Atlas Copco ZR-55 Instruction Book
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Atlas Copco ZR-55 Instruction Book

Stationary air compressor
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Stationary Air Compressor
ZR-55, ZR-75, ZR-90, ZT-55, ZT-75, ZT-90
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www.atlascopco.com

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Summary of Contents for Atlas Copco ZR-55

  • Page 1 Stationary Air Compressor ZR-55, ZR-75, ZR-90, ZT-55, ZT-75, ZT-90 Instruction book www.atlascopco.com...
  • Page 2 Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Website www.atlascopco.com Printed Matter No. 9096 3266 00 2008-08 Atlas Copco Compressors Sales (A Division of Atlas copco (india) Ltd.) Oil-free Air Pune - india...

  • Page 3: Table Of Contents

    Instruction book Table of contents Safety precautions......................5 ...........................5 AFETY ICONS ...................5 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................10 ..........................10 NTRODUCTION ............................19 IR FLOW ......................26 ONDENSATE DRAIN SYSTEM ............................29 IL SYSTEM ..........................31 OOLING SYSTEM ..........................35...
  • Page 4 Instruction book 3.12 .............................55 EST MENU 3.13 .......................56 ODIFY PARAMETERS MENU 3.14 ........................56 ODIFYING PARAMETERS 3.15 .....................57 ODIFYING REGULATION SETTINGS 3.16 ......................58 ODIFYING PROTECTION SETTINGS 3.17 ........................59 ODIFYING SERVICE PLANS 3.18 ......................60 ROGRAMMING CLOCK FUNCTION 3.19 ....................65 ODIFYING CONFIGURATION SETTINGS 3.20 ..........................66 ERVICE MENU...
  • Page 5 Instruction book ........................115 AINTENANCE WARNINGS ....................115 REVENTIVE MAINTENANCE SCHEDULE ..........................116 ERVICE KITS ........................116 ERVICE AGREEMENTS ..........................116 ERVICE PLAN ..........................116 OTOR GREASING ........................118 IL SPECIFICATIONS ......................118 TORAGE AFTER INSTALLATION Servicing procedures....................119 (AF)..........................119 IR FILTER ......................121 IL AND OIL FILTER CHANGE ..........................122 AFETY VALVES Problem solving......................123 ........................123...

  • Page 6: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.
  • Page 7 Instruction book dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment. 2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct.

  • Page 8: Safety Precautions During Operation

    Instruction book Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. General precautions 1.

  • Page 9: Safety Precautions During Maintenance Or Repair

    Instruction book 9. Do not remove any of, or tamper with, the sound-damping material. 10. 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 pressure shall be protected by a pressure-relieving device or devices as required.
  • Page 10 Instruction book 7. Close the compressor air outlet valve before connecting or disconnecting a pipe. 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. 9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours of cleaning liquids.

  • Page 11: General Description

    Instruction book General description Introduction Description This 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 the compressed air.
  • Page 12 Instruction book General view of ZR 55 up to ZR 90 Full-Feature with Energy Recovery...
  • Page 13 Instruction book Front view of ZR 55 up to ZR 90 Pack...
  • Page 14 Instruction book Rear view of ZR 55 up to ZR 90 Pack Front view of ZR 55 up to ZR 90 Full-Feature with Energy Recovery...
  • Page 15 Instruction book Views of ZT General view of ZT 55 up to ZT 90 Pack...
  • Page 16 Instruction book General view of ZT 55 up to ZT 90 Full-Feature General view...
  • Page 17 Instruction book Rear view Main components Name Air filter Air outlet Silencer By-pass valve, oil cooler Pre-aftercooler Aftercooler Intercooler Oil cooler Automatic condensate outlet, aftercooler Automatic condensate outlet, intercooler Oil drain valve, gear casing High-pressure compressor element Low-pressure compressor element Energy recovery system ERwi Water inlet, energy recovery system...
  • Page 18 Instruction book Name EWDi Electronic water drain, intercooler Elektronikon regulator Oil filler cap Cooling fan IMD/IND Integrated dryer Drive motor Fan motor Moisture trap, aftercooler Moisture trap, intercooler Oil filter Emergency stop button Oil level sight-glass Safety valve, dryer High-pressure safety valve Low-pressure safety valve Load/no-load valve Silencer...
  • Page 19 A water shut-off valve is provided in the cooling water system to shut off the system when the compressor is not in operation. Energy recovery The compressor is provided with an Atlas Copco energy recovery system to recover the major part of the compression heat in the form of hot water. SPM monitoring A number of vibration sensors are provided on the drive motor and compressor elements.

  • Page 20: Air Flow

    Instruction book The low load compensator is needed when the load cycle of the compressor is below 40 %. Full-Feature ND The Z Full-Feature ND compressor has an integrated heat of compression rotary drum dryer. The regeneration air passes over a heater. The heater maintains a preset regeneration temperature to a have guaranteed dew point at stated conditions.
  • Page 21 Instruction book Flow diagram, ZR Full-Feature...
  • Page 22 Instruction book Flow diagram, ZR Full-Feature ND and ZR Full-Feature with Low Load option...
  • Page 23 Instruction book Flow diagram, ZT...
  • Page 24 Instruction book Flow diagram, ZT Full-Feature...
  • Page 25 Instruction book Flow diagram, ZT Full-Feature ND and ZT Full-Feature with Low Load option Name Air inlet Air flow Oil flow Air outlet Water flow...
  • Page 26 Instruction book Air flow Air drawn through filter (AF) is compressed in low-pressure compressor element (El) and discharged to intercooler (Ci). The cooled air is further compressed in high-pressure compressor element (Eh) and discharged through silencer (AS) and aftercoolers. A check valve (CV) is provided downstream of the silencer. The wet air from the aftercooler enters water separator (18) via the nozzle of ejector (14).

  • Page 27: Condensate Drain System

    Instruction book Condensate drain system Flow diagram, ZR...
  • Page 28 Instruction book Flow diagram, ZT Explanation of arrows Name Air inlet Air flow Oil flow Air outlet Water flow...
  • Page 29 Instruction book Description Two condensate traps are installed: one downstream of the intercooler (MTi) to prevent condensate from entering compressor element (Eh) and one downstream of the aftercooler (MTa) to prevent condensate from entering the air outlet pipe. The condensate traps are connected to Electronic Water Drains (EWDi and EWDa respectively).

  • Page 30: Oil System

    Instruction book Briefly press the TEST button and check that the valve opens for condensate discharge. Checking the alarm signal • Press the test button for at least 1 minute. • Check that the alarm LED flashes. • Release the test button. Oil system Flow diagram, ZR...
  • Page 31 Instruction book Flow diagram, ZT Explanation of arrows Name Air inlet Air flow Oil flow Water flow Air outlet Oil system On ZR compressors, oil is circulated by pump (OP) from the sump of the gear casing to cooler (Co). From there, the oil flows through filter (OF) towards the bearings and timing gears.

  • Page 32: Cooling System

    Instruction book On ZT compressors, oil is circulated by pump (OP) from the sump of the gear casing to cooler (Co). Then, the oil flows through the cooling jackets of compressor elements (El and Eh). From there, the oil flows through filter (OF) towards the bearings and timing gears.
  • Page 33 Instruction book Flow diagram, ZR Full-Feature...
  • Page 34 Instruction book Flow diagram, ZT...
  • Page 35 Instruction book Flow diagram, ZT Full-Feature Explanation of arrows Name Air inlet Air flow Oil flow Air outlet Water flow...

  • Page 36: Energy Recovery

    Instruction book Cooling system, ZR compressors The cooling system has two circuits: • One for the oil cooler (Co) and the cooling jackets of both compressor elements (Eh and El). • One for intercooler (Ci) and aftercooler (Ca). Full-Feature compressors have an extra cooling circuit for the regeneration cooler of the integrated dryer. Cooling system, ZT compressors The compressors are provided with an air-cooled oil cooler (Co), intercooler (Ci), pre-aftercooler (Ca1) and aftercooler (Ca2).
  • Page 37 Pump unit Atlas Copco supplies pump units to transfer the energy recovered from the compressor to the heat consumer (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 compressor through the heat consumer and back to the compressor.
  • Page 38 In case the compressors operate in high ambient temperatures and with high water inlet temperatures, the maximum working pressure is 0.5 bar (7.25 psi) lower than for standard compressors. Consult the Atlas Copco Customer Centre.

  • Page 39: Low Load Compensator

    Instruction book Settings - limitations Item Setting Maximum cooling water temperature at compressor 90 ˚C (85 ˚C if MD dryer is fitted) outlet 194 ˚F (185 ˚F if MD dryer is fitted) Maximum cooling water temperature at compressor 40 ˚C inlet 104 ˚F Safety valve opening pressure...

  • Page 40: Electrical System

    (compressor in unload) the PDP is maintained by purging a small amount of heated, dryed air through the rotor (4). This is needed when the load cycle is below 40 % (consult your Atlas Copco Customer Centre). Electrical system...
  • Page 41 Instruction book Electric cabinet Typical example Typical example...
  • Page 42 Instruction book Drive motor (M1) Drive motor (M1)

  • Page 43: Elektronikon Regulator

    Instruction book Elektronikon regulator ® Elektronikon regulator Control panel Introduction In general, the Elektronikon regulator has following functions: • Controlling the compressor • Protecting the compressor • Monitoring components subject to service • Automatic restart after voltage failure (made inactive) Automatic control of compressor operation The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor.
  • Page 44 The regulator has a built-in function to automatically restart the compressor if the voltage is restored after voltage failure. For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. If activated and provided the regulator was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period.

  • Page 45: Control Panel

    Instruction book Control panel Elektronikon regulator Control panel Parts and functions Reference Designation Function Start button Button to start the compressor. LED (8) lights up indicating that the Elektronikon regulator is operative. Display Shows messages about the compressor operating condition, a service need or a fault. Scroll keys Keys to scroll upwards or downwards through the display.

  • Page 46: Function Keys

    To return to a previously shown option or menu “Cancel” To cancel a programmed setting when programming parameters “Delete” To delete compressor start/stop commands “Help” To find the Atlas Copco internet address “Limits” To show limits for a programmable setting “Load” To load the compressor manually “Mainscreen”...

  • Page 47: Scroll Keys

    Instruction book Scroll keys Control panel The keys (1) allow the operator to scroll through the display. As long as a downwards pointing arrow is shown at the utmost right position of the display, the scroll key with the same symbol can be used to see the next item. As long as an upwards pointing arrow is shown at the utmost right position of the display, the scroll key with the same symbol can be used to see the previous item.

  • Page 48: Control Programs

    Instruction book Before starting any maintenance or repairs, wait until the compressor has stopped and open the isolating switch (customer's installation) to switch off the voltage to the compressor. Close the air outlet valve and open the manual condensate drain valves to depressurize the air system.
  • Page 49 Instruction book Menu flow for ZR/ZT 55 up to ZR/ZT 90 (simplified) Main menu Program Function Main screen Shows in short the operation status of the compressor. Is the gateway to all functions. “Status data” Calls up the status of the compressor protection functions (shut-down, shut-down warning, service warning and warning).

  • Page 50: Calling Up Menus

    Instruction book Program Function “Measured data” Calls up the data currently measured and the status of a number of inputs. “Counters” Calls up the running hours, regulator (module) hours and number of motor starts. “Test” Display test. “Modify parameters” Modifies the settings for: •...

  • Page 51: Main Screen Menu

    Instruction book • Either press the tabulator key (2) to select this menu, • or use the arrow down key (1) until the desired submenu is followed by a horizontal arrow and then press the tabulator key (2) to select this menu. The arrow down key (1) can be used for a quick look at the actual compressor status.

  • Page 52: Status Data Menu

    Instruction book Status data menu Warning Before starting any maintenance or repairs, press the stop button (4), wait until the compressor has stopped, press the red emergency stop button and open the isolating switch (customer's installation) to switch off the voltage to the compressor. Close the air outlet valve and depressurize the air system.
  • Page 53 Instruction book A shut-down message exists • In case the compressor is shut down, LED (1) will blink. • In case of a shut-down due to too high a temperature at the outlet of the compressor element: “Element Outlet” 114˚C “Shutdown”...

  • Page 54: Measured Data Menu

    “Status Data” menu to “Inputs” and press the “Reset” key to reset the service message. • In case the service message was referring to “Plan”: carry out the service actions related to the indicated plans. Reset the timers of the related plans. Contact your Atlas Copco Customer Centre. See Service menu.

  • Page 55: Counters Menu

    Instruction book Function To call up information regarding the actually measured data and the status of some inputs such as the motor overload protection. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): •...

  • Page 56: Test Menu

    Instruction book Example of a Counters screen “Running Hours” 2455 “hrs” “Loaded Hours” 1973 “hrs” “Motor Starts” “Menu” 3.12 Test menu Control panel Function To carry out a display test, i.e. to check whether the display and LEDs are still intact. Procedure •...

  • Page 57: Modify Parameters Menu

    Instruction book 3.13 Modify parameters menu Function To modify a number of programmable settings: • Parameters (see section Modifying parameters). • Protections (see section Modifying protections). • Service plan settings (see section Modifying service plan settings). • Clock function settings (see section Modifying clock function settings).

  • Page 58: Modifying Regulation Settings

    Instruction book • The screen shows the current setting. To modify this setting, press the key “Modify” (F2); the setting will blink. • The key “Limits” (F2) can be used to find out the limitations for the parameter. • Use the scroll keys (1) to change the setting. •...

  • Page 59: Modifying Protection Settings

    Instruction book “Low Load” “Unconditionally Activated” “Menu” “Modify” • The screen shows that the low load setting is “Unconditionally Activated”. To modify this setting, press the “Modify” key (F2); the setting wil blink. • Use the scroll keys to change the setting. •...

  • Page 60: Modifying Service Plans

    Instruction book Procedure Starting from the Main screen (see Main screen menu): • Press the “Menu” (F1) key. • Press the arrow down key (1) until “Modify parameters” is followed by a horizontal arrow. • Activate the menu by pressing the tabulator key (2). •...

  • Page 61: Programming Clock Function

    Instruction book Always consult your Atlas Copco Customer Centre in case any timer should be changed. The intervals must not exceed the programmed nominal values. 3.18 Programming clock function Control panel Function To program: • Time-based start/stop commands for the compressor •...
  • Page 62 Instruction book “Clock Function” “Not Activated” “Menu” “Modify” “Delete” • Press the tabulator key (2), following screen appears: “Monday” “Tuesday” “Wednesday” “Menu” “Delete” • Use the scroll keys (1) until the day on which a command must be programmed is followed by a horizontal arrow.
  • Page 63 Instruction book • Press the tabulator key (2) to activate the menu. • Use the arrow down key until the option “Clock Function” is followed by a horizontal arrow, press the tabulator key (2), following screen appears: “Clock Function” “Not Activated” “Menu”...
  • Page 64 Instruction book “Monday” “Tuesday” “Wednesday” “Menu” “Delete” • Scroll through the display until “Saturday” is followed by a horizontal arrow. Press the tabulator key (2). If necessary, scroll through the commands until the command to be modified is followed by a horizontal arrow.
  • Page 65 Instruction book • 06:00 Pressure Band 1 • 18:00 Stop Compressor The regulator does not allow to enter a new command which is situated before the last command in the list timewise. Scroll through the display until the command before which the new command must be entered is followed by a horizontal arrow (in the example above: “18:00 Stop Compressor”) and press the key “Modify”.

  • Page 66: Modifying Configuration Settings

    Instruction book 3.19 Modifying configuration settings Control panel Function To modify a number of parameters. Consult the menu flow in section Control programs. Procedure Starting from the Main screen (see Main screen menu): • Press the key “Menu” (F1). • Press the arrow down key (1) until “Modify Parameters” is followed by an arrow pointing to the right. •...

  • Page 67: Service Menu

    Instruction book “C.C.M.” “Local Control” “Program” “Cancel” • “Local Control” is blinking, use the scroll keys (1) to select the desired control mode. • Press the key “Program” to program the new control mode or “Cancel” to quit without reprogramming. 3.20 Service menu Control panel Function...
  • Page 68 Instruction book Service actions according to Intervals Service plan A 4000 running hours Service plan A and B 8000 running hours Service plan A 12000 running hours Service plan A, B and C 16000 running hours Procedure Starting from the Main screen (see Main screen menu): •...

  • Page 69: Saved Data Menu

    Instruction book The “Reset” button only appears when the “Next Timer” level is almost reached. After pressing the arrow down key in the “Service Timer” screen, the “Life Time” hours are shown, i.e. the number of hours elapsed since initial programming ex-factory. This timer is not taken into account.

  • Page 70: Programmable Settings

    Instruction book 3.22 Programmable settings Parameters Minimum Factory Maximum setting setting setting Motor running time in star Load delay time (star-delta) Number of motor starts starts/day Minimum stop time Programmed stop time Power recovery time (ARAVF) 3600 Restart delay Communication time-out Unloading pressure bar(e) 7.25...
  • Page 71 Instruction book Protections Minimum Factory Maximum setting setting setting Oil pressure (shut-down warning level) bar(e) Oil pressure (shut-down warning level) psig 14.5 27.5 Oil pressure (shut-down level) bar(e) Oil pressure (shut-down level) psig 14.5 17.4 27.5 Delay at start, oil pressure Delay at signal, oil pressure Compressor element 1 outlet temperature ˚C...
  • Page 72 See remark Remark A number of service operations are grouped (Level A, Level B, ...). Each level stands for a number of service operations to be carried out at the intervals programmed. Consult your Atlas Copco Service Centre. Terminology Term...
  • Page 73 The recommended minimum pressure difference between loading and unloading is 9 psig. Delay at shut- Is the period during which the signal must exist before the compressor is shut down. If it down signal should be required to program this setting at another value, consult Atlas Copco.

  • Page 74: Installation

    Instruction book Installation Dimension drawings Dimension drawing, ZR Pack...
  • Page 75 Instruction book Dimension drawing, ZR Pack with energy recovery...
  • Page 76 Instruction book Dimension drawing, ZR Full-Feature...
  • Page 77 Instruction book Dimension drawing, ZR Full-Feature with energy recovery...
  • Page 78 Instruction book Dimension drawing, ZT Pack...
  • Page 79 Instruction book Dimension drawing, ZT Full-Feature Text on drawing Name Voltage supply entry Compressed air outlet Cooling air outlet Opening for transportation 4 slotted holes only for horizontally pulling unit out of container...
  • Page 80 Instruction book Name Cooling air inlet Hole pattern ducting Automatic drain, aftercooler Automatic drain, intercooler (10) Compressed air outlet, compensator (11) Mass (12) Water in/out compensator (13) Water out (14) Water in (15) Automatic drain, dryer inlet (17) Automatic drain, dryer outlet (18) Cooling Full-Feature air outlet (19)

  • Page 81: Installation Proposals

    Instruction book Installation proposals Installation proposal, ZR Pack, ZR Full-Feature and ZR Pack with energy recovery...
  • Page 82 Instruction book Installation proposal, ZR Full-Feature with energy recovery...
  • Page 83 Instruction book Installation proposal, ZT Pack...
  • Page 84 Instruction book Installation proposal, ZT Full-Feature Text on figures Name Minimum free area to be reserved Ventilation proposal Cooling air outlet...
  • Page 85 Instruction book Name Cooling air inlet Cooling Full-Feature air outlet Cooling Full-Feature air inlet Description Description 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).

  • Page 86: Electric Cables

    Instruction book 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. 50Hz IEC Pack and Full-Feature compressors 400 V...
  • Page 87 Instruction book PANEL GA ZR 55 - 90 PACK...
  • Page 88 Instruction book...
  • Page 89 Instruction book...
  • Page 90 Instruction book...

  • Page 91: Cooling Water Requirements

    Instruction book Name (15) To be installed by the customer Cooling water requirements Recommendations The cooling water quality must meet certain minimum requirements. No general recommendation can encompass the effects of all combinations of the various compounds, solids and gases typically found in cooling water in interaction with different materials. Only non-treated water must be used.
  • Page 92 Instruction book Symbol Explanation Depends on the total solids concentration (mg/l) Depends on the highest cooling water temperature (˚C/˚F), (T=65 ˚C/149 ˚F) Depends on the calcium hardness (ppm CaCO Depends on the HCO concentration or M-alkalinity (mval/l) The values of A, B, C and D can be found in the following table. Total dissolved Temperature Ca-hardness (ppm...
  • Page 93 Instruction book Water condition Action 7.6<RSI<9.0 Strong corrosion Regular inspection necessary, use of corrosion inhibitor recommended. 9.1<RSI<11 Very strong corrosion Regular inspection necessary, use of corrosion inhibitor required. RSI>11 Very strong corrosion in Water should not be used. complete water system The table indicates that distilled or demineralised water should never be used, as their RSI is >...

  • Page 94: Pictographs

    Instruction book / SO should be > 1 Ammonia < 0.5 ppm Copper < 1 ppm Iron and manganese < 1 ppm Organics No algae No oil Suspended solids Non-soluble particles, size < 1 mm. < 10 ppm Pictographs Explanation of pictographs...
  • Page 95 Instruction book Name Start Scroll keys Tabulator key Voltage on Alarm Automatic operation Stop Automatic condensate outlet, intercooler Automatic condensate outlet, aftercooler Warning: under tension Read Instruction book before starting the compressor Switch off the voltage and depressurize the compressor before maintenance or repair Before connecting the compressor electrically, consult the Instruction book for the motor rotation direction Torques for steel (Fe) or brass (CuZn) bolts...
  • Page 96 Instruction book Additional pictographs on Full-Feature compressors Reference Name Arrow, indicating rotation direction Warning, voltage Instruction for delta P reading Purge internal impulse line before any reading of delta P on U-tube (close isolation valves of U-tube) Indication for correct adjusting of the U-tube water level...

  • Page 97: Operating Instructions

    Instruction book Operating instructions Operation introduction Warning The operator must apply all relevant “Safety precautions”. Ambient conditions Consult “Limits” for the limits with regard to the ambient conditions and altitude operation. Moving/lifting In order not to damage the frame, the compressor must be moved either by a lift truck or by using lifting equipment as described below.
  • Page 98 Instruction book • On ZR compressors, remove support (1) at the gear casing side. • On ZT compressors, remove bolts (1) and supports (2) immobilizing the vibration dampers of the coolers. Remove support (3), immobilizing the vibration dampers of the gear casing.
  • Page 99 Instruction book • Remove flange (1) and take out the silica gel bags installed in the intercooler at the condensate drain receiver side. Refit the flange.
  • Page 100 Instruction book Position of silica gel bags on ZT compressors...
  • Page 101 1617 7572 00 1617 7571 00 • The setpoint of the dryer heater depends on the working conditions, consult the Atlas Copco Customer 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 of one of the compressor elements (Eh, El) in a plastic bag.
  • Page 102 Instruction book...
  • Page 103 Instruction book • On ZR compressors, check that the cooling water drain valves (customer's installation) in the inlet and outlet lines are closed. Open the water inlet valve and outlet valve (customer's installation) and check for water flow. • On ZR Full-Feature, the inlet and outlet valves of the cooling water circuit of the regeneration cooler must be opened completely.
  • Page 104 Instruction book • Check that the electrical connections correspond to the local codes. The installation must be earthed and protected by fuses in all phases. An isolating switch must be provided. • Check the connections at the primary sides of transformers (T1 and T2). Typical example...
  • Page 105 Instruction book Typical example • Switch on the voltage. Start the compressor and stop it immediately. Check for correct direction of rotation while the motor is coasting to a stop. An arrow on the gear casing indicates the correct rotation direction. If the rotation direction is wrong, switch off the voltage and reverse two incoming electric lines.
  • Page 106 Instruction book Adjustment of the pressure difference of the dryer compartments Delta P indicator View of PDP sensor...
  • Page 107 Instruction book 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). •...

  • Page 108: Before Starting

    Instruction book 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.
  • Page 109 Instruction book Position of oil sight-glass on ZR compressors Position of oil sight-glass on ZT compressors...

  • Page 110: Starting

    Instruction book Starting Control panel Procedure Step Action Open the air outlet valve (customer's installation). Switch on the voltage and check that voltage on LED (2) lights up. Press start button (1). The compressor starts running and automatic operation LED (3) lights up.

  • Page 111: During Operation

    Instruction book During operation Control panel Procedure When automatic operation LED (1) is alight, the Elektronikon regulator is automatically controlling the compressor: the air delivery is matched to the air consumption, the compressor will start and stop whenever necessary. Avoid short compressor loading periods (minimum 50% load) and operation at very low working pressures as otherwise the performance of the dryer will diminish.

  • Page 112: Stopping

    The display will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded. Carry out the service actions of the indicated plans or replace the component and reset the relevant timer. Consult your Atlas Copco Customer Centre. See also “Preventive maintenance schedule”.
  • Page 113 Instruction book Procedure Position of water drain plug on LP compressor element Position of water drain plug on HP compressor element...
  • Page 114 Instruction book Position of water drain plug of oil cooler Position of water drain plugs of cooler block Frequently stopping the compressor using the emergency stop button may damage the compressor, only use the emergency stop button in case of emergency.

  • Page 115: Taking Out Of Operation

    Instruction book Step Action Press the test button on top of the electronic water drains while the compressor is running loaded. Press stop button (1): the compressor will stop and LED (2) will go out. Close the air outlet valve. To stop the compressor immediately, press emergency stop button (S2).

  • Page 116: Maintenance

    Open the isolating switch (customer's installation) to switch off the voltage to the compressor. Warranty-Product Liability Use only Atlas Copco authorized genuine parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Preventive maintenance schedule...

  • Page 117: Service Kits

    Service kits Service kits Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low.
  • Page 118 Instruction book Drive motor (M1) of ZR compressor Drive motor (M1) of ZT compressor Motor grease Do not mix greases of different types. The recommended motor grease is KLÜBERQUIET BQH 72-102. Contact your Customer Centre for the greasing quantity and interval for the motor bearings.

  • Page 119: Oil Specifications

    Instruction book Oil specifications Oil type Use Atlas Copco Roto-Z oil which has been specially developed for oil-free rotary compressors. This oil has a long service life and ensures optimum lubrication. Never mix oils of different brands or types. Atlas Copco Roto-Z oil...

  • Page 120: Servicing Procedures

    Instruction book Servicing procedures Air filter (AF) Location of the air filter on ZR compressors...
  • Page 121 Instruction book Location of the air filter on ZT compressors Procedure Step Action Stop the compressor and switch off the voltage to the compressor. Remove the filter. Fit the new filter. After carrying out the service actions of the related service plan, the service warning must be reset.

  • Page 122: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Control panel Oil system components, ZR...

  • Page 123: Safety Valves

    Safety valves Testing The valves can be tested on a separate compressed air line. If a valve does not open at the pressure specified “Settings of safety valves”, consult Atlas Copco. • Never run the compressor without safety valves. •...

  • Page 124: Problem Solving

    Replace filter Insufficient cooling water flow Check water temperature and increase cooling water flow Restriction in cooling water Consult Atlas Copco system due to formation of scale or settling down of dirt Condensate is not discharged Discharge flexible clogged Check and correct as necessary...
  • Page 125 U-tube are airtight Operating pressure too low Do not operate dryer at a pressure less than 4 bar(e) Rotor does not turn Consult Atlas Copco Rotor compartment sealing ring, Consult Atlas Copco sealing sectors and rotor need inspection...
  • Page 126 On water-cooled dryers, cooling Arrange so as to decrease water temperature too high temperature Regeneration cooler clogged Consult Atlas Copco internally Only on water-cooled dryers, Regeneration air cooler core tube Remove cooler, plug broken tube or water flows from one or both...

  • Page 127: Principal Data

    Instruction book Principal data Readings on display Display Reference Unit Reading Outlet pressure bar(e) Depends on pressure setpoint. Maximum working pressure bar(e) “Compressor data”. Full-Feature compressors Temperature readings Item Reading (min - max) Reading (min - max) Dryer heater outlet (optional) 130 - 210 ˚C 266 - 410 ˚F Dryer PDP (optional)

  • Page 128: Settings Of Safety Valves

    Instruction book Item Reading (min - max) Reading (min - max) Temperature difference, dryer cooling water out 0 - 10 ˚C 0 - 18 ˚F Other readings Item Reading Dryer rotation speed 2 - 11 rph Dryer direction Anti-clockwise Settings of safety valves Settings Reference Value...

  • Page 129: Reference Conditions

    Instruction book ZT/ZR90 Voltage Fuses Type Pack and Full-Feature Full-Feature 200 V 14.0 10.0 13.0 2x315 230 V 12.0 10.1 15.0 400 V 1.2/1.6 500 V 0.96 Location of components “Electrical system” for location of components. Reference conditions Reference Unit Value Absolute inlet pressure bar(a)

  • Page 130: Compressor Data

    Instruction book Compressor data ZR - 7.5 bar - 50Hz Unit ZR55 ZR75 ZR90 Nominal working pressure Nominal working pressure 101.53 101.53 101.53 Maximum working pressure, ZR Pack Maximum working pressure, ZR Pack 108.78 108.78 108.78 Maximum working pressure, ZR Full- 7.25 7.25 7.25...
  • Page 131 Instruction book Unit ZR55 ZR75 ZR90 Cooling water consumption at temperature 2.96 3.81 4.45 rise of 27 ˚F, ZR Full-Feature ZR - 8.6 bar - 50Hz Unit ZR55 ZR75 ZR90 Nominal working pressure Nominal working pressure 116.03 116.03 116.03 Maximum working pressure, ZR Pack Maximum working pressure, ZR Pack 124.73 124.73...
  • Page 132 Instruction book Unit ZR55 ZR75 ZR90 Cooling water consumption at temperature 2.96 3.81 4.45 rise of 15 ˚C, ZR Full-Feature Cooling water consumption at temperature 2.96 3.81 4.45 rise of 27 ˚F, ZR Full-Feature ZR - 10 bar - 50Hz Unit ZR55 ZR75...
  • Page 133 Instruction book Unit ZR55 ZR75 ZR90 Cooling water consumption at temperature rise of 27 ˚F, ZR Full-Feature Cooling water consumption at temperature 2.96 3.81 4.45 rise of 15 ˚C, ZR Full-Feature Cooling water consumption at temperature 2.96 3.81 4.45 rise of 27 ˚F, ZR Full-Feature ZT - 7.5 bar - 50Hz Unit ZT55...
  • Page 134 Instruction book ZT - 8.6 bar - 50Hz Unit ZT55 ZT75 ZT90 Nominal working pressure Nominal working pressure 116.03 116.03 116.03 Maximum working pressure, ZT Pack Maximum working pressure, ZT Pack 124.73 124.73 124.73 Maximum working pressure, ZT Full- 8.35 8.35 8.35 Feature...
  • Page 135 Instruction book Unit ZT55 ZT75 ZT90 Power input at maximum working pressure, 64.9 89.8 105.5 ZT Full-Feature Power input at maximum working pressure, 87.03 120.42 141.48 ZT Full-Feature Oil capacity Oil capacity Us gal 11.88 11.88 11.88 Oil capacity Imp gal 9.90 9.90 9.90...

  • Page 136: Pressure Equipment Directives

    Instruction book Pressure equipment directives 10.1 Pressure equipment directives PED instructions ZR/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 to 97/23/ Parts of article 3.3 of 97/23/EC are subject to good engineering practice.
  • Page 137 Instruction book...
  • Page 138 www.atlascopco.com...

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Zr-75Zr-90Zt-55Zt-75Zt-90

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