EFFICIENCY

MATTERS

Atlas Copco Air Compressors

ZB VSD range

Variable speed direct drive centrifugal air compressors

for low pressure applications

guara nteed

10

0%oil-free

air

any contamination risk for 100% – and guaranteeing the

utmost reliability around the clock. And not just today, but

day after day, year after year, with minimal maintenance

cost, few service interventions and long overhaul intervals.

The shortest route to maximum profitability is to

minimize operational cost. The design of the Atlas Copco ZB

VSD compressors is focused on substantially saving energy,

ensuring product safety – only oil-free machines can exclude

Expertise

Since 1903, Atlas Copco’s philosophy has

been to continually improve our products

through intensive R&D, with the aim to

maximize the value for our customers.

Complete safety

Process, products and environment

free from contamination

Choice

Atlas Copco masters each compression

principle and offers the most energy

efficient technology for the application.

The right drive

Fixed speed machines are fine at full load

but when air demand fluctuates, a Variable

Speed Drive ensures substantial savings.

The integrated design

Internal piping, Variable Speed Drive,

100 % matched components... the only way

to ensure total reliability.

Trouble-free installation & commissioning

The ZB VSD centrifugal compressor is truly

plug-and-play. Put it on a flat floor, connect the

power line and the air outlet… and push the

start button.

The professional follow-up

Service Contracts will ensure you of the right

preventative maintenance, immediate response

and genuine spare parts… all over the globe.

Extending the limits in energy efficiency,

safety and reliability

Optimal use

Central control of a multi-compressor

installation can reduce the pressure

band and achieve the lowest overall

energy cost.

Energy

Safety

Reliability

Approvals and performances

EC directive 98/37/EC

Low voltage directive 73/23/EC

Pressure equipment directive 97/23/EC

Electromagnetic compatibility 89/336/EC

Noise level emission 67 dB(A), acc. ISO 9614 test code

UL approval

The Atlas Copco ZB VSD (Variable Speed Drive)

centrifugal air compressor is a completely innovative

approach to low pressure compressed air applications.

Because of the combination of revolutionary

technologies, the ZB VSD offers a range of features

and benefits that were previously impossible to combine

into one machine.

The centrifugal air compressor

of the new age

Standard

Air inlet system (incl. filters)

Sound enclosure

Outlet check valve

Blow-off valve (incl. silencer)

Electronic controller

Fully equipped electrical system

VSD - Variable Speed Drive system

Options

LAN or Internet control/monitoring

Aftercooler (water cooled)

Fine inlet filters 99% @ 1 µm

Complete

"all-in" package

Innovative design

brings numerous benefits

Unparalleled savings in life cycle cost

highest efficiency with VSD energy savings

lowest maintenance cost

reduced parts count for enhanced reliability

very low cooling water usage,

less energy to keep unit cool

low installation costs

Simple and safe "oil-less" design

no oil at all

no pumping system

no oil heater

no oil filter

no journal bearings

no speed increasing gears

Complete, compact size and low weight

weight 1200 kg

plug-and-play installation, no foundations

small footprint (mm)

Caring for the work environment

standard baffled sound enclosure

blow-off silencer

vibration-free operation

extremely low noise level < 67 dB(A)

totally oil-free, no oil-induced environmental issues

Contactless magnetic bearings

no contact means no wear, no vibration, no friction

no oil-lubricated journal or land bearings

magnetic bearings dynamically align the rotor shaft

on-board processor with real-time response

unsurpassed machine lifetime

dramatically reduced maintenance requirements

2080

14501520

1

2

3

For larger flow volumes, multiple ZB VSD units can

be connected in parallel. Two, three or more units offer

the advantages of a modular concept:

higher availabilityreliability through redundancywider operating range and efficiencyspace savingextremely low noise levelsexpandability

Modular electronics

The control cubicle houses theElektronikon® and the magneticbearing controller.The Variable Speed Drive (VSD)cubicle houses a state-of-the-artfast switching frequencyconverter and efficient power conditioning devices.

Advanced Elektronikon® monitoring & control

Operating modes: constant pressure mode (flow range: 50 - 100 %)constant flow moderemote 4-20 mA input (flow or pressure)

Functions:control– speed regulation– surge control– blow-off regulationsafetymonitoringself diagnosiscommunication– internal, with frequency converter and magnetic

bearing controller– external ( Modbus, Profibus )

Multiple compressor installation

In multiple compressor installations, the ES centralcontroller will ensure the optimal compressor mix. The total system can be monitored locally or remotely, via the network or from anywhere in the world.

Standalone or integrated solutions

Control

cubicle

VSD

cubicle

ZB 160 - 2ZB 160 - 2ZB 160 - 2

100%

100%

98%

96%

94%

100

90

85

80

75

Efficiency matters

2.5 %losses

losses

5 % 10 %

CONVENTIONAL SINGLE STAGE CENTRIFUGAL TECHNOLOGY

Drive

efficiency

83.4 %100 %

power

supply

oil-pump,

fans

motor gear and

bearings

1 % 3 % 1 %

ZB VSD DIRECT DRIVE CENTRIFUGAL TECHNOLOGY

Drive

efficiency

92.2 %

100 %

power

supply

pump,

fans

converter electric

filter

3 %

electric

motor

Broad operating range and no sacrifice of efficiency at partload conditions with Variable Speed Drive control.

ZB 160 - 2

Re

lati

ve

pre

ss

ure

ra

tio

(

)

0 0.5 1.0 1.5 2.0 l/s

100 %

Relative volume flow ( ) V

VA

P PA

VARIABLE SPEED PERFORMANCE CHARACTERISTICS

Relative speed ( ) Relative efficiency ( )n

na

N

NA

Direct drive technology

The ZB VSD is directly driven by a permanent magnetsynchronous motor, which is vastly superior to conventionaltypes. It reduces energy losses and cooling requirementsand offers a higher speed in a more compact design.A consistently high motor efficiency with low rotor losses ismaintained across the entire speed range... both at full loadand part load.Whereas conventional motors need power to excite amagnetic field in the rotor, the ZB VSD motor does not,thanks to the permanent magnets in the rotor.

Total absence of pump losses

With the impeller directly mounted onto the motor shaft andby absence of a gear box, the ZB VSD is totally oil-free,which excludes traditional oil-system losses.

Highest efficiency impeller

The unique stainless-steel backward lean impeller is a proprietary Atlas Copco design with labyrinth seals for highest efficiency with minimal air leakage.

9 %

energy savings with VSD

Process pressure

Pressure - standard load-unload

Pressure - turbo-modulating

Pressure - VSD

Why Variable Speed Drive (VSD) ?

Because a VSD compressor precisely follows the

varying air demand that is typical in most production

facilities, it dramatically reduces the energy bill and

provides many additional benefits. The result is a fast

payback of the investment and huge yearly savings long

after that.

Because energy constitutes the biggest portion of the

life cycle cost of a compressor, these savings have a

significant impact on the operational costs of your

compressed air system.

Predicting your savings

Call upon the expertise of Atlas Copco specialists and have an

assessment carried out in your factory.

A detailed report will show your current operation and the

achievable savings when adding a VSD solution to your

compressed air system.

Direct energy savings

Low load operation of a VSD compressor does not result

in energy losses or in blowing off compressed air to

the atmosphere.

The precise pressure control of the VSD compressor allows

a tighter and often lower discharge working pressure,

resulting in reduced energy consumption, less leak losses

and a more efficient and optimized process.

Tight control for superior process stability

The constant net pressure obtained by the VSD

compressor provides additional yearly savings:

– other base-load compressors will consume less

– leak losses – always present in compressed air

systems – are significantly reduced.

The stable pressure is highly beneficial to many processes,

avoiding expensive production interruptions, product loss

or quality issues.

STABLE NET PRESSURE

investment

maintenance

energy

0.1

bar

0

400

800

10 20

NO CURRENT PEAKS

Star Delta

DOL

Soft Starter

VSD

% F

ull

lo

ad

cu

rre

nt

Seconds

100 %

COMBINED MOTOR/CONVERTER EFFICIENCY

maximumminimum

Motor speed

integrated VSD

non-integrated VSD

Integrated VSD - The only way

The Elektronikon® system controls both thecompressor and the integrated converter; this ensures maximum machine safety andallows easy networking of the compressor.

All Atlas Copco VSD compressors are EMC tested and certified.External sources do not influence the compressor operation, nor does the compressor disturb other equipment via emissions or via the power supply line.

No current peaks during start-up

VSD compressors can be started and stopped

without limitation

frequent start-stops no longer lead to current

peak penalties

the electrical installation can often be rated for a

lower current, meaning savings in investment

Electrical filters

bar(e) psig

m3/h

cfm

ZB 160 VSD

ZB 120 VSD

ZB 80 VSD

0 1000 2000 3000 4000

589 1177 1766 2354

2.5

2.0

1.5

1.0

0.5

0

36.3

29.0

21.8

14.5

7.25

0

Volume flow

Pre

ss

ure

bar(e)

m3/h

cfm

ZB 100 VSD

0 2000 4000 6000

1177 2354 3531

1.2

1.0

0.8

0.6

0.4

0.2

0

psig

17.4

14.5

11.6

8.7

5.8

2.9

0

Volume flow

Pre

ss

ure

Single blower unit

Multiple ZB VSD in parallel

0 20 40 60 80 100 120

120

100

80

60

40

20

0

%

ZB VSD characteristics

The ZB VSD series offers a variety of pressure

ranges and flow cuts, to perfectly match the needs of

your application.

Multiple installation

For flow ranges beyond that of an individual ZB VSD

centrifugal compressor, multiple machines are easily

teamed up to meet the flow requirements. Because they

were designed to work in parallel, the overall system

efficiency remains high, regardless of the flow demands.

%

1st

1 & 2

1, 2 & 3

1, 2, 3 & 4

Sy

ste

m p

ow

er

System flow

1

SYSTEM EFFICIENCY

ZB 80 VSD

ZB 100 VSD

Atlas Copco offers a complete portfolio of

Aftermarket products, unrivaled in today’s compressed

air industry.

High quality service is delivered locally: Atlas Copco

is present in 150 countries around the world.

A sophisticated logistics concept brings genuine parts

to your doorstep in record times, across the globe.

These parts never carry a risk of incompatibility or

premature failure. Cost effective service kits are

available for periodic interventions based on

running hours.

Service Plans perfectly meet the needs of your

business and ensure a productivity at peak level.

Three levels are available: Total Responsibility Plan,

Preventative Maintenance Plan and Inspection Plan.

Fixed price repair is ideal for individual repairs; it is

streamlined to allow for a quick flow from quotation

to execution, without surprises.

The element exchange program offers the customer

the possibility of scheduled intervention rather than a

reaction to an element failure.

Consultancy services and on-site measurements help

to optimize the complete air net, minimize leak losses

and maximize energy savings. The following

packages can be included individually or combined:

in-depth system audits based on

actual measurements of the air

supply distribution system.

remote monitoring via the Internet;

negative trends can be detected

before any actual failure of the

equipment.

energy savings via system control

and management.

Global presence

Local service

2935 0

443 1

3 -

Pri

nte

d i

n B

elg

ium

- S

ubje

ct

to a

ltera

tion w

ithout

pri

or

noti

ce.

What sets Atlas Copco apart as a company is our

conviction that we can only excel in what we do, if we

provide the best possible know-how and technology to really

help our customers produce, grow and succeed.

There is a unique way of achieving that - we simply call

it the Atlas Copco way. It builds on interaction, on long-term

relationships and involvement in the customers' process,

needs and objectives. It means having the flexibility to adapt

to the diverse demands of the people we cater for.

It's the commitment to our customers' business that

drives our effort towards increasing their productivity through

better solutions. It starts with fully supporting existing

products and continuously doing things better, but it goes

much further, creating advances in technology through

innovation. Not for the sake of technology, but for the sake

of our customer's bottom line and peace-of-mind.

That is how Atlas Copco will strive to remain the first

choice, to succeed in attracting new business and to maintain

our position as the industry leader.

www.atlascopco.com

Never use compressed air

as breathing air without

prior purification in

accordance with local

legislation and standards.

IISSOO 99000011

A consistent quality earned

us the industry’s leadership

and the customer’s trust.

IISSOO 1144000011

Atlas Copco’s

Environmental Management

System forms an integral part

of each business process.