diaphragm
5 Condensate trap, dryer
6 Air/air heat exchanger
7 Air/refrigerant heat exchanger/evaporator
8 Capillary tube
9 Accumulator
10 Refrigerant condenser
11 Intercooler
12 Hot-gas by-pass valve
13 Liquid refrigerant filter/dryer
14 Water outlet valve (customer’s installation)
15 Aftercooler
16 Oil cooler
17 Regulating valve, oil cooler and intercooler water circuit
18 Regulating valve, aftercooler water circuit
19 Water inlet valve (customer’s installation)
Figs. 1.6 Flow diagrams/regulating systems for Full-Feature compressors with ID dryer
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Instruction book
7 8
SVh
AV 28
5 6
10
9
21 12
29
20
19 26
14 29
18
27
17
13 FN1
MTa 15
11
16
22
UV TV UA 2 3 Y1 CM
1
AF
Elektronikon
F1 F2 F3
4 AS
US
MTi
OP
EWDi
55365D
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Instruction book
AF
CM 3 2 UA TV UV
1
Y1
Elektronikon
23 31
F1 F2 F3
16
4 US OP
OF
AIR INLET (1)
AIR FLOW (2) El
MTi CV
SVl
11
EWDi 15
24
30
7 8
AV 28
5 6
SVh
10 29
9
21 12 22
29
25
MTa
20
19 26
14
18
27
55364D
17
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Instruction book
AF Air filter
AS Pulsation damper
AV Air outlet valve (customer’s installation)
CM Elektronikon regulator
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
EWDi Electronic water drain, intercooler
FN1 Cooling fan
MTa Condensate trap, aftercooler
MTi Condensate trap, intercooler
OF Oil filter
OP Oil pump
SVh High-pressure safety valve
SVl Low-pressure safety valve
TV Load/no-load valve
UA Unloader
US Silencer
UV Unloading valve
Y1 Loading solenoid valve
1 Chamber
2 Plunger
3 Chamber
4 Diaphragm
5 Valve for (+) connection, pressure difference gauge
6 Valve for (-) connection, pressure difference gauge
7 Throttle valve, regeneration inlet air
8 Shut-off valve, hot regeneration inlet air
9 Strainer
10 Sealing sector, regeneration air inlet (unsaturated side)
11 Intercooler
12 Rotor
13 Fan motor, air coolers
14 Ejector
15 Aftercooler
16 Oil cooler
17 Electronic water drain, inlet air
18 Water separator, inlet air
19 Demister
20 Rotor sealing arrangement
21 Dry air outlet compartment
22 Regeneration air cooler
23 Regulating valve, oil cooler and intercooler water circuit
24 Regulating valve, aftercooler water circuit
25 Regulating valve, regeneration air cooler water circuit
26 IMD air inlet valve
27 IMD by-pass valve
28 IMD outlet valve
29 Electronic drains, regeneration air cooler
30 Water shut-off valve, water outlet (customer’s installation)
31 Shut-off valve, water inlet (customer’s installation)
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Instruction book
The liquid flows through liquid refrigerant dryer/filter (13) to capillary tube (8). The refrigerant leaves
the capillary tube at evaporating pressure.
The refrigerant enters evaporator (7) where it withdraws heat from the compressed air by further
evaporation at constant pressure. The heated refrigerant leaves the evaporator and is sucked in by
the compressor.
In the demister (18), water droplets are removed from the air. The air is then led through rotor (19),
which adsorbs the water vapour. The dried air leaves the dryer through outlet valve (28).
The hot saturated air is then cooled down in regeneration air cooler (22) and led to the suction
chamber of ejector (14), where it is mixed with the wet compressed air from the compressor
aftercooler.
If the controller registers a malfunction, the red alarm LED (Fig. 1.8) starts flashing and the electronic
drain valve will automatically change to the alarm mode, opening and closing the valve according to a
built-in sequence. This condition continues until the fault is remedied. If the fault is not remedied
automatically, maintenance is required. Consult your Atlas Copco Customer Centre.
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Instruction book
Functional test
Briefly press the TEST button (Fig. 1.8) and check that the valve opens for condensate discharge.
F1/2 Fuses
F4/5/6 Fuses
F21 Overload relay, drive motor
K21 Line contactor
K22 Star contactor
K23 Delta contactor
Q15 Circuit breaker, fan motor (on ZT)
T1 Main transformer
T2 Transformer, control circuit
1X1/4/5/6 Terminal strips
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Instruction book
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 stopping period is too short,
the compressor is kept running to prevent too-short standstill periods.
Warning
A number of time-based automatic start/stop commands may be programmed. Take into account that
a start command will be executed (if programmed and activated), even after manually stopping the
compressor.
The compressor will also be stopped in case of overload of the drive motor.
Consult the safety precautions as mentioned in section 4 and remedy the trouble. See also the User
manual for Elektronikon regulator, section “Status data menu”.
Shut-down warning
If the regulator detects a temperature or pressure just below the programmed shut-down level, this will
be indicated on the control panel to warn the operator before the shut-down level is reached.
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Instruction book
Warning
If activated and provided the module was in the automatic operation mode, the compressor will
automatically restart if the supply voltage to the module is restored within a programmed time period.
The power recovery time (the period within which the voltage must be restored to have an automatic
restart) can be set between 1 and 255 seconds or to Infinite. If the power recovery time is set to
Infinite, the compressor will always restart after a voltage failure, no matter how long it takes to restore
the voltage. A restart delay can also be programmed, allowing e.g. two compressors to be restarted
one after the other.
1.9.1 LEDs/buttons/keys
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1.9.2 Display
The following is a typical example of the main screen, showing in short the status of the compressor:
Automatically Loaded ↓
Menu Unload
F1 F2 F3
The functions of the keys vary, depending on the displayed menu. The actual function is indicated on
the bottom line of the display just above the relevant key.
Designation Function
Add To add compressor start/stop commands (day/hour)
Back To return to a previously shown option or menu
Cancel To cancel a programmed setting when programming parameters
Delete To delete compressor start/stop commands
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 (Fig. 1.11)
Menu Starting from the main screen (Fig. 1.11), to have access to submenus
Menu Starting from a submenu, to return to a previous menu
Modify To modify programmable settings
Program To program modified settings
Reset To reset a timer or message
Return To return to a previously shown option or menu
Unload To unload the compressor manually
Extra To find information regarding the installed modules
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Instruction book
Pressing the button breaks the circuit to the drive motor. The circuit to the control circuit and other
electrical components is not broken.
Warning
Before starting any maintenance or repairs:
- Stop the compressor and close the air outlet valve.
- Press the test buttons (Fig. 1.8) on top of the electronic water drains to depressurize the air
system and open the drain valve (1-Fig. 3.5). If an IMD dryer is installed, open drain valve (8-
Fig. 1.5).
- Open the isolating switch (customer's installation) to switch off the voltage to the compressor.
Apply all relevant safety precautions, including those mentioned in this book.
To facilitate programming and controlling the compressor, menu-driven programs are implemented in
the electronic module.
Program/Function Description
Main screen Shows in short the operation status of the compressor. It is the gateway to
all functions. See Fig. 1.13.
Status data Calling up the status of the compressor protection functions:
- shut-down
- shut-down warning
- service warning
Resetting of a shut-down, motor overload and service condition.
Measured data Calling up:
- actually measured data
- the status of a number of inputs
Counters Calling up the:
- running hours
- number of motor starts
- regulator (module) hours
Test Allows a display test.
Modify parameters Modifying the settings for:
- parameters: loading and unloading pressures,…
- protections: compressor element outlet temperature,…
- service plans: timers for service plans
- clock functions: automatic start/stop/pressure band commands
- configuration: time, date, display language, …
Service Calling up service plans and resetting the timers after carrying out the
service actions belonging to a plan. See section 4.
Saved data Calling up the saved data: last shut-down, last emergency stop data
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Instruction book
Automatically Loaded ↓
Menu
F1 F2 F3
If the function keys or arrow keys are not used for some minutes, the display will automatically return
to the Main screen.
Whenever displayed on a submenu screen, press the Mainscreen key to return to the Main screen.
Warning
Before connecting external equipment, stop the compressor and apply the safety precautions as
mentioned in section 4.
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Instruction book
2 INSTALLATION
2.1 Dimension drawings
(1) (3) (4)
(25)
(21)
(5)
(2) (6)
(19) (7)
(8)
(9) (11)
(10)
(14) (12)
(16)
(15) (17)
(19)
(13)
(27) (28)
2920 1472 03 25
Instruction book
(1) (3)
(4)
(21)
(25)
(5)
(6)
(19) (7)
(8)
(9)
(11)
(10)
(12)
(14) (16)
(15) (17)
(13)
(27) (28)
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Instruction book
(5)
(21)
(6)
(2)
(19) (7)
(8)
(11)
(9)
(10)
(12)
(14)
(16)
(15)
(17)
(19)
(13)
2920 1472 03 27
Instruction book
(4) (3)
(1)
(25)
(20)
(5)
(21)
(2) (6)
(19) (7)
(8)
(9) (11)
(10)
(12)
(14) (16)
(15)
(17)
(19)
(13)
(27) (28)
9820 3712 00/02
55362D
2920 1472 03 28
Instruction book
(5)
(23)
(24)
(20) (21)
(6)
(2)
(19)
(7)
(8)
(11)
(9)
(10)
(14)
(12)
(16)
(15) (17)
(19)
9820 3821 00
(13) 52637D
2920 1472 03 29
Instruction book
1. Install the compressor on a level floor, suitable for taking its weight. Recommended minimum
distance between the top of the bodywork and the ceiling: 1200 mm.
2. Remove the plastic plug (if provided) from the compressor air outlet pipe and install an air
outlet valve. Close the valve and connect it to the air net.
3. The pressure drop over the delivery pipe can be calculated as follows:
The connection of the compressor air delivery pipe should be made on top of the main air net
pipe to minimize carry-over of possible remainder of condensate.
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Instruction book
4. The inlet grids and ventilation fan should be installed in such a way that any recirculation of
cooling air to the compressor is avoided. The air velocity to the grids should be limited to 5
m/s. The required ventilation capacity (per compressor installed) to limit the compressor room
temperature can be calculated as follows:
If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30
Pa. Common ducting for several compressors is not allowed.
5. Lay out the drain piping from automatic condensate outlets towards the condensate collector.
The drain pipes must not dip into the water of the collector. It is recommended to provide a
funnel to allow visual inspection of the condensate flow.
7. See section 2.3 for the recommended cable size of the supply cables. Check that the
electrical connections correspond to the local codes. The installation must be earthed and
protected against short circuits by fuses in all phases. An isolating switch must be installed
near the compressor.
8. Provide a condensate drain valve in the lowest part of the pipe between the compressor outlet
valve and the air net.
9. On ZR30 up to ZR45: position of cooling water pipes. Remove the plastic plugs (if provided)
from the compressor water pipes and connect the pipes to the cooling water circuit. Provide a
valve in the compressor water inlet pipe and outlet pipe.
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Instruction book
(2)
(3) (4)
(1)
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(2)
(3)
(1)
9820 3823 00
52638D
2920 1472 03 33
Instruction book
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Instruction book
Remarks
- Local regulations remain applicable if they are stricter than the values proposed below.
- For 50 Hz compressors, the size is valid for cable PVC with insulation 70°C at ambient
temperature of 40°C.
- For 60 Hz compressors, the size is valid for cable with insulation 90°C at ambient temperature
of 40°C.
2920 1472 03 35
(1)
(16)
2920 1472 03
(13)
Instruction book
(11)
(18)
(14)
(12)
(15)
(2)
(10)
(17)
(19)
O O
O O
(5)
(3) (4)
-
O -
O -
O -
O -
O -
O -
O -
O -
O -
O -
O
(9) (22)
(7)
(6)
(23)
O O
(8)
9820 3659 29/06
55399D
36
Instruction book
2920 1472 03 37
Instruction book
Reference Description
1 Start
2 Scroll keys
3 Tabulator key
4 Voltage on
5 Alarm
6 Automatic operation
7 Stop
8 Automatic condensate outlets
9 Manual condensate outlets
10 Warning: under tension
11 Read Instruction book before starting the compressor
12 Switch off the voltage and depressurize the compressor before maintenance or repair
13 Before connecting the compressor electrically, consult the Instruction book for the motor
rotation direction
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Instruction book
Reference Description
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 the Instruction book before maintenance or repair
19 Cooling water outlet
20 Cooling water inlet
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.
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.
RSI = 2*pHs - pH
pHs= (9.3 + A + B) - (C + D)
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This table indicates that distilled or demineralised water should never be used, as their RSI is > 11.
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:
Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited:
However, if the water is scaling, lower limits should be used. (See The Ryznar stability index (RSI)).
Sulphates (SO4--)
Closed cooling system: Sulphates < 400 ppm
Open cooling systems: Sulphates < 150 ppm
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Instruction book
Carbonate hardness
Closed cooling system: 50-1000 ppm CaCO3
Open cooling system: 50-500 ppm CaCO3
Ammonia
< 0.5 ppm
Copper
< 1 ppm
Organics
No algae.
No oil.
Suspended solids
Non-soluble particles, size < 1 mm.
< 10 ppm.
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Instruction book
3 OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all related safety precautions, including those mentioned in this book.
Ambient conditions
Consult section 7 for the limitations with regard to the ambient conditions and altitude operation.
Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks
protrude from the other side of the frame. The compressor can also be lifted after inserting beams in
the slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The
chains must be held parallel to the bodywork by chain spreaders in order not to damage the
compressor. The lifting equipment must be placed in such a way that the compressor will be lifted
perpendicularly. Lift smoothly and avoid twisting.
1 Flange
2 Label
3 Pipe
4 Bag with bolts/O-ring
5 Coupling
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Instruction book
Components
1 Bolt
2 Nut
3 Bolt
4 Nut
Fig. 3.1a Vibration dampers on earlier production units 5 Bush
6 Motor support
or gear casing
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Instruction book
6. The compressor and motor are secured to the frame, immobilizing the vibration dampers
during transport (Figs. 3.1). After installing the compressor:
a On earlier production units (Fig. 3.1a) loosen the nuts (2 and 4) of the long central
bolt of each damper, screw the bolts (1 and 3) as far out as indicated and tighten the
nuts again.
b On recent production units, remove the transport fixations (Fig. 3.1b), which are
painted red. Unscrew bolt (1) and remove transport bush (5). Four transport fixations
are provided: two at the gear casing side and two at the motor side.
7. Check that the gear casing is filled with oil: the level should be in the middle of sight-glass
(SG-Fig. 3.3).
8. Check that the electrical connections correspond to the local codes. The installation must be
earthed and protected by fuses in all phases. An isolating switch must be provided.
9. Check the connections at the primary sides of transformers (T1 and T2-Fig. 1.9). Check the
settings of circuit breaker (Q15) and overload relay (F21).
10. Close the manual drain valve of the condensate trap (1-Fig. 3.5).
On ZR only:
11. Check that the cooling water drain valves (customer’s installation) in the inlet and outlet lines
are closed. Open the water inlet and outlet valves (customer’s installation) and check for water
flow. Open the water flow regulating valves (1 and 4-Fig. 3.6 and 7-Fig. 3.7 in case of IMD).
On all compressors:
15. Switch on the voltage. Start the compressor and stop it immediately. Check for correct
direction of rotation while the motor is coasting to a stop. Arrow (1-Fig. 3.3) on the gear
casing indicates the correct rotation direction. If the rotation direction is wrong, switch off the
voltage and reverse two incoming electric lines. On ZT, check the rotation direction of the fan
motor. Cooling air must be blown through the outlet grating on the roof. If the rotation
direction is wrong, switch off the voltage and reverse two connections at the terminals of
circuit breaker (Q15-Fig. 1.9).
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The average difference between both legs must be 8 ± 3 mm. (Fig. 3.2b) The level in the leg
marked (-) must always be above the level in the leg marked (+). In case of fluctuating water
levels, the average difference can be set at a maximum of 11 mm to keep the level in the leg
marked (-) at any time above the level in the leg marked (+). When the average difference is
set at 11 mm and the level in the leg marked (-) does not stay at any time above the level in
the leg marked (+), consult Atlas Copco.
On all compressors:
26. Run the compressor for a few minutes and check that it operates normally.
27. Stop the compressor. If necessary, top up the gear casing with oil to the middle of sight-glass
(SG-Fig. 3.3).
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Co Oil cooler
Dmo Oil drain valve, gear casing
FC Oil filler cap
OF Oil filter
SG Oil level sight-glass
1 Arrow, indicating correct rotation
direction of drive motor
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Warning
- When the compressor is stopped and automatic operation LED (8) 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. Consult the User manual for Elektronikon regulator, section “Programming Clock
function”.
1. Daily check the display for readings and messages. Normally, the main screen (Fig. 1.11) is
shown, indicating the compressor outlet pressure, the status of the compressor and the
functions of the keys below the display.
2. Always check the display and remedy the trouble if alarm LED (7) is alight or blinks. Consult
section 1.8.
3. The display will show a service message if a service plan interval has been exceeded or if a
service level for a monitored component has been exceeded. Carry out the service actions of
the indicated plans or replace the component and reset the relevant timer. Consult your Atlas
Copco Customer Centre. See also section 4.1.
4. Regularly check the actual compressor status by pressing the ↓ key from the main screen.
Warning
Before starting any maintenance or repairs:
- Stop the compressor and close the air outlet valve.
- Press the test buttons (Fig. 1.8) on top of the electronic water drains to depressurize the air
system and open the drain valve (1-Fig. 3.5). If an IMD dryer is installed, open drain valve (8-
Fig. 1.5).
- Open the isolating switch (customer's installation) to switch off the voltage to the compressor.
Apply all relevant safety precautions, including those mentioned in this book.
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1 Manual condensate drain, aftercooler 4 Prepared for electronic drain (only for
2 Electronic condensate drain, intercooler IMD)
3 Automatic condensate drain, aftercooler
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1. Close the air outlet valve and stop the compressor. Press the test buttons (Fig. 1.8) on top of
the electronic water drains to depressurize and open the drain valve (1-Fig. 3.5). If an IMD
dryer is installed, open drain valve (8-Fig. 1.5).
2. Switch off the voltage and disconnect the compressor from the mains.
3. Shut off and depressurize the part of the air net which is connected to the outlet valve.
4. Disconnect the compressor air outlet pipe from the air net.
5. Drain the oil and condensate circuits.
6. Disconnect the compressor condensate piping from the condensate drain net.
7. On ZR, drain the cooling water circuit and disconnect the cooling water pipes from the
compressor.
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4 MAINTENANCE
Warning
Before starting any maintenance or repairs:
- Stop the compressor and close the air outlet valve.
- Press the test buttons (Fig. 1.8) on top of the electronic water drains to depressurize the air
system and open the drain valve (1-Fig. 3.5). If an IMD dryer is installed, open drain valve (8-
Fig. 1.5).
- Open the isolating switch (customer's installation) to switch off the voltage to the compressor.
Apply all relevant safety precautions, including those mentioned in this book.
Warranty-Product Liability
Use only Atlas Copco authorized genuine parts. Any damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty or Product Liability.
The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the
environmental and working conditions of the compressor.
- 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.
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When reaching a level, a message will appear on the screen. After carrying out all service actions, the
interval timers are to be reset using the key "Reset" in menu "Service". Consult your Atlas Copco
Customer Centre.
The bearings are greased for life; contact your Customer Centre for the replacement interval of the
motor bearings.
ZT/ZR30 up to ZT/ZR45
Important
Never mix greases of different brands or types.
Important
Never mix oils of different brands or types.
If the compressor is going to be stored without running from time to time, protective measures must be
taken. Consult Atlas Copco.
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5 SERVICING PROCEDURES
5.1 Air filter (AF-Fig. 1.3)
5.1.1 Recommendations
1. Never remove the element while the compressor is running.
2. For minimum compressor down-time, replace the dirty element by a new one.
3. Discard the element when damaged.
5.1.2 Servicing
1. Stop the compressor and switch off the voltage.
2. Remove the air filter cover and remove the filter element.
3. Clean the cover. Discard the filter element.
4. Install a new element and the cover.
5. After carrying out the service actions of the related service plan, the service warning must be
reset. See also section 4.1.
Warning
Never run the compressor without safety valves.
No adjustments are allowed.
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6 PROBLEM SOLVING
Warning
Before starting any maintenance or repairs:
- Stop the compressor and close the air outlet valve.
- Press the test buttons (Fig. 1.8) on top of the electronic water drains to depressurize the air
system and open the drain valve (1-Fig. 3.5). If an IMD dryer is installed, open drain valve (8-
Fig. 1.5).
- Open the isolating switch (customer's installation) to switch off the voltage to the compressor.
Apply all relevant safety precautions, including those mentioned in this book.
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7 PRINCIPAL DATA
7.1 Readings on display (2-Fig. 3.4)
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Notes
- For 50 Hz compressors, according to Directive 73/23/EEC (low-voltage directive) EN 60204
- For 60 Hz compressors, according to CSA standards C22,2 Nos. 0; 0.4; 0.5; 0.12; 14; 68; and
UL508
7.4.2 Limitations
Unit ZT15 ZT15 ZT15 ZT18 ZT18 ZT18 ZT22 ZT22 ZT22
-7.5 -8.6 -10 -7.5 -8.6 -10 -7.5 -8.6 -10
Nominal working bar(e) 7 8 9.5 7 8 9.5 7 8 9.5
pressure
Maximum bar(e) 7.5 8.6 10 7.5 8.6 10 7.5 8.6 10
working
pressure
Maximum bar(e) 7.25 8.35 9.75 7.25 8.35 9.75 7.25 8.35 9.75
working
pressure, Full-
Feature
Minimum bar(e) 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0
working
pressure
Installed motor kW 15 15 15 18.5 18.5 18.5 22 22 22
power
Oil capacity l 25 25 25 25 25 25 25 25 25
Sound pressure dB(A) 69 69 69 71 71 71 73 73 73
level 1)
Sound pressure dB(A) 65 65 65 67 67 67 69 69 69
level, WorkPlace
Air System 1)
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Footnotes chapter 7
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9 PED
9.1 Components subject to 97/23/EC Pressure Equipment Directive
Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to Category II
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Notes:
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Notes:
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O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................
SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:
These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.
1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
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 Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.
2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:
8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.
1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.
3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.