20184900.pdf

ZR 55, ZR 75, ZR 90, ZT 55, ZT 75, ZT 90

Instruction book

Atlas Copco

ZR 55, ZR 75, ZR 90, ZT 55, ZT 75, ZT 90

Instruction bookOriginal instructions

Copyright NoticeAny unauthorized use or copying of the contents or any part thereof is prohibited.

This applies in particular to trademarks, model denominations, part numbers anddrawings.

This instruction book is valid for CE as well as non-CE labelled machines. It meets therequirements for instructions specified by the applicable European directives asidentified in the Declaration of Conformity.

2014 - 12

No. 2920 1849 00

www.atlascopco.com

Table of contents

1 Safety precautions..........................................................................................................5

1.1 SAFETY ICONS................................................................................................................................... 5

1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................5

1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6

1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8

2 General description......................................................................................................10

2.1 INTRODUCTION.................................................................................................................................10

2.2 AIR FLOW....................................................................................................................................... 23

2.3 ELEKTRONIKON REGULATED DRAIN (ERD)............................................................................................29

2.4 OIL SYSTEM.................................................................................................................................... 31

2.5 COOLING SYSTEM.............................................................................................................................31

2.6 ENERGY RECOVERY.......................................................................................................................... 31

2.7 LOW LOAD COMPENSATOR..................................................................................................................34

2.8 ELECTRICAL SYSTEM.........................................................................................................................35

2.9 SMARTBOX AND SMARTLINK.................................................................................................... 37

3 Elektronikon Graphic controller..................................................................................41

3.1 CONTROL PANEL.............................................................................................................................. 41

3.2 DIGITAL OUTPUT CONTACTS................................................................................................................42

3.3 ICONS USED.................................................................................................................................... 43

3.4 MAIN SCREEN..................................................................................................................................47

3.5 CONTROLLER MENU STRUCTURE..........................................................................................................51

3.6 WEB SERVER.................................................................................................................................. 54

4 Installation.....................................................................................................................62

4.1 DIMENSION DRAWINGS.......................................................................................................................62

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4.2 INSTALLATION PROPOSALS..................................................................................................................75

4.3 INSTALLATION REQUIREMENTS FOR RUBBER COMPENSATORS.....................................................................84

4.4 ELECTRIC CABLES............................................................................................................................ 91

4.5 ELECTRIC CONNECTIONS....................................................................................................................94

4.6 QUALITY OF SAFETY COMPONENTS.......................................................................................................96

4.7 COOLING WATER REQUIREMENTS.........................................................................................................97

4.8 PICTOGRAPHS............................................................................................................................... 100

5 Operating instructions............................................................................................... 103

5.1 OPERATION INTRODUCTION...............................................................................................................103

5.2 INITIAL START-UP............................................................................................................................103

5.3 BEFORE STARTING..........................................................................................................................115

5.4 ROUTINE STARTING.........................................................................................................................117

5.5 DURING OPERATION........................................................................................................................118

5.6 STOPPING.....................................................................................................................................119

5.7 TAKING OUT OF OPERATION..............................................................................................................122

6 Maintenance................................................................................................................123

6.1 MAINTENANCE WARNINGS................................................................................................................ 123

6.2 PREVENTIVE MAINTENANCE SCHEDULE................................................................................................123

6.3 SERVICE KITS................................................................................................................................ 124

6.4 SERVICE AGREEMENTS.................................................................................................................... 124

6.5 SERVICE PLAN............................................................................................................................... 124

6.6 MOTOR GREASING..........................................................................................................................124

6.7 OIL SPECIFICATIONS........................................................................................................................126

6.8 STORAGE AFTER INSTALLATION......................................................................................................... 126

7 Servicing procedures.................................................................................................127

7.1 AIR FILTER (AF)............................................................................................................................127

7.2 OIL AND OIL FILTER CHANGE.............................................................................................................127

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7.3 SAFETY VALVES............................................................................................................................. 129

8 Problem solving..........................................................................................................130

8.1 FAULTS AND REMEDIES....................................................................................................................130

9 Principal data.............................................................................................................. 132

9.1 READINGS ON DISPLAY.................................................................................................................... 132

9.2 SETTINGS OF SAFETY VALVES........................................................................................................... 133

9.3 CIRCUIT BREAKERS AND FUSES......................................................................................................... 133

9.4 REFERENCE CONDITIONS................................................................................................................. 138

9.5 LIMITATIONS.................................................................................................................................. 138

9.6 COMPRESSOR DATA........................................................................................................................138

10 Pressure equipment directives................................................................................. 139

11 Documentation............................................................................................................140

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 General safety precautions1. The operator must employ safe working practices and observe all related work safety requirements

and regulations.2. If any of the following statements does not comply with the applicable legislation, the stricter of the

two shall apply.3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,

specialized personnel. The personnel should apply safe working practices by use of personalprotection equipment, appropriate tools and defined procedures.

4. The compressor is not considered capable of producing air of breathing quality. For air of breathingquality, the compressed air must be adequately purified according to the applicable legislation andstandards.

5. Before any maintenance, repair work, adjustment or any other non-routine checks:• Stop the compressor• Press the emergency stop button• Switch off the voltage• Depressurize the compressor• Lock Out - Tag Out (LOTO):

• Open the power isolating switch and lock it with a personal lock• Tag the power isolating switch with the name of the service technician.

• On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.• Never rely on indicator lamps or electrical door locks before maintenance work, always

disconnect and check with measuring device.

If the machine is equipped with an automatic restart after voltage failure function and ifthis function is active, be aware that the machine will restart automatically when thepower is restored if it was running when the power was interrupted!

6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so withextreme caution and wear eye protection.

7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessoriesshall be replaced if unsuitable for safe operation.

8. It is prohibited to walk or stand on the unit or on its components.

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1.3 Safety precautions during installationAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during installation1. The machine must only be lifted using suitable equipment in accordance with the applicable safety

regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden todwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be keptwithin safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.

2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;consult your supplier.

3. In case the device is a compressor, place the machine where the ambient air is as cool and clean aspossible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken tominimize the entry of moisture at the inlet air.

4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or

worn hoses. Distribution pipes and connections must be of the correct size and suitable for theworking pressure.

6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors andparticles, e.g. paint solvents, that can lead to internal fire or explosion.

7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannotbe drawn in.

8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand underheat and that it is not in contact with or close to flammable materials.

9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is

remotely controlled and may start without warning.The operator has to make sure that the machine is stopped and depressurized and that the electricalisolating switch is open, locked and labelled with a temporary warning before any maintenance orrepair. As a further safeguard, persons switching on or off remotely controlled machines shall takeadequate precautions to ensure that there is no one checking or working on the machine. To this end,a suitable notice shall be affixed to the start equipment.

11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is availableand that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.

12. The electrical connections must correspond to the applicable codes. The machines must be earthedand protected against short circuits by fuses in all phases. A lockable power isolating switch must beinstalled near the compressor.

13. On machines with automatic start/stop system or if the automatic restart function after voltage failureis activated, a sign stating "This machine may start without warning" must be affixed near theinstrument panel.

14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return valves (check valves) must not be relied upon for isolating pressure systems.

15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Everypressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressuremust be protected by a pressure relieving device or devices as required.

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16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentallytouched by personnel in normal operation must be guarded or insulated. Other high temperaturepiping must be clearly marked.

17. For water-cooled machines, the cooling water system installed outside the machine has to beprotected by a safety device with set pressure according to the maximum cooling water inlet pressure.

18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer,

safety valves must be installed in the vessels of the dryer.

Also consult following safety precautions: Safety precautions during operation andSafety precautions during maintenance.These precautions apply to machinery processing or consuming air or inert gas.Processing of any other gas requires additional safety precautions typical to theapplication which are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

1.4 Safety precautions during operationAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during operation1. Never touch any piping or components of the machine during operation.2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose

or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Makesure that a hose is fully depressurized before disconnecting it.

3. Persons switching on remotely controlled machines shall take adequate precautions to ensure thatthere is no one checking or working on the machine. To this end, a suitable notice shall be affixed tothe remote start equipment.

4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vaporsor particles.

5. Never operate the machine below or in excess of its limit ratings.6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g.

to carry out routine checks. Wear ear protectors when opening a door.On machines without bodywork, wear ear protection in the vicinity of the machine.

7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)shall wear ear protectors.

8. Periodically check that:• All guards are in place and securely fastened• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing• No leaks occur• All fasteners are tight• All electrical leads are secure and in good order• Safety valves and other pressure relief devices are not obstructed by dirt or paint• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good

repair, free of wear or abuse

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• Air cooling filters of the electrical cabinet are not clogged9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom,

take precautions against air pollution and possible contamination of the breathing air.10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to

avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.11. Do not remove any of, or tamper with, the sound-damping material.12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every

pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressureshall be protected by a pressure relieving device or devices as required.

13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must berespected. Local regulations remain applicable if they are more strict.

Also consult following safety precautions: Safety precautions during installation andSafety precautions during maintenance.These precautions apply to machinery processing or consuming air or inert gas.Processing of any other gas requires additional safety precautions typical to theapplication which are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

1.5 Safety precautions during maintenance or repairAll responsibility for any damage or injury resulting from neglecting these precautions, ornon observance of the normal caution and care required for installation, operation,maintenance and repair, even if not expressly stated, will be disclaimed by themanufacturer.

Precautions during maintenance or repair1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).2. Use only the correct tools for maintenance and repair work.3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or

injuries caused by the use of non-genuine spare parts.4. All maintenance work shall only be undertaken when the machine has cooled down.5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the

starting equipment.6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that

there is no one checking or working on the machine. To this end, a suitable notice shall be affixed tothe remote start equipment.

7. Close the compressor air outlet valve and depressurize the compressor before connecting ordisconnecting a pipe.

8. Before removing any pressurized component, effectively isolate the machine from all sources ofpressure and relieve the entire system of pressure.

9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautionsagainst toxic vapors of cleaning liquids.

10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering theparts and exposed openings with a clean cloth, paper or tape.

11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completelypurged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any waymodify, pressure vessels.

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12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, themachine shall be stopped but no inspection covers shall be opened before sufficient cooling time haselapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.

13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.14. Make sure that no tools, loose parts or rags are left in or on the machine.15. All regulating and safety devices shall be maintained with due care to ensure that they function

properly. They may not be put out of action.16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,

temperatures and time settings are correct. Check that all control and shut-down devices are fitted andthat they function correctly. If removed, check that the coupling guard of the compressor drive shafthas been reinstalled.

17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oilseparator vessel for carbon deposits; if excessive, the deposits should be removed.

18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture fromentering them, e.g. when steam cleaning.

19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on thebodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,replace it by genuine material from the manufacturer to prevent the sound pressure level fromincreasing.

20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.21. Only if applicable, the following safety precautions are stressed when handling refrigerant:

• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; ifrequired, use breathing protection.

• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin withwater. 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 refrigerant is flushed away; thenseek medical first aid.

Also consult following safety precautions: Safety precautions during installation andSafety precautions during operation.These precautions apply to machinery processing or consuming air or inert gas.Processing of any other gas requires additional safety precautions typical to theapplication which are not included herein.Some precautions are general and cover several machine types and equipment; hencesome statements may not apply to your machine.

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2 General description

2.1 Introduction

DescriptionThis unit is a two-stage screw compressor driven by an electric motor. The compressor delivers oil-free,pulsation-free air.

ZR compressors are water-cooled.

ZT compressors are air-cooled.

Full-Feature compressors are aditionally provided with an air dryer which removes moisture from thecompressed air. The dryer is integrated in the bodywork of the compressor.

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Views of ZR

General view of ZR 55 up to ZR 90 Pack, ZR 55 up to ZR 90 Full-Feature

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Inside view of ZR 55 up to ZR 90 Pack, ZR 55 up to ZR 90 Full-Feature

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Front view of ZR 55 up to ZR 90 Pack

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Rear view of ZR 55 up to ZR 90 Pack

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Views of ZT

General view of ZT 55 up to ZT 90 Pack

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General view of ZT 55 up to ZT 90 Full-Feature

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Front inside view of ZT 55 up to ZT 90 Pack

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Rear inside view of ZT 55 up to ZT 90 Pack

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General view

Energy recovery, Full-Feature

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Energy recovery, Pack

Main components

Ref NameAF Air filterAO Air outletAS SilencerBV By-pass valve, oil coolerCa1 Pre-aftercoolerCaCa2

Aftercooler

Ci IntercoolerCo Oil coolerDmo Oil drain valve, gear casingEh High-pressure compressor elementEl Low-pressure compressor elementER Energy recovery systemERwi Water inlet, energy recovery systemERwo Water outlet, energy recovery systemEWDa Electronic water drain, aftercoolerEWDi Electronic water drain, intercoolerE1 Elektronikon regulatorFC Oil filler capFN Cooling fanIMD/IND Integrated dryerM1 Drive motorM25 Fan motorMTa Moisture trap, aftercoolerMTi Moisture trap, intercoolerOF Oil filterS2 Emergency stop button

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Ref NameSG Oil level sight-glassSVd Safety valve, dryerSVh High-pressure safety valveSVl Low-pressure safety valveTV Load/no-load valveUS SilencerWI Cooling water inletWO Cooling water outletY1 Loading solenoid valve

Optional equipmentFollowing equipment is available as an option:

Full-FeatureThe compressor is additionally provided with an IMD adsoption dryer. The dryer is integrated in thebodywork and removes moisture from the compressed air.

ConnectionsThis compressor can be provided on the compressed air outlet and water pipes with:

ANSI flanges

DIN flanges

Motor temperature protectionPT1000s are embedded in the windings and/or bearings of the drive motor to warn the operator if thetemperature becomes too high and to shut down the compressor, thereby protecting the motor fromoverheating.

Teflon-free compressor elementsThe rotors of the compressor elements have an epoxy-based coating.

Automatic water shut-offA water shut-off valve is provided in the cooling water system to shut off the system when the compressoris not in operation.

Energy recoveryThe compressor is provided with an Atlas Copco energy recovery system to recover the major part of thecompression heat in the form of hot water.

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SPM monitoringA number of vibration sensors are provided on the drive motor and compressor elements. The readings canbe called up on the display of the Elektronikon regulator.

High ambient temperature (HAT)The compressor is specially designed for continuous operation under humid and high ambient temperatureconditions. The maximum ambient temperature is 50˚C (122˚F).

Anchor padsSteel plates, fitting in the forklift slots, and bolts are shipped loose with the compressor. With these platesand bolts, the compressor frame can be fixed to the floor.

Anti-condensation heatersElectric heaters are installed in the motor windings and connected to the compressor cubicle. When thecompressor is stopped, the heaters are automatically switched on. The heaters in the motor will preventcondensation during stand-still.

PDP sensorThe pressure dewpoint of the compressed air leaving the IMD dryer is continuously shown on the displayof the Elektronikon regulator. This allows to monitor the performance of the dryer and to make sure thatthe compressed air is dry enough for the application.

Low load compensatorThe low load installation allows the dryer to be operated in low load conditions of the compressor. At theseconditions (compressor in unload) the pressure dewpoint is maintained by purging a small amount ofheated, dryed air through the rotor of the dryer.

The low load compensator is needed when the load cycle of the compressor is below 40 %.

Full-Feature NDThe Z Full-Feature ND compressor has an integrated heat of compression rotary drum dryer. Theregeneration air passes over a heater. The heater maintains a preset regeneration temperature to have aguaranteed dew point at stated conditions. A thermostatic control puts on the heater and shuts it offautomatically based on the regeneration temperature requirements.

SmartboxWhen ordering the compressor, it is possible (except for Japan and Korea) to choose the free SMARTBOXoption which is mounted in the electrical cabinet. The SMARTBOX allows read-out of the compressorparameters on a login-protected web site called SMARTLINK. The connected antenna is mounted on theoutside of the electrical cabinet. Refer to the Smartbox and Smartlink section.

Kit for purge air during stand-stillWhen frequent and long standstills occur, it is recommended to install a kit for purge of dry air to guaranteethe life time of the oil-free screw elements. During standstill, condensation (which triggers corrosion)might occur. This results in an expected element lifetime reduction or even a compressor stage blocking

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during standstill. Condensation is prevented by blowing a small amount of dry air through the small gapbetween rotor-rotor and rotor-housing once the compressor is stopped. To avoid long standstills, regularstarting can be programmed in the Elektronikon controller or by a central Atlas Copco ES controller.

2.2 Air flow

Air Flow

Flow diagram, ZT 55-90 Pack

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Flow diagram, ZT 55-90 Full-Feature

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Flow diagram, ZR 55-90 Pack

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Flow diagram, ZR 55-90 Full-Feature with Energy recovery

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Flow diagram, ZR 55-90 Full-Feature

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Flow diagram, ZR 55-90 Full-Feature with Energy recovery

Ref Name(1) Air inlet(2) Air outlet(3) Air to gearbox breathing system from air outlet(4) From transducer sensors

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Air flowAir drawn through filter (100) is compressed in low-pressure compressor element (104) and discharged tointercooler (108). The cooled air is further compressed in high-pressure compressor element (111) anddischarged through silencer (112) and aftercoolers (116). A check valve (115) is provided downstream ofthe silencer (112).

The wet air from the aftercooler (116) enters water separator (117) via the nozzle of ejector (211). Indemister (212), the water droplets are removed from the air. The air is then led through rotor, whichadsorbs the water vapor.

The compressed air leaves the compressor via the air outlet (2).

Regenerating circuit of the dryerHot regeneration air is branched off from the aftercooler (116). The regeneration air passes through shut-off valve (115), throttle valve (223) and strainer, and is blown through the wet rotor channels.

The hot saturated air is then cooled down in the regeneration air cooler. The regeneration air is then mixedwith the wet compressed air from the compressor aftercooler (116).

2.3 Elektronikon regulated drain (ERD)

DescriptionThe drain consists of a capacitive sensor which is incorporated in the drain collector and of a pilot valvewhich is placed outside the drain collector. A drain opening delay timer is started when the collector isfilled up to the level of the capacitive sensor. As long as the delay timer is running, extra condensate willbe collected and the level will rise even higher than the position of the sensor. As soon as the delay timerhas expired, the pilot valve (normally open) is deactivated and the diaphragm opens the outlet, dischargingthe condensate. From the moment that the sensor is not detecting any condensate anymore, a drain closingdelay timer is started. The pilot valve will still drain the condensate during the run of this timer to makesure that the remaining amount of condensate is drained. The pilot valve is activated when the timer hasexpired, the outlet closes quickly without wasting compressed air.

for ZR compressors

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for ZT compressors

Reference Description1 Solenoid valve2 Connector3 Sensor4 Bushing5 Drain receiver

If the controller detects water in the intercooler or aftercooler drain receiver for too long a period, ashutdown is generated. If water is detected on the integrated dryer drain receiver for too long a period, awarning is generated.

The level switch is a capacitive sensor which generates a high signal when no water is present. Thesolenoid valves of the intercooler and aftercooler/integrated dryer drains are different. The solenoid valveof the intercooler drain has a high flow but cannot handle high pressures. The solenoid valve on theaftercooler/integrated dryer drains has less flow but can handle higher pressures. It is not allowed to openthe valves as they can loose their set point. Special attention must be paid to the correct wiring of thedifferent level switches and solenoid valves.

The output of the level switch can be called up on the screen of the Elektronikon regulator. The readingdoes not indicate whether the solenoid valve is open or closed, but indicates whether the level switch isdetecting water in the collector. Since there is a drain opening delay timer, the display on the Elektronikoncan show "Condensate Drain IC Open", while the solenoid valve is still closed. Changes to theElektronikon settings are not allowed. The "Always pressurized" bit must be activated on aftercooler andintegrated dryer drains. On the intercooler it is not allowed to activate this bit.

A functionality test is possible through the Elektronikon regulator. By performing this test, all solenoidvalves will be opened for a short time (e.g. 15 seconds). Refer to the Elektronikon chapter for more details.

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2.4 Oil systemRefer to the topic Air flow for flow diagrams.

On ZR compressors, oil is circulated by pump (131) from the sump (130) of the gear casing to cooler(132). From there, the oil flows through filter (133) towards the bearings and timing gears.

On ZT compressors, oil is circulated by pump (131) from the sump (130) of the gear casing to cooler (132).Then, the oil flows through the cooling jackets of compressor elements (104 and 111). From there, the oilflows through filter (133) towards the bearings and timing gears.

2.5 Cooling system

Cooling system, ZR compressorsRefer to the topic Air flow for flow diagrams.

The cooling system has two circuits:

• One for the oil cooler (132) and the cooling jackets of both compressor elements (104).• One for intercooler (108) and aftercooler (116).

Full-Feature compressors have an extra cooling circuit for the regeneration cooler of the integrated dryer.

Cooling system, ZT compressorsThe compressors are provided with an air-cooled oil cooler (132), intercooler (108), pre-aftercooler (116b)and aftercooler (116). An electric motor-driven fan (150) generates the cooling air.

Full-Feature compressors have an additional regeneration air cooler; the cooling air for this cooler isgenerated by an extra fan (153a).

2.6 Energy recovery

General

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The system recovers the major part of the compression heat. The percentage of shaft input power availablefor recovery is between 80 and 95, depending on the operating conditions.

If an MD dryer is installed downstream of the compressor, this percentage is reduced to approx. 70 of theshaft input instead of approx. 90, as part of the heat in the compressed air is used for regeneration in thedrying process.

A complete energy recovery system includes:

• Compressor with modified cooling system (ZR)• A pump unit (PU) to transfer the recovered energy from the compressor cooling system to the heat

consumer (HC)• The heat consumer (HC), i.e. the equipment to transfer the energy to the industrial process

Modified cooling water systemThe compressor cooling system has been modified to achieve both high cooling water temperatures andsufficient cooling for the compressor.

The cooling water enters the oil cooler and then flows through the high-pressure compressor element, thelow-pressure compressor element and finally the intercooler and the aftercooler. This sequence ensuresoptimal temperature differences with relation to the heat transfer in the individual components.

On Full-Feature compressors, additional connections are provided for the water circuit of the additionalaftercooler and the cooler of the IMD dryer. To ensure that the IMD dryer works properly, low-temperaturecooling water should be used for this cooling water circuit. The heat of this cooling water circuit is notrecovered by the energy recovery system.

Pump unit

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Atlas Copco supplies pump units to transfer the energy recovered from the compressor to the heatconsumer (HC). The pump unit constitutes a closed water circuit with the compressor cooling system.

Two water pumps (WP1/2) are fitted. One pump circulates the hot cooling water from the compressorthrough the heat consumer and back to the compressor. The other is a stand-by pump. Check valves(CV1/2) at the delivery side of the pumps prevent backflow of water in the stand-by pump. The pump unitis fitted with a make-up water connection, an air trap with automatic de-aeration device (AT), a pressureand temperature gauge (PI and TI), a safety valve (SV) and an expansion tank (ET).

Cooling water requirementsClosed recirculating water systems minimize make-up water requirements. Therefore, it is economicallyfeasible to use softened water to eliminate the problem of scaling deposits.

Corrosion control is important. The best results are obtained by adding corrosion inhibitors as used inengine cooling systems.

Using anti-freeze products is an alternative solution to avoid problems, e.g. adding 20 % to 30 % ethylene-glycol based anti-freeze to the tap water.

For open cooling water systems (e.g. boiler feed water preparation), consult the Atlas Copco CustomerCentre to avoid problems related to deposit control, corrosion control and microbiological growth control.

Water flow regulation through heat exchangersDepending on the amount of energy transferred in the heat consumer (HC), the heat exchanger (HE) of thepump unit is completely or partly by-passed by means of a thermostatic valve (RV2). The valve is normallyadjusted to achieve a cooling water temperature of 40 ˚C (corresponding to the maximum allowabletemperature at the compressor inlet). It is advisable to adjust the setting of the valve as close as possible tothe temperature of the cooling water returning from the heat consumer (HC).

Depending on the amount of energy transferred in the heat consumer (HC), the heat exchanger (HE) of thepump unit is completely or partly by-passed by means of a thermostatic valve (RV2). The valve is normallyadjusted to achieve a cooling water temperature of 104 ˚F (corresponding to the maximum allowabletemperature at the compressor inlet). It is advisable to adjust the setting of the valve as close as possible tothe temperature of the cooling water returning from the heat consumer (HC).

Sufficient low-temperature cooling water must be available for the heat exchanger to achieve a watertemperature that does not exceed 40 ˚C/104 ˚F.

Electrical systemThe pumps (WP1 and WP2) are driven by an electric motor. Each motor is equipped with manual startingequipment including a circuit breaker.

The first time it is started, check that the rotation direction matches the direction indicated by the arrows onthe motor flanges. If necessary, stop the unit, switch off the voltage and reverse two incoming electriclines.

Important remarksCompressed air quality and reliability of any compressor, dryer or other equipment should never be madesubordinate to the energy recovery system. In some cases, especially installations where air dryers areinstalled, an additional aftercooler is required to reduce the compressor air outlet temperature to a level atwhich the dryers operate at maximum efficiency. This aftercooler and the dryer (if water-cooled) need tobe cooled separately by low-temperature water. Consult the Atlas Copco Customer Centre.

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The general temperature level of compressors with a modified cooling system for energy recovery isapprox. 20 to 25 ˚C (68 to 77 ˚F) higher than the level of compressors with a standard cooling system,resulting in a slight decrease in free air delivery and a slight increase in shaft power.

In case the compressors operate in high ambient temperatures and with high water inlet temperatures, themaximum working pressure is 0.5 bar (7.25 psi) lower than for standard compressors. Consult the AtlasCopco Customer Centre.

Settings - limitations

Item SettingMaximum cooling water temperature at compressoroutlet

90 ˚C (85 ˚C if MD dryer is fitted)194 ˚F (185 ˚F if MD dryer is fitted)

Maximum cooling water temperature at compressorinlet

40 ˚C104 ˚F

Safety valve opening pressure 2.5 bar(e)36.3 psig

2.7 Low load compensator

Description

Reference Name1 Low load during unload cycle2 Heater3 Air net4 Rotor5 Motor6 Cooler7 Solenoid valve8 Silencer

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Reference Name9 Air outlet (compressor)10 Mechanical link11 Drain12 Water13 No air flow14 Air flow15 Flow direction16 Regeneration air (compressor)

Using the low load installation will allow the dryer to operate in low load conditions of the compressor. Atthese conditions (compressor in unload) the PDP is maintained by purging a small amount of heated, dryedair through the rotor (4).

This is needed when the load cycle is below 40 % (consult your Atlas Copco Customer Centre).

2.8 Electrical system

Main componentsThe electrical system mainly includes:

• Elektronikon® regulator• Emergency stop button (S2)• Electric cabinet• Drive motor (M1)• Pressure and temperature sensors

Elektronikon regulator (1) and emergency stop button (S2)

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Electric cabinet

Components DescriptionF21 Overload relay of main motorK21 Main contactorK22 Star contactorK23 Delta contactorQ25 Circuit breaker of fan motorK25 Contactor of fan motorQ41 Circuit breaker of fan motor of dryerK41 Contactor of fan motor of dryerQ32 Circuit breaker of low load heaterK32 Contactor of low load heaterT1 Control transformerF1, F2 Fuses of control transformerF25 Fuse of fan motorF32 Fuse of low load heaterF41 Fuse of fan motor of dryerK13 Relay running1X0 Power distribution1X8 Ring type terminalsS2 Terminal stripF40 Fuse of dryer motor

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Drive motor (M1)

Drive motor (M1)

2.9 SMARTBOX and SMARTLINK

GeneralThe machine comes with a SMARTBOX mounted in the electrical cabinet.

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The SMARTBOX allows read-out of a number of parameters of the machine on a user login-protected website called SMARTLINK. The connected antenna is mounted on the outside of the machine.

Safety precautionsIt is important to follow all regulations regarding the use of radio equipment, in particular regarding thepossibility of radio frequency (RF) interference. Please follow the safety advice given below carefully.

• Respect restrictions on the use of radio equipment in fuel depots, chemical plants or other explosiveenvironments.

• Avoid SMARTBOX operation close to inadequately protected personal medical devices such ashearing aids and pacemakers. Consult the manufacturers of the medical device to determine if it isadequately protected.

• Avoid SMARTBOX operation close to other electronic equipment which may also cause interferenceif the equipment is inadequately protected. Observe any warning signs and manufacturerrecommendations.

• Respect a distance from the human body of at least 20 cm (8 inch) during SMARTBOX operation.• Do not operate the SMARTBOX in areas where cellular modems are not advised without proper

device certifications. These areas include environments where cellular radio can interfere, such asexplosive atmospheres, medical equipment, or any other equipment which may be susceptible to anyform of radio interference. The modem can transmit signals that could interfere with this equipment.

SMARTLINKThe machine is SMARTLINK-ready.

SMARTLINK is Atlas Copco’s web-based platform to monitor compressed air installations. It is availablein 3 product levels:

• SMARTLINK ServiceSMARTLINK Service rules out all uncertainties. Scheduling maintenance visits becomes as simpleand easy as it should be; the service log book is always just one click away and the online link withAtlas Copco allows to request and quickly receive quotes for spare parts or additional services.This product level is free of charge and available for 3 years following the machine purchase.

• SMARTLINK UptimeSMARTLINK Uptime keeps your compressors up and running. By e-mail and/or text, you receive allrelevant machine indications (warnings and shutdowns) in advance. Based on this information, youcan then take all necessary actions and measures to avoid the risk of a breakdown.This product level is available as a free of charge 3-month trial.

• SMARTLINK EnergySMARTLINK Energy safeguards the performance of your equipment. It enables you to continuouslymonitor and analyze the energy efficiency of the compressor room. You decide which performance

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indicators, benchmarks and reports are created. You can make accurate and immediate improvementswhen needed. The results can be used for energy monitoring according to ISO50001.This product level is available as a free of charge 3-month trial.

Once a SMARTLINK level is chosen, gaining access is the next step. To gain access at least one machineSMARTLINK-ready component (compressor, dryer, ...) is required. Follow the next steps:

• Gather the information about the SMARTLINK-ready machine(s) (e.g. picture of the data plate;invoice,…)

• Go to the SMARTLINK web site http://www.atlascopco.com/smartlink• Click on the left button in the screen below.

• Use the data of the SMARTLINK–ready machine to register as a user.

• You will receive an e-mail with login credentials.

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• Go to the SMARTLINK web site http://www.atlascopco.com/smartlink, log in with the usercredentials.

• Enjoy SMARTLINK!• In case more SMARTLINK-ready machines are available, you can add these via My Profile.

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3 Elektronikon Graphic controller

3.1 Control panel

Elektronikon Graphic Controller

Reference Designation Function1 Display Shows the compressor operating condition and a

number of icons to navigate through the menu.2 Pictogram Automatic operation3 Pictogram General alarm4 General alarm LED Blinks when operating in shutdown warning

condition.5 Pictogram Service6 Service LED Lights up when service is needed.7 Automatic operation LED Indicates that the controller runs in automatic mode.8 Voltage on LED Lights up when supply is switched on. Compressor

unit might start automatically!9 Pictogram Voltage on10 Enter key Enter and confirmation key11 Escape key To navigate to previous screen or to cancel current

action12 Scroll keys Keys to scroll through the menu13 Stop button Button to stop the compressor. LED (7) dims.14 Start button Button to start the compressor. LED (7) lights up,

indicating that the Elektronikon controller isoperational.

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3.2 Digital output contacts

Warning

Voltage-free outputs may only be used to control or monitor functional systems. Theyshould NOT be used to control, switch or interrupt safety related circuits.

Stop the compressor and switch off the supply before connecting external equipment. Checkthe Safety precautions.

Connections for external equipmentThe Elektronikon (Mk5) always comes with expansion module IO2 that has a number of digital outputcontacts which can be used to connect external equipment.

Depending on the optional equipment, extra expansion modules are added to the machine configuration(IO2, IO34).

Expansion Module IO2 for Elektronikon (Mk5)

The digital output contacts have following specifications:

Relay Connector Maximum loadK01 3 X 31 15 A / 250 V AC

15 A / 30 V DCRC* protected

K02 3 X 31 15 A / 250 V AC15 A / 30 V DCRC* protected

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Relay Connector Maximum loadK03 3 X 31 15 A / 250 V AC

15 A / 30 V DCRC* protected

K04 3 X 31 10 A / 250 V AC10 A / 30 V DCresistive load












* = Resistor Capacitor

3.3 Icons used

Status icons

Name Icon Description

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Stopped / Running When the compressor is stopped, the icon is motionless.When the compressor is running, the icon rotates.

Compressor status Motor stopped

Running unloaded

Running loaded

Machine control mode

Local start / stop

Remote start / stop

Network control

Automatic restart after voltagefailure Automatic restart after voltage failure is enabled

Week timer Week timer is active

Active protection functions

Emergency stop

Shutdown

Warning

Service

Service required

Error

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Main screen Displayed when 2 or 4 line layout is picked.

Displayed when chart layout is picked.

Menu icons

Icon DescriptionService

Alarms (warnings, shutdowns)

Week timer

Info

Test

Counters

Regulation setpoints

Inputs

Outputs

Event history (saved data)

Settings

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Input icons

Icon DescriptionPressure

Temperature

Digital input

Special protection

System icons

Icon DescriptionCompressor element (LP, HP, ...)

Drain(s) (icon only visible when Electronically Regulated Drain (ERD) is installed oncompressor unit)

Filter(s)

Frequency converter

Motor

Expansion module

Cooler

Network settings/problem

General alarm

Auxiliary equipment overload: dryer

Oil circuit

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Regulation

General settings

Access key / User password

Temperature rise over the low pressure compressor stage.

Navigation arrows

Icon DescriptionUp

Down

3.4 Main screen

Control panel

Control panel

(1) Enter key(2) Cancel / Escape key(3) Scroll keys

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FunctionThe main screen shows the status of the compressor and is the gateway to all functionality implemented inthe controller.

The main screen is shown automatically when the power is switched on. The display switches to sleepmode when no keys are pushed for a programmable time.

Five different main screens can be chosen:

1. Two value lines2. Four value lines3. Chart (High resolution)4. Chart (Medium resolution)5. Chart (Low resolution)

Two and four value views

Typical Main screen (Four value lines)

Text on figures

(1), (2) Compressor Outlet(3) Inlet Guide Vanes % Open(4) Blow-Off Valve % Closed(5) Starting(6) Menu(7) Unload

• Section A displays information regarding the compressor operation (e.g. outlet pressure, temperatureat compressor outlet ).

• Section B displays Status icons. Following icon types are shown in this field:• Fixed icons

These icons are always shown in the main screen and cannot be selected by the cursor (e.g.Compressor stopped or running)

• Shortcut iconsThese icons are always shown in the main screen. If the icon is selected and the Enter key ispushed, the screen will jump to the corresponding menu (e.g. if the icon for Motor stopped or

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Running Loaded is selected, the screen will jump directly to the regulation menu after pressingthe Enter key).

• Control mode iconsThese icons are always shown in the main screen. If the icon is selected and the Enter key ispushed, the screen jumps to the control mode menu. Following control modes are available:

Local control

Remote control

Network control

• Optional iconsThese icons are only shown if their corresponding function is activated (e.g. week timer,automatic restart after voltage failure, etc.)

• Pop up iconsThese icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)

To show more information about displayed icons, select the icon using the scroll keys and push theEnter key.

• Section C is called the Status barThis bar shows the text that corresponds to the selected icon.

• Section D shows the Action buttons. These buttons are used:• to call-up or program settings• to reset a shutdown, service message or emergency stop• to have access to all data collected by the controller

The function of the buttons depends on the displayed menu. The most common functions are:

Designation FunctionMenu To go to the menuModify To modify programmable settingsReset To reset a timer or message

To enable an action button, highlight this button by using the Scroll keys and push the Enter key.To go back to the previous menu, push the Cancel / Escape key.

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Chart views

When the Chart (High Resolution) display is selected, a chart with an X-axis covering 4 minutes isdisplayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chartdot represents 1 second.

When the Chart (Medium Resolution) display is selected, a chart with an X-axis covering 4 hours isdisplayed. The value displayed on the Y-axis depends on the selection made in the input screen. Each chartdot represents a 1 minute average value.

When the Chart (Low Resolution) display is selected, a chart with an X-axis covering 10 days is displayed.The value displayed on the Y-axis depends on the selection made in the input screen. Each chart dotrepresents a 1 hour average value.

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3.5 Controller menu structure

Main menuPress the Enter key to go to the main menu screen that is shown below.

Menu structurePlease find the tree structure on the 2 top levels below. The items are mentioned as they appear on thescreen from top to bottom and left to right. If questions regarding lower levels appear, please consult yourlocal Atlas Copco Customer Centre.

SERVICE PLAN

Topic DescriptionOverview Displays an overview of the running service plansService Plan Displays configuration of the service plansNext Service Displays the next service taskHistory Displays a log of all automatic shutdowns that have appeared in the past

PROTECTIONS

Topic DescriptionGeneral Displays a list of main protectionsElement(s) Displays a list of protections related to the compressor stagesConvertor(s) Displays errors concerning actuatorsDrain(s) Displays protections on electronic drain failuresMain Motor Displays motor related protections to avoid motor damageCooler(s) Displays a number of temperature protections of the coolersOil Circuit Displays a number of protections in the oil circuit

WEEK TIMER

Topic Description

Week Action SchemesDisplays 4 programmable week action schemesEach week action scheme contains 7 programmable days and these days cancontain a number of successive events on selected time slots.

Week Cycle Contains 10 weeks and each week can be selected as 1 of the 4 week actionschemes

Status Displays the status (On/Off) of the week timer functionalityRemaining RunningTime

Allows to set a timer to keep the compressor running for 1-240 minutes

INFORMATION

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Topic Description

www.atlascopco.comRefers to the company website where more detailed info on the product can befound

More The More button displays the software versions, addresses, licenses, ...

TEST

Topic DescriptionDrain Test Allows a functionality check of the (optional) electronic water drains

Safety Valve Test Allows a functionality check of the safety valve. (This feature can only beenabled by a service technician.)

COUNTERS

Topic Description

Running hoursDisplays the number of hours the compressor has been running in unloaded &loaded mode

Loaded Hours Displays the number of hours the compressor has been running in loaded modeMotor Starts Displays the number of motor startsLoad Relay Displays the number of load relay toggles (thus unload/load transitions)

Fast Starts Displays the number of manual motor starts that exceed the automatic motorstarts

Fan starts Displays the number of times the fan has been startedModule Hours Displays the number of hours the module has been poweredEmergency stops Displays the number of compressor stops by use of the emergency stop

REGULATION

Topic Description

Unloading pressure 1 The pressure setpoint that is higher than setpoint 1, where the loadedcompressor switches to unload

Loading pressure 1 The pressure setpoint that is lower than setpoint 1, where the unloadedcompressor switches to load

Unloading pressure 2 The pressure setpoint that is higher than setpoint 2, where the loadedcompressor switches to unload

Loading pressure 2 The pressure setpoint that is lower than setpoint 2, where the unloadedcompressor switches to load

Pressure band used Selection of 1st or 2nd pressure band. A pressure band is a combination of aloading pressure, a setpoint and an unloading pressure

Digital pressure bandselection

Allows a remote signal to control the pressure band selection.

INPUTS

Topic DescriptionGeneral Displays a number of general readouts and bipolar statesElement(s) Displays a list of readouts related to the compressor stages

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Topic DescriptionDryer Displays the status of the dryerDrains Displays the status of the drainsMain Motor Displays a number of readouts and bipolar states concerning the main motorNetwork Displays a number of bipolar states of remote signalsCooler Displays a number of cooler temperature readoutsOil Circuit Displays a number of readouts and bipolar states concerning the oil circuit

OUTPUTS

Topic DescriptionGeneral Displays a number of analogue and digital outputsDryer Displays the activation of the dryerDrains Displays the activation of the drainsMain Motor Displays a number of digital outputs concerning the main motor status

SPM (Shock Pulse Method)

Topic DescriptionMotor, drive end Displays the vibration level at the drive end of the motorMotor, non-drive end Displays the vibration level at the non-drive end of the motorLow pressure stage,drive end

Displays the vibration level at the drive end of the low pressure compressorstage

Low pressure stage, non-drive end

Displays the vibration level at the non-drive end of the low pressure compressorstage

High pressure stage,drive end

Displays the vibration level at the drive end of the high pressure compressorstage

High pressure stage,non-drive end

Displays the vibration level at the non-drive end of the high pressurecompressor stage

Gearbox Displays the vibration level at the gearbox

EVENT HISTORY

Topic Description

- Displays a log file of all shutdowns and shows the status of the type, counters,inputs and outputs at the moment a shutdown appeared

SETTINGS

Topic DescriptionNetwork Displays the CAN and ethernet configurationRegulation Displays settings concerning the compressed air flow regulationGeneral Displays settings concerning time, date, unit and display time-outDryer Displays the dryer settingsAccess Key Displays the controller access level that can be modified with password input

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Topic Description

Automatic RestartOnly displayed when compressor motor voltage < 690V and when ARAVF isavailable. Automatic Restart After Voltage Failure can only be enabled by aservice technician.

Access Key Displays the controller access level that can be modified with password input

User Password Displays the availability to use a password to protect the controller fromunwanted manipulation

Main Chart Displays the input and the range of the main chart

Service Displays a list of service settings with values that can only be adjusted by aservice technician.

3.6 Web serverAll Elektronikon controllers have a built-in web server that allows direct connection to the companynetwork or to a dedicated PC via a local area network (LAN). This allows to consult certain data andsettings via a PC instead of the display of the controller.

Getting started

If the compressor is equipped with a SMARTBOX, the network connection of theElektronikon is already in use. To allow the web server functionality, the network cablethat is connected to the SMARTBOX should be unplugged and replaced by the cable ofthe company network.If both the web server functionality and SMARTBOX are required, please contact yourlocal Atlas Copco Customer Center for support.

Make sure you are logged in as administrator.

• Use the internal network card from your computer or a USB to LAN adapter (see picture below).

USB to LAN adapter

• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).

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Configuration of the network card (in Windows XP)• Go to My Network places (1).

• Click on View Network connections (1).

• Select the Local Area connection (1), which is connected to the controller.

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• Click with the right button and select properties (1).

• Use the check box Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, uncheck otherproperties if they are checked. After selecting TCP/IP, click on the Properties button (2) to change thesettings.

• Use the following settings:• IP Address 192.168.100.200• Subnetmask 255.255.255.0

Click OK and close network connections.

Configuration of the web serverConfigure the web interface (for Internet Explorer)

• Open Internet Explorer and click on Tools - Internet options (2).

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• Click on the Connections tab (1) and then click on the LAN settings button (2).

• In the Proxy server Group box, click on the Advanced button (1).

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• In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can begiven but they must be separated with semicolons (;).Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2). Nowyou add 192.168.100.100 and separate the 3 IP addresses by putting semicolons between them (1)(see picture).Click OK (2) to close the window.

Viewing the controller data

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All screen shots are indicative. The number of displayed fields depends on the selectedoptions.

• Open your browser and type the IP address of the controller you want to view in your browser (in thisexample http://192.168.100.100). The interface opens:

Screen shot (example!)

Navigation and options

• The banner shows the compressor type and the language selector. In this example, three languages areavailable on the controller.

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Compressor settingsAll compressor settings can be displayed or hidden. Put a check mark in front of each point of interest andit will be displayed. Only the machine status is fixed and can not be removed from the main screen.

Analog inputs

Lists all current analog input values. The measurement units can be changed in the preference button fromthe navigation menu.

Counters

Lists all current counter values from controller and compressor.

Info status

Machine status is always shown on the web interface.

Digital inputs

Lists all Digital inputs and their status.

Digital outputs

Lists all Digital outputs and their status.

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Special protections

Lists all special protections of the compressor.

Service plan

Displays all levels of the service plan and their status. This screen shot underneath only shows the runninghours. It is also possible to show the current status of the service interval.

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4 Installation

4.1 Dimension drawings

Dimension drawing, ZR Pack

Dimension drawing ZR 55 up to ZR 90 Pack (metric units)

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Dimension drawing ZR 55 up to ZR 90 Pack (imperial units)

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Dimension drawing ZR 55 up to ZR 90 Pack, with Energy Recovery (metric units)

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Dimension drawing ZR 55 up to ZR 90 Pack, with Energy Recovery (imperial units)

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Dimension drawing, ZR Full-Feature

Dimension drawing ZR 55 up to ZR 90 Full-Feature (metric units)

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Dimension drawing ZR 55 up to ZR 90 Full-Feature (imperial units)

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Dimension drawing ZR 55 up to ZR 90 Full-Feature, with Energy recovery (metric units)

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Dimension drawing ZR 55 up to ZR 90 Full-Feature, with Energy recovery (imperial units)

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Dimension drawings, ZT Pack

Dimension drawing ZT 55 up to ZT 90 Pack (metric units)

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Dimension drawing ZT 55 up to ZT 90 Pack (imperial units)

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Dimension drawing, ZT Full-Feature

Dimension drawing ZT 55 up to ZT 90 Full-Feature (metric units)

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Dimension drawing ZT 55 up to ZT 90 Full-Feature (imperial units)

Text on drawing

Ref Name(1) Voltage supply entry(2) Compressed air outlet(3) Cooling air outlet(4) Opening for transportation(5) 4 slotted holes only for horizontally pulling unit out of container

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Ref Name(6) Cooling air inlet(7) Hole pattern ducting(8) Automatic drain, aftercooler(9) Automatic drain, intercooler(10) Compressed air outlet, compensator(11) Mass(12) Water in/out compensator(13) Water out(15) Automatic drain, dryer inlet(16) Automatic drain, regeneration air outlet(17) Automatic drain, dryer outlet(18) Cooling Full-Feature air outlet(19) Cooling Full-Feature air inlet(20) If option: Prepared for MD(21) Cable box included for EC variants(22) Cable box not included for CSA/UL variants(23) Automatic drain, regeneration outlet(24) Low load drain (optional)(25) Automatic drain, extra aftercooler

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4.2 Installation proposals

Installation proposal, ZR Pack (with Energy recovery) or Full-Feature

Installation proposal ZR 55 up to ZR 90 Pack (with Energy recovery) or Full-Feature (in metric units)

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Installation proposal ZR 55 up to ZR 90 Pack (with Energy recovery) or Full-Feature (in imperial units)

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Installation proposal, ZR Full-Feature with Energy recovery

Installation proposal ZR 55 up to ZR 90 Full-Feature with Energy recovery (in metric units)

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Installation proposal ZR 55 up to ZR 90 Full-Feature with Energy recovery (in imperial units)

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Installation proposal, ZT Pack

Installation proposal ZT 55 Pack up to ZT 90 Pack (in metric units)

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Installation proposal ZT 55 Pack up to ZT 90 Pack (in imperial units)

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Installation proposal, ZT Full-Feature

Installation proposal ZT 55 up to ZT 90 Full-Feature (in metric units)

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Installation proposal ZT 55 up to ZT 90 Full-Feature (in imperial units)

Text on figures

Ref Name(1) Minimum free area to be reserved(2) Ventilation proposal(3) Cooling air outlet(4) Cooling air inlet(5) Cooling Full-Feature air outlet

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Ref Name(6) Cooling Full-Feature air inlet

Description

Ref Description1 Install the compressor on a level floor suitable for taking the weight of the compressor.

Recommended minimum distance between the top of the bodywork and the ceiling:1200 mm (46.80 in).

2 Remove the plastic plug or cap (if provided) from the compressor air outlet pipe andinstall 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:dp = (L x 450 x Qc1.85) / (d5 x P)

• dp = pressure drop (recommended maximum = 0.1 bar)• L = length of outlet pipe in m• d = inner diameter of the delivery pipe in mm• P = absolute pressure at the compressor outlet in bar(a)• Qc = free air delivery of the compressor in l/s

The connection of the compressor air delivery pipe should be made on top of the mainair net pipe to minimize carry-over of possible remainder of condensate.

4 The inlet grids and ventilation fan should be installed in such a way that anyrecirculation of cooling air to the compressor is avoided.The air velocity to the grids should be limited to 5 m/s (195 in/s).The required ventilation capacity (per compressor installed) to limit the compressorroom temperature can be calculated as follows:On ZR compressors: Qv = 0.1 N / dTOn ZT compressors: Qv = 0.92 N/ dT

• Qv = required ventilation capacity in m3/s• N = shaft input of the compressor in kW• dT = temperature rise over ambient in ˚C

If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is30 Pa. Common ducting for several compressors is not allowed.

5 Lay out the drain piping from automatic condensate outlets (EWD) towards thecondensate collector. The drain pipes must not dip into the water of the collector. It isrecommended to provide a funnel to allow visual inspection of the condensate flow.

6 Elektronikon control system with control panel.7 See Electric cables for the recommended cable size of the supply cables. Check that

the electrical connections correspond to the local codes. The installation must beearthed and protected against short circuits by fuses in all phases. An isolating switchmust be installed near the compressor.

8 Provide a condensate drain valve in the lowest part of the pipe between the compressoroutlet valve and the air net.

9 Remove the plastic plugs (if provided) from the compressor water pipes and connect thepipes to the cooling water circuit. Provide a valve in the compressor water inlet pipe andoutlet pipe.

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4.3 Installation requirements for rubber compensators

Types and sizesAtlas Copco oil-free air products with aftercooler are equipped with rubber compensators on the air outletand water connections.

Types of misalignmentsThe supplied compensators can cope with 2 types of minor misalignments when the customer pipe end ismounted:

• Axial ΔL• Lateral ΔR

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Drawing reference DescriptionA Atlas Copco compressor pipe endB Customer installation pipe end

Angular misalignments Δα are NOT allowed!

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Misalignment tolerances• Single direction misalignments

Axial 1: ΔL mm 20Axial 1: ΔL in 0.8Lateral: ΔR mm 20Lateral: ΔR in 0.8Δα2 ° 0

1 = stretch or compression2 = NO angular misalignment is tolerated!

• Combined direction misalignments

Drawing reference Description(1) Compression(2) Stretch

Do NOT operate outside of the black polygon.

Do NOT exceed the misalignment tolerances to avoid compensator damage! The pipingsystem of the customer should be designed to fit the misalignment tolerances both duringstandstill and operation.

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Temperature correction factors

Medium temperature(°C)

Medium temperature(°F)

Correction factor for maximum working pressure ofthe compensator

0 32 150 122 180 176 185 185 0.9290 194 0.8395 203 0.75100 212 0.67105 221 0.6110 230 0.54

Torque valuesCompensator bolts should be torqued in 3 successive steps

• Step 1: Hand-tighten each bolt.• Step 2: Torque the bolts crosswise up to the value mentioned in the table below and allow a

stabilization period of 30 minutes before moving to step 3.• Step 3: Torque the bolts crosswise up to the value mentioned in the table below.

• Mind the parallelism of the sealing.• Excessive torque will damage the sealing.

DN(mm)

DN(inch)

Step 1 Step 2(Nm)

Step 2(lbfin)

Step 3(Nm)

Step 3(lbfin)

20 – 80 2 – 3 hand tight 50 443 80 708100 – 300 4 – 12 hand tight 50 443 100 885350 – 500 14 – 20 hand tight 50 443 130 1551

Do's and don'tsThe supplied compensators are NOT designed:

• to carry the weight of the mounted customer pipe end.• to work as a damper for unanchored pipe ends.• to carry the thrust forces of the compressed air.

Therefore, adequate supporting and anchoring of the customer pipe end should be foreseen to avoidcompensator damage.

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The compensator loads (Fg and Ft) that are mentioned on the drawing are strictly forbidden:• Weight loads Fg• Thrust forces Ft

For the design of piping and supporting structures, use an approved standard code (e.g. EN 13480 orASME 16.5/B31.3).

Mind that the connected pipe at customer side does not create any flow restrictioncaused by e.g. section reduction.

While installing the compensator, please mind the following check points to avoid sealing damage.

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Situation DescriptionA Flat DIN flanges prevent damage of the rubber sealings.B Collared flanges prevent premature wear.C Add a flat sealing or if necessary a metal disc with flat seal in case of damage risk.D Avoid excessive torque to prevent damage to the bended pipes or the sealings.

ERubber sealings will get damaged when the inner pipe diameter exceeds the inner sealingdiameter.

F Rough pipe ends will damage the rubber sealing.G Avoid contact between the pipe end and the rubber sealing.

Refer to the pictures below for a visual overview of 5 do's and don'ts when installing rubber compensators:• WRONG installation!

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• CORRECT installation!

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Drawing reference Description(1) Larger than maximum allowed installation length.(2) Less than or equal to maximum allowed installation length(3) Minimum 1 mm of free space

Do NOT:• Paint the rubber bellows of the expansion joint since:

• Solvents can damage the rubber cover.• The colored coating avoids decent visual inspection of the rubber condition.

• Weld, cut or grind without protecting the rubber bellows• Expose the compensator to permanent radiation heat above 90 °C (194 °F)

4.4 Electric cables

Remarks

• The cable sizes below are applicable for the MAINS + EARTH CABLE• The cable size is valid at maximum ambient temperature of 40 ˚C.

The cable size is valid at maximum ambient temperature of 104 ˚F.IEC compressors

• Cables calculated according to IEC 60364-5-52• Mounting type: E (Multicore cables in free air)• Multiple circuit arrangement:• 4 (Perforated cable tray)• For standard 40 °C ambient temperature units: Use 70 °C (158 °F) cables (Type

H07V-K)• For HAT 50 °C ambient temperature compressors use 90 °C (194 °F) cables (Type

H07V2-K)CSA/UL compressors

• Cables calculated according to CEC C22.1/NFPA 70• Multicore cables on perforated tray or ladder system• Use 90 °C (194 °F) cables (Type R90, RW90, T90)

The voltage drop must not exceed 10% of the nominal voltage. It may be necessary touse cables with a larger size than those stated to comply with this requirement.

50 Hz IEC

Model Voltage Cables STD 40°C Cables HAT 50°C Cablelugs

Maximumcable

length (m)

MCAline*

ZR/ZT 55 200 V 3x150mm²+95mm² 3x185mm²+95mm² M8 150 271 A



ZR/ZT 55 500 V 3x70mm²+35mm² 3x95mm²+50mm² M8 150 112 AZR/ZT 55 690 V 3x70mm²+35mm² 3x95mm²+50mm² M8 150 80 A

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Maximumcable

length (m)

MCAline*






ZR/ZT 90 200 V 2x(3x150mm²+95mm²)

3x240mm²+120mm² M10 150 420 A





* MCA line = Minimum Circuit Ampacity of the line current

60 Hz IEC

Model Voltage Cables STD 40°C Cables HAT 50°C Cable lugs

Maximum cablelength

(m)

MCAline*


ZR/ZT 55 220-230 3x150mm²+95mm² 3x185mm²+95mm² M8 150 269 A




ZR/ZT 75 220-230 3x240mm²+120mm² 3x240mm²+120mm² M10 150 352 A



ZR/ZT 90 200 V 2x(3x150mm²+95mm²)

2x(3x185mm²+95mm²) M10 150 449 A

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Model Voltage Cables STD 40°C Cables HAT 50°C Cable lugs

Maximum cablelength

(m)

MCAline*

ZR/ZT 90 220-230 2(x3x150mm²+95mm²)

2x(3x185mm²+95mm²) M10 150 415 A




60 Hz CSA/UL


Maximum cablelength

(m)

MCAline*

ZR/ZT 55 460 V 3xAWG4/0+AWG4 3xMCM250+AWG3 M8 150 130 AZR/ZT 55 575 V 3xAWG4/0+AWG6 3xMCM250+AWG4 M8 150 103 AZR/ZT 75 460 V 3xMCM300+AWG3 3xMCM350+AWG3 M8 150 172 AZR/ZT 75 575 V 3xAWG4/0+AWG4 3xMCM250+AWG4 M8 150 136 AZR/ZT 90 460 V 3xMCM300+AWG2 3xMCM350+AWG2 M8 150 200 AZR/ZT 90 575 V 3xMCM300+AWG4 3xMCM350+AWG4 M8 150 160 A


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4.5 Electric connections

Example of electric cabinet

Electric connections ZR/ZT 55 up to ZR/ZT 90

Ref NameF3/4 Circuit breakers, control circuitF17 Circuit breaker for electronically controlled automatic condensate drainsF21 Overload relay, drive motorK11 Auxiliary relay, loadingK21 Line contactorK22 Star contactorK23 Delta contactorQ1 Circuit breakerT1 Main transformerT2 Transformer, control circuit1X0 Power supply terminals1X4/5/6/7 Terminal strips

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Electric diagram

Electric diagram Z 55-90 YD MK5

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Electric diagram Z 55-90, No motor, MK5

Reference Name(1) Customer's Installation(2) Compressor motor(3) Drive motor(4) Use the Lock out Tag out procedure to de-energize the machine for maintenance(5) 3 Fuses in case of bridges between K21 and K23(6) 6 Fuses(7) Customer motor starter

4.6 Quality of safety componentsWhen installing a remote emergency button or a motor contactor, the following B10d values are advised:

• Emergency stop button: 500 000• Main contactor: 1 333 333

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4.7 Cooling water requirements

RecommendationsThe 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.

Only non-treated water must be used.

This recommendation is a general guide line for acceptable coolant quality.

Type of systemIt is important to define the used cooling water system:

• an open system• a closed system

In a closed system, the same cooling water circulates through a system without contact with air.

An open system is a pass-through system, or a circulating system with a cooling tower. In the latter case,the composition of the water that enters the compressor must be considered, and not the composition of themake-up water. Due to the evaporative effect in the cooling tower, much higher concentrations of ions canbe obtained in the circulating water than in the make-up water.

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

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

The Ryznar Stability Index is calculated as follows :

RSI = 2*pHs - pH

Symbol ExplanationpH Measured pH (at room temperature) of water samplepHs pH at saturation

The pHs is calculated by using :

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

Symbol ExplanationA Depends on the total solids concentration (mg/l)B Depends on the highest cooling water temperature (˚C/˚F), (T=65 ˚C/149 ˚F)C Depends on the calcium hardness (ppm CaCO3)

D Depends on the HCO3- concentration or M-alkalinity (mval/l)

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The values of A, B, C and D can be found in the following table.

Total dissolvedsolids (mg/l)

A Temperature(˚C)

B Ca-hardness (ppmCaCO3)

C M-alkalinity (mval/l) D

50 - 300 0.1 0 - 1 2.6 10 - 11 0.6 0.20 - 0.22 1.0400-1000 0.2 2 - 6 2.5 12 - 13 0.7 0.24 - 0.26 1.1 7 - 9 2.4 14 - 17 0.8 0.28 - 0.34 1.2 10 - 13 2.3 18 - 22 0.9 0.36 - 0.44 1.3 14 - 17 2.2 23 - 27 1.0 0.46 - 0.54 1.4 18 - 21 2.1 28 - 34 1.1 0.56 - 0.70 1.5 22 - 27 2.0 35 - 43 1.2 0.72 - 0.88 1.6 28 - 31 1.9 44 - 55 1.3 0.90 - 1.10 1.7 32 - 37 1.8 56 - 69 1.4 1.12 - 1.38 1.8 38 - 44 1.7 70 - 87 1.5 1.40 - 1.76 1.9 45 - 50 1.6 88 - 110 1.6 1.78 - 2.20 2.0 51 - 56 1.5 111 - 138 1.7 2.22 - 2.78 2.1 57 - 63 1.4 138 - 174 1.8 2.80 - 3.54 2.2 64 - 71 1.3 175 - 220 1.9 3.54 - 4.40 2.3 72 - 80 1.2 230 - 270 2.0 4.6 - 5.4 2.4 280 - 340 2.1 5.6 - 7.0 2.5 350 - 430 2.2 7.2 - 8.8 2.6 440 - 550 2.3 9.0 - 11.0 2.7 560 - 690 2.4 11.2 - 13.8 2.8 700 - 870 2.5 14.0 - 17.6 2.9 880 - 1000 2.6 17.8 - 20.0 3.0

Interpretation of the value obtained

RSI Water condition ActionRSI<3.9 Very high scale formation Water cannot be used.4.0<RSI<5.5 High boiler scale formation Regular inspection and descaling operation

necessary.5.6<RSI<6.2 Slight boiler scale formation Water treatment not necessary.

Occasional inspection recommended.6.3<RSI<6.8 Neutral water Water treatment not necessary.

Occasional inspection recommended.6.9<RSI<7.5 Slight corrosion at higher

temperatureWater treatment not necessary.Occasional inspection recommended.

7.6<RSI<9.0 Strong corrosion Regular inspection necessary, use of corrosioninhibitor recommended.

9.1<RSI<11 Very strong corrosion Regular inspection necessary, use of corrosioninhibitor required.

RSI>11 Very strong corrosion incomplete water system

Water should not be used.

The table indicates that distilled or demineralized water should never be used, as their RSI is > 11.

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The RSI only indicates the equilibrium of scaling - descaling. A cooling water showing good RSIconditions can still be unsuitable due to other factors.

From the table above, the RSI index should be between 5.6 and 7.5; if not, consult your local Atlas CopcoCustomer Centre.

pHThe effect of pH is already calculated in the Ryznar index, but the pH itself has some additionallimitations : 6.8 < pH < 8.5

Total Dissolved Solids (TDS)This is the sum of all the ions in the water. It can be derived from the dry residue after evaporation (but notincluding suspended solids), or it can be estimated from the electrical conductivity.

In a closed system, the following limits apply : TDS < 3000 mg/l (< 3800 microS/cm)

For an open system, the following limits apply : TDS < 750 mg/l ( < 960 microS/cm)

Chlorides (Cl-)Chloride ions will create pitting corrosion 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)

A level of 0.5 ppm should not be exceeded for long periods.

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 hardnessClosed cooling system : 50-1000 ppm CaCO3

Open cooling system : 50-500 ppm CaCO3

HCO3- / SO4

2- should be > 1

Ammonia< 0.5 ppm

Copper< 1 ppm

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Iron and manganese< 1 ppm

OrganicsNo algae

No oil

Suspended solidsNon-soluble particles, size < 1 mm.

< 10 ppm

4.8 Pictographs

Explanation of pictographs

Reference Name1 Alarm2 Service3 Automatic operation4 Voltage on5 Enter6 Escape7 Scroll keys8 Stop9 Start

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Ref Name8 Automatic condensate outlet, intercooler9 Automatic condensate outlet, aftercooler10 Warning: under tension11 Read Instruction book before starting the compressor12 Switch off the voltage and depressurize the compressor before maintenance or repair13 Before connecting the compressor electrically, consult the Instruction book for the motor

rotation direction14 Torques for steel (Fe) or brass (CuZn) bolts15 Consult the Instruction book before greasing16 Switch off the voltage before removing the protecting cover inside the electric cabinet17 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn)18 Consult the Instruction book before maintenance or repair19 Cooling water inlet20 Cooling water outlet

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Additional pictographs on Full-Feature compressors

Reference Name1 Arrow, indicating rotation direction2 Warning, voltage3 Instruction for delta P reading

Purge internal impulse line before any reading of delta P on U-tube (close isolationvalves of U-tube)

4 Indication for correct adjusting of the U-tube water level

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5 Operating instructions

5.1 Operation introduction

Warning

The operator must apply all relevant “Safety precautions”.

Ambient conditionsConsult “Limits” for the limits with regard to the ambient conditions and altitude operation.

Moving/liftingIn order not to damage the frame, the compressor must be moved either by a lift truck or by using liftingequipment as described below.

When moving the compressor with a lift truck, use the slots in the frame. Make sure that the forks protrudefrom the other side of the frame. When moving the compressor with a lifting device, insert beams in theslots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chainsmust be held parallel to the bodywork by chain spreaders in order not to damage the compressor. Thelifting equipment must be placed in such a way that the compressor is lifted perpendicularly. Lift gentlyand avoid twisting.

5.2 Initial start-up

Procedure• Consult Electric cables, Installation proposals and Dimension drawings.• A sticker dealing in short with the operation instructions is delivered with the literature set. Affix the

sticker next to the control panel.• A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect

the compressor against corrosion. Remove the plates.• The compressor and motor are secured to the frame immobilizing the vibration dampers during

transport:• At the motor side, loosen nut (1), remove bolts (2) and turn bracket (3) 90˚. Tighten nut (1).

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• On ZR compressors, remove support (1) at the gear casing side.

• On ZT compressors, remove bolts (1) and supports (2) immobilizing the vibration dampers ofthe coolers. Remove support (3), immobilizing the vibration dampers of the gear casing.

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• Remove flange (1) and take out the silica gel bags installed in the intercooler at the condensate drainreceiver side. Refit the flange.

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Position of silica gel bags on ZT compressors

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Position of silica gel bags on ZR compressors

• On Full-Feature compressors with Low-Load option and Full-Feature ND compressors, the nozzletype depends on the working pressure. Install the correct nozzle according to the table below.

Compressor Nozzle at 4 bar (58psi)

Nozzle at 7 bar(102 psi)

Nozzle at 8.6 bar(125 psi)

Nozzle at 10 bar(145 psi)

Z 55 FF 1617 7572 00 1617 7571 00 1617 7571 00 1617 7571 00Z 75 FF 1617 7573 00 1617 7571 00 1617 7571 00 1617 7571 00Z 90 FF 1617 7440 00 1617 7572 00 1617 7572 00 1617 7571 00

• The setpoint of the dryer heater depends on the working conditions, consult the Atlas CopcoCustomer Centre to have the setpoint adjusted.

• On ZR compressors, fit the water drain plugs (1, DP1, DP2, DP3) that are fixed to the water pipe ofone of the compressor elements (Eh, El) in a plastic bag. The plugs are painted green and theirpositions are shown below.

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• On ZR compressors, check that the cooling water drain valves (customer's installation) in the inletand outlet lines are closed. Open the water inlet valve and outlet valve (customer's installation) andcheck for water flow.

• On ZR Full-Feature, the inlet and outlet valves of the cooling water circuit of the regeneration coolermust be opened completely.

• Check that the gear casing is filled with oil: the level should be in the middle of sight-glass (SG).

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• Check that the electrical connections correspond to the local codes. The installation must be earthedand protected by fuses in all phases. An isolating switch must be provided.

• Check the connections at the primary sides of transformers (T1 and T2).

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• Switch on the voltage. Start the compressor and stop it immediately. Check for correct direction ofrotation while the motor is coasting to a stop. An arrow on the gear casing indicates the correctrotation direction. If the rotation direction is wrong, switch off the voltage and reverse two incomingelectric lines.

• On ZT compressors, remove panel (1) and check the rotation direction of the fan motor. If the rotationdirection is wrong, switch off the voltage and reverse two connections at terminals 221 up to 226 ofterminal strip (1X1).On ZT Full-Feature compressors, also check the rotation of the fan motor of the regeneration cooler(Cr), the correct rotation direction is indicated by an arrow on the fan motor.

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• Run the compressor for a few minutes and check that it operates normally.• Stop the compressor. If necessary, top up the gear casing with oil to the middle of sight-glass (SG).

Adjustment of the pressure difference of the dryer compartments1. Start and load the compressor2. Check the rotation direction of the dryer motor, the correct rotation direction is indicated by an arrow

on the motor housing.3. Close valves 1 and 2. Fill a transparent tube halfway with water. Install the tube to the valves. Open

the valve marked (-), slightly open the valve marked (+), while watching the water levels in the U-tube.Two conditions are possible:

• The water level in the leg marked (+) rises. Close the valve at once, decrease the regeneration airinlet pressure as described in step 4. Do this as often as necessary, until the water level drops.

• The water in the leg marked (-) rises, which should normally be the case. If the level in this legrises 30 mm (1.17 in) above the level in the leg marked (+), close the valve at once as there is arisk that the water will be ejected from the U-tube and dissappear into the pressure vessel.Increase the regeneration air inlet pressure as described in step 4 and open the valve again.

4. Once the water column has stabilized, adjust the pressure difference as follows:• Remove the protecting cap from the adjusting screw.

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• Loosen the check nut and turn the screw in to increase or out to decrease the pressuredifferential.The water level in the leg marked (-) must be bedween 20 and 40 mm (0.78 and 1.56 in) abovethat in the leg marked (+).

• Monitor the water level for about 10 minutes.

5. Stop the compressor.

Adjustment of the pressure difference of the dryer compartments

Delta P indicator

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View of PDP sensor

View of throttle valve

To start up the unit for the first time or after a long period of standstill, proceed as follows:

1. Check if U-tube is filled halfway with water. If not, continue as follows:• Close the valves (9 and 10) and open valve (6).• Remove the plugs (8) of the two vent valves (7) of the delta P indicator and open the valves.• Fill the U-tube halfway with water, close the valves (7) and refit the plugs.

2. On compressors equipped with a PDP sensor, close valve (11) to this sensor.3. For dryers with low load option: Check that circuit breaker (F 32, compressor cubicle) is in the "I"

position.4. Close the manual drain valve of the aftercooler drain trap of the compressor.5. On ZR compressors, check for water flow.6. Switch on the voltage at the mains.

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7. Start and load the compressor.8. Open the valve (if installed) to the air net or air receiver and blow off some air from the air net to

keep the compressor running loaded.9. Open valves (9 and 10). Open valve (6) slightly, while monitoring the water levels in the U-tube.

There are two possible conditions:• The water level in the leg marked (+) rises. Close valve (6) at once, decrease the regeneration air

inlet pressure (see next step). Do this as often as necessary until the water level drops.• The water level in the leg marked (-) rises, which should normally be the case. If the level in this

leg rises 30 mm above the level in the leg marked (+), close valve (6) at once, as there is a riskthat the water will escape the U-tube and disappear into the pressure vessel. Increase theregeneration air inlet pressure (see next step) and open valve (6) again.

10. Once the water column has stabilised, adjust the pressure differential as follows:• Remove the protective cap from the adjusting screw of throttle valve (12).• Loosen its check nut (13) and turn the screw to alter the pressure differential.• Monitor the water level for about 10 minutes.• Tighten the check nut and reinstall the protective cap.

11. Check the dryer connections for air leaks.12. On compressors equipped with a PDP sensor, open valve (11) to the PDP sensor 15 minutes after the

dryer is in operation.13. Check that the pressure dewpoint is OK after 1 hour.14. Close the blow-off valve of the air net, unload and stop the compressor. Close the air outlet valve of

the dryer.15. Switch off the voltage.16. Depressurize the dryer, see section Maintenance instructions.

5.3 Before starting

Safety

The operator must apply all related “Safety precautions”.In case the water system was drained, close the drain valves and fit the drain plugs.

Procedure

Step Action1 Check the oil level, which must be in the middle of sight-glass (SG). Top up, if

necessary, with the correct type of oil.2 Open the water inlet valve and outlet valve (customer's installation). Opening of the

water outlet valve can be overlooked if, after previous operation, the setting of this valvehas not been disturbed.

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Position of oil sight-glass on ZR compressors

Position of oil sight-glass on ZT compressors

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5.4 Routine starting

Control panel

Control panel of Elektronikon GraphicPlus controller

Procedure

Step Action1 Open the air outlet valve (customer's installation).2 Switch on the voltage and check that voltage on LED (8) lights up.3 Press start button (14). The compressor starts running in unloaded condition and

automatic operation LED (7) lights up.4 Approx. 25 seconds later (programmable), the compressor starts running loaded.

See section Readings for the cooling water temperature.See section Compressor data for the cooling water consumption.

If the motor is stopped and automatic operation LED (7) is alight, the motor may startautomatically.If the start/stop timer is active, the compressor can start automatically, even if it wasstopped manually.

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5.5 During operation

Control panel

Control panel of Elektronikon GraphicPlus controller

Procedure

When automatic operation LED (7) is alight, starting and stopping of the motor isautomatically controlled: when the motor is stopped, it may restart automatically.

Step Action1 Check the readings on display (1).2 When reaching the preset unloading pressure, shown on display (1), the compressor will

start running unloaded. From now on, the electronic control module will calculate theoptimum moment to stop and restart the compressor motor automatically, depending onthe maximum permissible number of motor starts and on the air consumption.

3 To unload the compressor manually, select Unload on the display using the cursor keysand press the Enter key.To put the compressor back into automatic operation, select Load on the display usingthe cursor keys and press the Enter key.

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5.6 Stopping

Control panel

Procedure

Position of water drain plug on LP compressor element

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Position of water drain plug on HP compressor element

Position of water drain plug of oil cooler

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Position of water drain plugs of cooler block

Frequently stopping the compressor using the emergency stop button may damage thecompressor, only use the emergency stop button in case of emergency.

Step Action1 Press the test button on top of the electronic water drains while the compressor is

running loaded.2 Press stop button (13): the compressor will stop and LED (7) will go out.3 Close the air outlet valve.4 To stop the compressor immediately, press emergency stop button (S2).5 Close the cooling water inlet valve.6 If the compressor is installed in a room where freezing temperatures are expected, drain

the cooling system completely:• By opening the main drain valves in the water inlet and outlet pipes (customer's

installation).• By removing drain plug (1) underneath the LP compressor element (El).• By removing drain plug (1) underneath the HP compressor element (Eh).• By removing drain plug (DP1) on the oil cooler.• By removing drain plugs (DP2 and DP3) underneath the cooler block (1).

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5.7 Taking out of operation

Procedure

Step Action1 Close the air outlet valve and stop the compressor.2 Switch off the voltage.

Disconnect the compressor from the mains.3 Shut off and depressurize the part of the air net which is connected to the outlet valve.

Disconnect the compressor air outlet pipe from the air net.4 Drain oil and condensate circuits.5 Disconnect the compressor condensate piping from the condensate drain net.

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6 Maintenance

6.1 Maintenance warnings

Warnings

Before starting any maintenance or repairs:• Stop the compressor. Close the air outlet valve.• Press the test buttons on top of the electronic water drains to depressurize the air

system.• Press the emergency stop button (S2).• Open the isolating switch (customer's installation) to switch off the voltage to the

compressor.

Warranty-Product LiabilityUse only Atlas Copco authorized genuine parts. Any damage or malfunction caused by the use ofunauthorized parts is not covered by Warranty or Product Liability.

6.2 Preventive maintenance schedule

Regular service operationsTo ensure safe operation and long service life, carry out following operations at the interval (period orrunning hours) which comes first. The "longer interval" checks must also include the "shorter interval"checks.

The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on theenvironmental and working conditions of the compressor.

Period Running hours Operation-- At initial start Check the pressure differential of the rotor

compartments of the integrated dryer. Adjust ifnecessary.

Daily 8 Check readings on display.Daily 8 Check that condensate is discharged during

loading.Daily -- Check oil level. Before starting, the level should

be in the middle of the sight-glass.Weekly 50 Check that the moisture indicator of the

integrated dryer shows blue.Weekly -- Drain condensate from the air receiver, if installedMonthly -- On Full-Feature ND compressors and Full-

Feature compressors with Low load option, checkthat air is purged from the low load system. Cleannozzle if necessary.

3-monthly -- Clean compressor.3-monthly -- Check for possible leaks.

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Period Running hours Operation3-monthly 500 Check coolers, clean if necessary.Yearly -- On compressors with Low Load option, check

nozzle and solenoid valve of the purge assembly.2-yearly 16000 Replace the demister sponge of the integrated

dryer.When displayed -- Carry out the service actions according to the

displayed service plans.

6.3 Service kits

Service kitsThe Customer Centres will be glad to provide you with a wide range of service kits. Service kits compriseall parts needed for servicing components and offer the benefits of genuine parts while keeping themaintenance budget low. All service kits are mentioned in the relevant Parts Lists.

6.4 Service agreements

The Customer Centres have a range of service agreements to suit your needs:

• An Inspection plan.• A Preventive maintenance plan.• A Total responsibility plan.

Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure optimumoperational efficiency, minimize downtime and reduce the total life cycle costs.

6.5 Service plan

A number of service operations are grouped (called Level A, Level B, Level C, ...). Each level stands for anumber of service actions to be carried out at the time intervals programmed in the controller.

When reaching a level, a message will appear on the screen. After carrying out all service actions, theinterval timers are to be reset using the key "Reset" in menu "Service". Consult your Customer Centre.

6.6 Motor greasing

Fan motor of ZT compressorsThe bearings of the fan motor are greased for life. Contact your Customer Center for the replacementinterval of the motor bearings.

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Drive motor (M1) of ZR compressor

Drive motor (M1) of ZT compressor

Motor grease

Stop the compressor and follow the LOTO procedure (Lock Out - Tag Out) (refer toGeneral Safety Precautions) before greasing.

Do not mix greases of different types.

Instruction book

2920 1849 00 125

Main motor bearings

Refer to the motor re-greasing data plate for the recommended grease type, greasing quantity and intervalfor the motor bearings.

Fan motor bearings of ZT compressors

The bearings of the fan motor are greased for life.

6.7 Oil specifications

Oil typeUse Atlas Copco Roto-Z oil which has been specially developed for oil-free rotary compressors. This oilhas a long service life and ensures optimum lubrication.

Never mix oils of different brands or types.

Atlas Copco Roto-Z oilAtlas Copco Roto-Z oil can be ordered in following quantities:

Quantity Ordering number5 l can1.32 Us gal can1.10 Imp gal can0.18 cu.ft can

2908 8503 00

20 l can5.28 Us gal can4.40 Imp gal can0.70 cu.ft can

2908 8501 01

209 l drum55.18 Us gal drum45.98 Imp gal drum7.32 cu.ft drum

2908 8500 00

6.8 Storage after installation

Run the compressor, e.g. twice a week, until warm.

If the compressor is going to be stored without running from time to time, protective measures must betaken. Consult Atlas Copco.

Instruction book

126 2920 1849 00

7 Servicing procedures

7.1 Air filter (AF)

Procedure

Step Action1 Stop the compressor and switch off the voltage to the compressor.2 Remove the filter.3 Fit the new filter.4 After carrying out the service actions of the related service plan, the service warning

must be reset. See also “Preventive maintenance schedule”.

7.2 Oil and oil filter change

Control panel

Instruction book

2920 1849 00 127

Oil system components, ZR

Oil system components, ZT

Instruction book

128 2920 1849 00

Procedure

Step Action1 Run the compressor until warm.2 Press stop button (1), wait until the compressor has stopped, press emergency stop

button (S2) and switch off the voltage to the compressor.3 Remove filler plug (FC). Drain the compressor sump by opening drain valve (Dmo).

Close the valve after draining.Drain the oil cooler by removing its drain plug and vent plug.

4 Remove the oil filter (OF). Clean the filter seat, oil the gasket of the new filter and screwit into place until the gasket contacts the seat. Then tighten by hand.

5 Fill the compressor sump to the middle of the oil level sight-glass (SG) with oil asspecified in “Oil specifications”. Reinstall the filler plug.

6 Switch on the voltage. Unlock the emergency stop button.7 Run the compressor for a few minutes. Stop the compressor. If necessary, top up the

gear casing with oil to the middle of the sight-glass (SG).8 After carrying out the maintenance operations of the related service plan, the service

warning must be reset. See also “Preventive maintenance schedule”.

7.3 Safety valves

TestingThe valves can be tested on a separate compressed air line. If a valve does not open at the pressurespecified in “Settings of safety valves”, consult Atlas Copco.

• Never run the compressor without safety valves.• No adjustments are allowed.

Instruction book

2920 1849 00 129

8 Problem solving

8.1 Faults and remedies

Warnings

• Before starting any maintenance or repairs, stop the compressor, wait until it hasstopped.

• Close the air outlet valve and press the test button on top of the electronic waterdrains to depressurize the air system.

• Open the isolating switch (customer's installation) to switch off the voltage to thecompressor.

• Apply all relevant “Safety precautions”.

Problem solving, compressor

Condition Fault RemedyCompressor capacity or workingpressure lower than normal

Air consumption exceedscapacity of compressor

Check pneumatic plant

Safety valves leaking Remove leaking valve and have itinspected

Oil pressure too low Oil level too low Top up level to the middle of the oillevel sight-glass

Oil filter clogged Replace filterAir temperature above normal Inlet temperature too high due to

bad room ventilation orrecirculation of cooling air

Improve ventilation of compressorroom and avoid cooling airrecirculation

Air filter clogged Replace filterCondensate is not dischargedfrom condensate traps duringoperation

Discharge flexible clogged Check and correct as necessary

Electronic water drainmalfunctioning

Consult Atlas Copco

LED's of electronic water drain donot light up

Compressor is running unloaded LED's will light up when thecompressor is loaded again.

Power supply to EWD's faulty Check power supply. Comparepower supply with voltagementioned on data label of EWD

Power supply board defective Check and replace as necessaryNo condensate discharged whenpressing test button on EWD

System pressure lower than 0.8bar(e)/11.6 psig

Load the compressor; as soon asthe system pressure exceeds 0.8bar(e), condensate will bedischarged

Condensate inlet and/or outletblocked

Check and correct as necessary

Control board defective Check and replace if necessary Solenoid valve defective Check and replace if necessary

Instruction book

130 2920 1849 00

Condition Fault RemedyCondensate only dischargedwhen test button is pressed

Sensor dirty Clean sensor

Air pressure below minimumpressure

Increase air pressure

EWD continuously discharges air Control air blocked Check and correct as necessary Sensor dirty Clean sensor

Problem solving, dryer

Condition Fault RemedyPressure dewpoint too high Compressor loading periods

repeatedly too shortTake necessary action to increaseduration of loading periods

Incorrect pressure differencebetween dryer compartments

Check pressure difference whichshould be within the range specifiedin section Initial start-up. Neveroperate the dryer with a pressuredifference beyond the specifiedrange. Always be sure that theconnections of the U-tube areairtight

Operating pressure too low Do not operate dryer at a pressureless than 4 bar(e)

Rotor does not turn Consult Atlas Copco Rotor compartment sealing ring,

sealing sectors and rotor needinspection

Consult Atlas Copco

Aftercooler air outlet temperaturetoo highRegeneration cooler air outlettemperature too high

Regeneration cooler air outlettemperature too low

Consult Atlas Copco

Drain system malfunctioning Inspect system and replace partswhere necessary

Dryer air inlet temperature ishigher than aftercooler air outlettemperature

Regeneration cooler air outlettemperature too high

Regeneration cooler cloggedinternally

Consult Atlas Copco

Regeneration air inlettemperature too low

Hot-air shut off valve closed Open the valve

Compressor loading periods tooshort

Take necessary action to increaseduration of loading periods

Nozzle of ejector partlyobstructed

Remove and clean nozzle.Investigate cause

Instruction book

2920 1849 00 131

9 Principal data

9.1 Readings on display

Display

The readings below are indicative values when operating at reference conditions.Check the section Reference conditions. These values are no rejection limits. Incase of doubt, consult your Atlas Copco Customer Center.

Reference Unit ReadingOutlet pressure bar(e) Depends on pressure setpoint.Maximum working pressure bar(e) See “Compressor data”.

Full-Feature compressors

Temperature readings

Item Reading (min -max)

Reading (min -max)

Dryer heater outlet (optional) 130 - 210 ˚C 266 - 410 ˚FDryer PDP (optional) (-50) - 0˚C (-58) - 32 ˚FDryer outlet maximum 80 ˚C maximum 176 ˚FRegeneration air inlet 120 - 200 ˚C 248 - 392 ˚FRegeneration air outlet 55 - 150 ˚C 131 - 302 ˚FDryer mix air maximum 50 ˚C maximum 122 ˚FDryer water out 0 - 50 ˚C 32 - 122 ˚FTemperature difference, dryer outlet - inlet maximum 25 ˚C maximum 45 ˚FTemperature difference, dryer regeneration air inlet - inlet 100 - 160 ˚C 180 - 288 ˚FTemperature difference, dryer mix. - inlet maximum 10 ˚C maximum 18 ˚F

Instruction book

132 2920 1849 00

Item Reading (min -max)

Reading (min -max)

Temperature difference, dryer regeneration inlet - outlet 30 - 80 ˚C 54 - 144 ˚FDryer PDP - inlet temperature (optional) -30 - (-60) ˚C -22 - (-76) ˚FTemperature difference, dryer cooling water out 0 - 10 ˚C 0 - 18 ˚F

Other readings

Item ReadingDryer rotation speed 2 - 11 rphDryer direction Anti-clockwise

9.2 Settings of safety valves

Settings

Reference Value ValueLow-pressure safety valve 3.7 bar(e) 54 psigHigh-pressure safety valve, ZT/ZR 55/75 7.25 bar/105psi and ZT/ZR 7.5 bar/109 psi

9.3 bar(e) 135 psig

High-pressure safety valve, ZT/ZR 90 7.25 bar/105 psiand ZT/ZR >7.5 bar/109 psi

11.0 bar(e) 160 psig

9.3 Circuit breakers and fuses

50Hz IEC

ZT/ZR 55

Voltage F21 orF26(A)

Q25(A)

Q32 orF33Full-FeatureMD(A)

Q32 orF33Full-FeatureND(A)

Q41orF42(A)

F25(A)

F41(A)

Proposedfuse gG/gLIEC (A)

Short circuitcurrent rating(Incombinationwithinstallation ofthe prescribedmain fuses)

200 V 127 10.0 10.0 13.0 4.5 20 8 3x315 50 kA230 V 111 8.3 10.1 15.0 4.5 16 8 3x315 50 kA500 V 52 4.0 4.4 6.3 2.1 8 4 3x200 50 kA690 V 37 2.8 4.2 4.2 1.5 6 4 3x200 50 kA

Instruction book

2920 1849 00 133

ZT/ZR 75

Voltage F21(A)

Q25or orF26(A)



Q41orF42(A)

F25(A)

F41(A)



200 V 181 14.0 10.0 13.0 4.5 25 8 3x400 50 kA230 V 157 12 10.1 15.0 4.5 25 8 3x400 50 kA400 V 89 7.0 6.3 8.7 2.6 16 6 3x315 50 kA500 V 72 5.5 4.4 6.3 2.1 10 4 3x315 50 kA690 V 52 4.1 4.2 4.2 1.5 8 4 3x200 50 kA

ZT/ZR 90

Voltage F21(A)

Q25or F26(A)



Q41orF42(A)

F25(A)

F41(A)


Short circuitcurrent rating(Incombinationwithinstallation oftheprescribedmain fuses)

200 V 203 14.0 10.0 13.0 4.5 25 8 2x(3x315) 50 kA230 V 176 12 10.1 15.0 4.5 25 8 3x400 50 kA400 V 102 7.0 6.3 8.7 2.6 16 6 3x315 50 kA500 V 82 5.5 4.4 6.3 2.1 10 4 3x315 50 kA690 V 59 4.1 4.2 4.2 1.5 8 4 3x315 50 kA

ZR/ZT 55 up to ZR/ZT 90, No motor

Model Voltage(V)

Q25or F26(A)

F25(A)

Q41 orF42 (A)

F41 (A) Q32 or F33(A)Full-FeatureMD

Q32 or F33(A)Full-FeatureND

Short circuitcurrent rating (Incombination withinstallation of theprescribed mainfuses)

ZR/ZT55 200 V 10.0 20 4.5 8 10.0 13.0 50 kA

ZR/ZT55 400 V 4.7 10 2.6 6 6.3 8.7 50 kA

ZR/ZT75 200 V 14.0 25 4.5 8 10.0 13.0 50 kA

ZR/ZT75 400 V 7.0 16 2.6 6 6.3 8.7 50 kA

ZR/ZT90 200 V 14.0 25 4.5 8 10.0 13.0 50 kA

Instruction book

134 2920 1849 00

Model Voltage(V)

Q25or F26(A)

F25(A)

Q41 orF42 (A)

F41 (A) Q32 or F33(A)Full-FeatureMD

Q32 or F33(A)Full-FeatureND

Short circuitcurrent rating (Incombination withinstallation of theprescribed mainfuses)

ZR/ZT90 400 V 7.0 16 2.6 6 6.3 8.7 50 kA

60Hz IEC

ZT/ZR 55

Voltage F21(A)

Q25or F26(A)



Q41 orF42(A)

F25(A)

F41(A)


Short circuitcurrentrating (Incombinationwithinstallationof theprescribedmain fuses)

200 V 138 10.5 10.0 13.0 4.8 16 10 3x315 50 kA220 V–230 V

125 8.3 10.1 15.0 4.8 16 10 3x315 50 kA

380 V 72 4.8 6.3 8.2 2.8 8 6 3x315 50 kA440 V 63 4.5 6.3 7.1 2.8 8 6 3x315 50 kA

ZT/ZR 75

Voltage F21(A)

Q25orF26(A)



Q41 orF42(A)

F25(A)

F41(A)


Short circuitcurrentrating (Incombinationwithinstallationof theprescribedmain fuses)

200 V 183 15 10.0 13.0 4.8 32 10 A 3x400 50 kA220 V–230 V

166 13.5 10.1 15.0 4.8 25 10 A 3x400 50 kA

380 V 97 7.3 6.3 8.2 2.8 16 6 A 3x315 50 kA

Instruction book

2920 1849 00 135

ZT/ZR 90

Voltage F21(A)

Q25 orF26(A)

Q32 or F33Full-Feature(A)

Q32 or F33Full-FeatureND(A)

Q41 orF42(A)

F25(A)

F41(A)

Proposed fusegG/gLIEC (A)

Short circuitcurrent rating(Incombinationwithinstallation oftheprescribedmain fuses)

200 V 217 15 10.0 13.0 4.8 32 10 2x(3x315)

50 kA

220 V–230 V

199 13.5 10.1 15.0 4.8 25 10 2x(3x315)

50 kA

380 V 115 7.3 6.3 8.2 2.8 16 6 3x315 50 kA440 V 99 7.1 6.3 7.1 2.8 16 6 3x315 50 kA


Model Voltage(V)

Q25 orF26(A)

F25 (A) Q41 orF42 (A)

F41 (A) Q32 orF33 (A)Full-FeatureMD

Q32 or F33ND (A)Full-Feature ND

Short circuitcurrent rating(In combinationwithinstallation ofthe prescribedmain fuses)

ZR/ZT 55 200 V 10.5 16 4.8 10 10.0 13.0 50 kAZR/ZT 55 220-230 V 8.3 16 4.8 10 10.1 15.0 50 kAZR/ZT 55 440 V 4.5 8 2.8 6 6.3 7.1 50 kAZR/ZT 75 200 V 15.0 32 4.8 10 10.0 13.0 50 kAZR/ZT 75 220-230 V 13.5 25 4.8 10 10.1 15.0 50 kAZR/ZT 75 440 V 7.1 16 2.8 6 6.3 7.1 50 kAZR/ZT 90 200 V 15.0 32 4.8 10 10.0 13.0 50 kAZR/ZT 90 220-230 V 13.5 25 4.8 10 10.1 15.0 50 kAZR/ZT 90 440 V 6.6 16 2.80 6 6.3 7.1 50 kA

Instruction book

136 2920 1849 00

60Hz CSA/UL

ZT/ZR 55

Voltage F21(A)

Q25 orF26(A)



Q41 orF42(A)

F25(A)

F41(A)

Proposedfuse LPJCSA/uL (A)


460 V 60 4.5 6.3 7.1 2.8 8 5 3x200 65 kA575 V 48 4.0 5.0 5.0 2.3 8 5 3x200 65 kA

ZT/ZR 75

Voltage F21(A)

Q25 orF26(A)


Q32 or F33Full-FeatureND(A)

Q41 orF42(A)

F25 (A) F41(A)

Proposedfuse LPJCSA/uL (A)


460 V 80 7.1 6.3 7.1 2.8 12 5 3x250 65 kA575 V 64 5.3 5.0 5.0 2.3 10 5 3x200 65 kA

ZT/ZR 90

Voltage F21(A)

Q25orF26(A)

Q32 or F33Full-Feature MD(A)


Q41 orF42(A)

F25 (A) F41 (A) Proposedfuse LPJCSA/uL (A)


460 V 95 7.1 6.3 7.1 2.8 12 5 3x250 65 kA575 V 77 5.3 5.0 5.0 2.3 10 5 3x250 65 kA


Model Voltage(V)

Q25 orF26(A)

F25(A)

Q41 orF42 (A)

F41(A)

Q32 or F33(A)Full-Feature

Q32 or F33NDFull-FeatureND (A)

Short circuit currentrating (Incombination withinstallation of theprescribed mainfuses)

ZR/ZT 55 460 V 4.5 8 2.8 5 6.3 7.1 65 kAZR/ZT 55 575 V 4.0 8 2.3 5 5.0 5.0 65 kAZR/ZT 75 460 V 7.1 12 2.8 5 6.3 7.1 65 kA

Instruction book

2920 1849 00 137

Model Voltage(V)

Q25 orF26(A)

F25(A)

Q41 orF42 (A)

F41(A)

Q32 or F33(A)Full-Feature

Q32 or F33NDFull-FeatureND (A)

Short circuit currentrating (Incombination withinstallation of theprescribed mainfuses)

ZR/ZT 75 575 V 5.3 10 2.3 5 5.0 5.0 65 kAZR/ZT 90 460 V 7.1 12 2.8 5 6.3 7.1 65 kAZR/ZT 90 575 V 5.3 10 2.3 5 5.0 5.0 65 kA

Location of components

See “Electrical system” for location of components.

9.4 Reference conditions

Contact your Atlas Copco Customer Center for specific data of your machine configuration.

9.5 Limitations

Contact your Atlas Copco Customer Center for specific data of your machine configuration.

9.6 Compressor dataContact your Atlas Copco Customer Center for specific data of your machine configuration.

Instruction book

138 2920 1849 00

10 Pressure equipment directives

PED instructionsZR/ZT 55 Pack up to ZR/ZT 90 Pack are pressure assemblies of cat. I according to 97/23/EC.

ZR/ZT 55 Full-Feature up to ZR/ZT 90 Full-Feature are pressure assemblies of cat. III according to97/23/EC.

Parts of article 3.3 of 97/23/EC are subject to good engineering practice.

Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion ofarticle I, section 3.6.

Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC accordingto article I, section 3.3.

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

• Safety valve: Category IVDesign code: AD-Merkblätter, A2

• Vessel IMD260: Category IIIDesign pressure 11 bar(e) (159.54 psig), content 91 l (24.02 US gal / 20.02 Imp gal / 3.19 cu.ft)Design standard: ASME section VIII div. 1.

Instruction book

2920 1849 00 139

11 Documentation

Declaration of conformityTypical example of a Declaration of Conformity document

Instruction book

140 2920 1849 00

Declaration of incorporationTypical example of a Declaration of Incorporation document

Instruction book

2920 1849 00 141

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What sets Atlas Copco apart as a company is our convictionthat we can only excel in what we do if we provide the bestpossible know-how and technology to really help our customersproduce, grow and succeed.

There is a unique way of achieving that - we simply call it theAtlas Copco way. It builds on interaction, on long-termrelationships and involvement in the customers’ process, needsand objectives. It means having the flexibility to adapt to thediverse demands of the people we cater for.

It’s the commitment to our customers’ business that drives oureffort towards increasing their productivity through bettersolutions. It starts with fully supporting existing products andcontinuously doing things better, but it goes much further,creating advances in technology through innovation. Not forthe sake of technology, but for the sake of our customer’sbottom line and peace-of-mind.

That is how Atlas Copco will strive to remain the first choice, tosucceed in attracting new business and to maintain our positionas the industry leader.

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