Atlas Copco ZS 4 VSD Instruction Book
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Atlas Copco ZS 4 VSD Instruction Book

Atlas Copco ZS 4 VSD Instruction Book

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AIF999999
ZS 4 VSD
Instruction book

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  • Page 1 AIF999999 ZS 4 VSD Instruction book...
  • Page 3 Atlas Copco ZS 4 VSD AIF999999 Instruction book Original instructions COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. This instruction book is valid for CE as well as non-CE labelled machines. It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................5 ........................... 5 AFETY ICONS ......................5 ENERAL SAFETY PRECAUTIONS ................... 6 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR .......................10 ISMANTLING AND DISPOSAL General description...................... 11 ..........................11 NTRODUCTION .........................13...
  • Page 5 Instruction book Installation........................44 ........................44 IMENSION DRAWING ........................46 NSTALLATION PROPOSAL .........................49 LECTRICAL CONNECTIONS .......................54 UALITY OF SAFETY COMPONENTS ..........................55 ICTOGRAPHS Operating instructions....................57 ..........................57 NITIAL START ..........................58 EFORE STARTING ............................59 TARTING .......................... 60 URING OPERATION ........................61 HECKING THE DISPLAY ............................62 TOPPING ........................62...
  • Page 6 Instruction book Technical data.......................72 ............................72 EADINGS ..................72 ETTINGS FOR OVERLOAD RELAY AND FUSES .................... 72 EFERENCE CONDITIONS AND LIMITATIONS ..........................73 ACHINE DATA Pressure equipment directives................... 74 Documentation......................75 AIF999999...

  • Page 7: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger to life Warning Important note General safety precautions 1. 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.

  • Page 8: Safety Precautions During Installation

    Instruction book 9. If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration.

  • Page 9: Safety Precautions During Operation

    Instruction book 12. The electrical connections must correspond to the applicable codes. The machines must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor. 13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning"...

  • Page 10: Safety Precautions During Maintenance Or Repair

    Instruction book 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.
  • Page 11 Instruction book 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.

  • Page 12: Dismantling And Disposal

    Instruction book Also consult following safety precautions: Safety precautions during installation Safety 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 the application which are not included herein. Some precautions are general and cover several machine types and equipment;...

  • Page 13: General Description

    Instruction book General description Introduction Product description The unit is an air-cooled, low-pressure, electric motor-driven screw blower, which delivers oil- free, pulsation-free air. A VSD (Variable Speed Drive) unit is continuously matching the speed of the drive motor to the air net pressure.
  • Page 14 Instruction book Rear view Ref. Name Air filter Oil cooler Blower element Blower motor Oil filter Pulsation damper Oil level sight glass SV/BLV Safety valve/blow-down valve Vibration dampers The unit includes mainly • Elektronikon control system • Air filter • Blower element •...

  • Page 15: Electrical System

    Instruction book • Frame • Bodywork Elektronikon control system The unit is controlled by an electronic regulator which: • Controls the operation of the unit • Reduces the power consumption • Warns the operator in case of an abnormal operating condition •...
  • Page 16 Instruction book The blow-off valve is mounted on the flanged opening on the pipe of the blower outlet. The inlet opening and valve seat are located in the bottom base (1). The main valve is formed by the metal/rubber bellows (2), which is fixed to the top base (3). The top base is firmly connected to the bottom base (1) by guide rods (4).
  • Page 17 Instruction book While the blower is starting, some pressure is generated in the space between the seat and the movable base. The pressure is then transported into the bellows through the control valve. As the surface of the bottom of the bellows is larger than the seat surface and thus the force is higher, the bellows will close within a few seconds due to the gradual pressure increase.
  • Page 18 Instruction book If the pressure exceeds the set limit, this is when the force generated by pressure against the annulus (the membrane surface minus the surface of the small ball contact) is higher than the force generated by the spring, the small ball will lift and release gas under pressure into the atmosphere.

  • Page 19: Flow Diagram And Cooling System

    Instruction book Flow diagram and cooling system Flow diagram Drawing reference Description Air inlet Intake filter Flexible connection Blower element Flexible connection Start-up and safety element Check valve Pulsation damper Air outlet Oil carter Breather Oil pump Bypass valve Oil cooler Oil filter Oil injection to bearings and gears Gears...
  • Page 20 Instruction book Air flow Air drawn through the air inlet (A) and intake filter (B) is compressed in the blower element (D) and discharged through check valve (G) and pulsation damper (H) towards the air net. Oil system Oil is circulated by pump (L) from the integrated oil reservoir (J) through cooler (N) and oil filter (O) to the gear wheels and bearings of the blower element (D).

  • Page 21: Elektronikon™ Touch Controller

    Instruction book Elektronikon™ Touch controller Controller The Elektronikon™ Touch controller Introduction The controller has the following functions: • Controlling the unit • Protecting the unit • Monitoring components subject to service • Automatic restart after voltage failure (ARAVF) Automatic control of the unit The controller maintains the net pressure between programmable limits by automatically loading and unloading the unit (fixed speed units) or by adapting the motor speed (units with frequency converter).
  • Page 22 Instruction book Protecting the unit Shutdown Several sensors are provided on the unit. If one of the measured signals exceeds the programmed shutdown level, the unit will be stopped. Example: If the element outlet temperature exceeds the programmed shutdown level, the unit will be stopped.

  • Page 23: Control Panel

    Instruction book Control panel Control panel Parts and functions Reference Designation Function Touch screen Shows the unit operating condition and several icons to navigate through the menu. The screen can be operated by touch. Warning sign Flashes in case of a shut-down and is lit in case of a warning condition.

  • Page 24: Icons Used

    Instruction book Icons used Menu icons Menu Icon Menu Icon Menu Icon Data Status Inputs Outputs Counters Aux. Equipment Converters Parameters Service Service Overview Service Plan Service History Service functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data AIF999999...
  • Page 25 Instruction book Menu Icon Menu Icon Menu Icon Machine Alarms Settings Regulation Control Parameters Aux. Equipment Converter(s) Parameters Internal SmartBox Auto Restart Controller Network Ethernet Settings Settings Settings CAN Settings Localisation Language Date/Time Units User Password Help Information Status icons Icon Description Motor Stopped...
  • Page 26 Instruction book Motor Stopped Wait Running Unloaded Manual Unload Running Unloaded Wait Running Loaded Failed to Load Running Loaded Wait Manual Stop Machine Control Mode, Local Machine Control Mode, Remote Machine Control Mode, LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description...
  • Page 27 Instruction book Antenna 50% Antenna 75% Antenna 100% Change between screens (indication) Energy recovery Dryer Element Drain(s) Analogue Output Menu Reset Auto Restart Filter(s) Cooler Valve(s) Power Meter Input icons Icon Description Pressure AIF999999...

  • Page 28: Main Screen

    Instruction book Temperature Special Protection Open Closed This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to every machine. Main screen Function The Main screen is the screen that is shown automatically when the voltage is switched on. It is switched off automatically after a few minutes when there is no touch input.

  • Page 29: Quick Access Screen

    Instruction book Reference Designation Function Alarm button The alarm button can be tapped to show the current alarms. If an alarm occurs, the icon on the button will be red. Service button The service button can be tapped to show the service information.

  • Page 30: Menu Screen

    Instruction book Function Description Setpoints Several setpoints can be modified by tapping this icon. Control mode The control mode can be changed by tapping this icon. • Local control via start/stop buttons • Remote control via digital input(s) • LAN control via the network. When in Remote or LAN control, the start/stop buttons on the controller will not work.
  • Page 31 Instruction book Reference Designation Function Service The service menu contains the Service information. The ‘Clean screen’ function can be used to clean the touchscreen. Week timer Multiple Week timers and a Remaining running time can be set through this menu. Event history In case of an alarm, the Status information of the unit is saved and can be viewed through this menu.

  • Page 32: Data Menu

    Instruction book Data menu Function This screen is used to display the following submenus: • Status • Inputs • Outputs • Counters • Aux. Equipment These submenus can be entered by tapping the icons. Procedure To enter the Data menu screen: 1.
  • Page 33 Instruction book If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the reset button (1). Before remedying, consult the Safety precautions. Before resetting a warning or shutdown message, always solve the problem. Frequently resetting these messages without remedying may damage the unit.

  • Page 34: Service Menu

    Instruction book This menu shows an overview of all actual hours and counters of the unit and controller. Auxiliary equipment menu Tap the Aux. Equipment icon to enter the Aux. equipment menu. This menu shows an overview of all auxiliary equipment fitted. Service menu Function This screen is used to display the following submenus:...
  • Page 35 Instruction book Description Reference Designation Service Service functions (Only visible as advanced user) Clean screen Service menu Tap the Service icon to enter the Service menu. This menu shows the remaining Running Hours and the remaining Real Time Hours until the next service.

  • Page 36: Week Timer Menu

    Instruction book Depending on the machine, this menu can have a different set of functions. Many of them are password protected, as they are only accessible for authorized personnel. Clean screen Tap the Clean Screen icon to start the 15 seconds countdown to perform cleaning of the touchscreen.

  • Page 37: 3.10 Event History Menu

    Instruction book Description Reference Designation Function Add or select week If less than 4 weeks are programmed, tap the ‘+’ button to add a week. Remove week Tap to remove a programmed week timer. Activate week timer A selection screen pops up. The user can choose the correct week by tapping ‘–’...

  • Page 38: 3.11 Machine Settings Menu

    Instruction book Reference Designation Saved Data Saved data Tap the Saved Data icon to enter the Saved Data menu. Scroll through the items swiping up and down in this list. The event date and time is shown at the right side of the screen. Press on one of the items in the list for more information reflecting the status of the unit when the shutdown occurred.
  • Page 39 Instruction book Description Reference Designation Alarms menu Regulation menu Control Parameters menu Aux. Equipment Parameters menu Auto Restart menu Alarms menu Tap the Alarms icon to enter the Alarms menu. A list of all alarms is shown. When pressing on one of the items in this list, the warning and/or shutdown levels are shown for this alarm.
  • Page 40 Instruction book When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’. Change a selection When tapping a list item, a selection screen pops up. The user can change the selection by swiping up or down and confirm by tapping ‘V’...

  • Page 41: 3.12 Controller Settings Menu

    Instruction book Through this menu, the automatic restart can be activated. The activation is password protected. The automatic restart settings can also be changed. Enter a password When tapping a password protected item, a selection screen pops up. The user can enter the password by swiping up or down to select the desired number.
  • Page 42 Instruction book Reference Designation Network Settings menu Localisation menu User Password menu Help menu Information menu Network settings menu Tap the Network Settings icon to enter the Network Settings menu. Ethernet Settings The list of Ethernet Settings is shown. When ethernet is turned off, the settings can be modified. CAN Settings The list of CAN Settings is shown.
  • Page 43 Instruction book The date and time settings of the controller can be modified through this menu. Units The units displayed can be modified through this menu. Modify a setting When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’...

  • Page 44: 3.13 Access Level

    Instruction book This menu shows information about the controller. 3.13 Access level Function Through this pop-up screen the access level settings can be viewed or changed. Procedure The Access Level screen can be viewed or changed by tapping the Access Level button at the upper right corner of the screen.
  • Page 45 Instruction book Service access level Tap the Service access level icon (1) and confirm (2). The screen information bar (1) now shows the current status of the unit instead of the machine serial number. The Received Signal Strength Indicator (RSSI) value is now shown in the Internal SmartBox menu.

  • Page 46: Installation

    Instruction book Installation Dimension drawing Dimension drawing, metric units Text on figure: AIF999999...
  • Page 47 Instruction book Air inlet for cubicle cooling Air outlet for blower cooling and cubicle cooling Air inlet for blower cooling and oil cooler cooling Air inlet for blower cooling and motor cooling Air inlet for blower Electrical cable passage Compressed air outlet Center of gravity View A (10)

  • Page 48: Installation Proposal

    Instruction book Installation proposal Unit room example Blower room example, metric units AIF999999...
  • Page 49 Instruction book Text on figure Drawing reference Description Blower and cubicle cooling air outlet Process air inlet Cooling air inlet, cubicle Cooling air inlet, oil cooler Cooling air inlet, motor Warning The maximum allowed pressure from the connected air net on the unit is 2 bar (29 psi). Thermal insulation should be provided to protect against the high temperature of the air outlet valve and air delivery pipe.
  • Page 50 Instruction book 8. Installation of acoustic insulation material to prevent sound reflections from the cooling air intake. 9. Ventilation proposals. If the installation is done without ducts, the ventilation flow can be calculated as follows: For SI Units Q = (0.1799 x N + 2.465) / dT •...

  • Page 51: Electrical Connections

    General instruction for the electrical installation of VSD units • Electrical equipment from Atlas Copco Compressor is designed in accordance with the safety regulations described in IEC60204-1 and CENELEC EN60204. • It is the responsibility of the customer to install the unit according to the safety regulations in order to protect people from electric shocks from direct or indirect contact.
  • Page 52 In the case of TT-systems, safety regulations mostly stipulate the use of an earth leakage circuit breaker (e.l.c.b). In combination with frequency converters, type B residual current-operated protective devices should be used. Atlas Copco advises customers to install the following earth leakage detection device: BENDER RCMA 470LY with external current transformer: http:// www.bender.org/prod.html...
  • Page 53 Instruction book In the TN-C power distribution system, the neutral and the protective earth functions are combined in a single conductor. Power system earth Exposed conductive parts Network type TN-C-S (Terra Neutral-Combined-Separate) : In the TN-C-S power distribution system, the neutral and the protective earth functions are combined to some degree in a single conductor, a direct earth to the exposed conductive parts of the installation exists in part.
  • Page 54 Instruction book Power system earth Exposed conductive parts Network type IT (Impedance Terra) : The IT power distribution system has no direct connection to Protective Earth (PE). It is earthed via a high ohmic impedance, so that the network is effectively behaving like an unearthed floating network.
  • Page 55 Instruction book Electrical connections ZS 4 VSD blower with starter Drawing reference Description Main motor Please refer to the electrical cabinet door for the entire service diagram. AIF999999...

  • Page 56: Quality Of Safety Components

    Instruction book ZS 4 VSD blower with starter Motor power (kW) Cable section Maximum cable Maximum current Maximum fuse (A) length (m) 95 mm² 213.3 AWG 0 188.0 Quality of safety components When installing a remote emergency button or a motor contactor, the following B10d values are advised: •...

  • Page 57: Pictographs

    Instruction book Pictographs Pictographs Reference Name Pictograph, Automatic start - Read manual - No service with voltage and pressure on Pictograph, warning: blow off Pictograph, warning: under tension Pictograph, warning: hot surface Pictograph, transport instructions Stop the unit before maintenance or repair Pictograph, earthing Rotation direction arrow Only use Roto-Z oil...
  • Page 58 Instruction book Reference Name CAUTION: capacitive voltage above 50 V may remain for 5 min after power disconnection Disconnect from the electrical supply before opening Pictographs on control panel Refer to the chapter Controller panel for pictographs of the Elektronikon controller. Torque instruction Please refer to the label in the electrical cabinet for the torque values of the electrical connections.

  • Page 59: Operating Instructions

    If the unit is installed outdoors or if the air inlet temperature can be below 0 ˚C/32 ˚F, precautions must be taken. If this is the case, or if the unit is being operated at high altitudes, consult the Atlas Copco Customer Center. Moving/lifting In order not to damage the frame, the unit must be moved either by a lift truck or by using lifting equipment as described below.

  • Page 60: Before Starting

    5. Switch on the voltage. Start the motor and stop it immediately. Check for correct direction of rotation as indicated by the arrow on the motor. Consult Atlas Copco if the rotation direction is wrong. Running the motor in the wrong direction of rotation may damage the element.

  • Page 61: Starting

    Instruction book Procedure 1. Check the oil level, which must be in the middle of the sight-glass. Top up, if necessary, with the correct type of oil. 2. Open the air outlet valve (customer's installation). 3. Switch on the voltage and check that voltage sign (5) lights up. Starting Control panel AIF999999...

  • Page 62: During Operation

    Instruction book Starting • If the motor is stopped and operation sign (4) is alight, the motor may start automatically. • If the week timer is active, the unit can start automatically, even if it was stopped manually. • Open the air outlet valve. •...

  • Page 63: Checking The Display

    Instruction book Checking the display Control panel Procedure Before carrying out any maintenance, repair or adjustment work, stop the unit, press the emergency stop button, switch off the voltage and depressurize the unit. Step Action Regularly check the display for readings and messages. Normally, the main display is shown, indicating the unit outlet pressure and the status of the unit.

  • Page 64: Stopping

    Instruction book Stopping Control panel Description • Press stop button (6). • Close the air outlet valve. Emergency stopping • To stop the unit immediately, press the emergency stop button. Warning sign (2) starts blinking. • Close the air outlet valve. •...
  • Page 65 Instruction book Step Action Drain the oil, catch the oil in a receptacle. Dispose of the oil according to local regulations. Also read section Used material for the disposal of used material. AIF999999...

  • Page 66: Maintenance

    Warranty or Product Liability. 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 67 Instruction book Period Running hours Operation Daily Check the oil level. Before starting, the level should be in the middle of the sight-glass. Weekly Drain condensate from the air receiver, if installed Every 3 months Clean unit. Every 3 months Check for possible leaks.

  • Page 68: Motor Greasing

    Oil specifications Roto-Z lubricating oil Use only Atlas Copco Roto-Z oil which is specially developed for oil-free rotary units. This oil has a long service life and ensures optimum lubrication. Atlas Copco Roto-Z oil can be ordered in following quantities:...

  • Page 69: Servicing Procedures

    Instruction book Servicing procedures Air filter Procedure 1. The filter must be serviced as soon as the service warning appears on the display. 2. Stop the unit, press the emergency stop button and switch off the voltage. Never remove the elements while the unit is running.

  • Page 70: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Oil system Procedure Step Action Run the unit until warm. Stop the unit, press the emergency stop button. Switch off the voltage. Remove filler plug (FC). Drain the sump by opening drain valve (Dm1). Remove the oil filter (OF).

  • Page 71: Safety Valve

    Instruction book Safety valve Description When the blower runs loaded, the main valve disk is closed. The bellows and outlet pipeline are connected by the control valve (5). If the pressure exceeds the limits, the control valve opens and releases air into the atmosphere. The pressure in the bellows is reduced and the main valve disk starts to open.

  • Page 72: Problem Solving

    Instruction book Problem solving Problem solving Before carrying out any maintenance, repair or adjustment work, stop the unit, switch off the voltage and close the air outlet valve. Press the emergency stop button. Open and lock the isolating switch. The operator must apply all relevant Safety precautions.
  • Page 73 Instruction book The service switch may only be used for a test run and not for continuous running. AIF999999...

  • Page 74: Technical Data

    Instruction book Technical data Readings Important The readings below are valid when operating at reference conditions. See Reference conditions. Readings on display For the maximum working pressure, consult section Machine data. The readings depend on the unit type. The values given below are average values and may differ depending on the unit type.

  • Page 75: Machine Data

    40 ˚C Minimum ambient temperature -20 ˚C For working points exceeding these limitations, please contact your customer centre. Machine data ZS 4 VSD, 90 kW input power, with starter Nominal/ maximum working pressure Mean sound pressure level dB(A) 78.5 Oil capacity (approximately)

  • Page 76: Pressure Equipment Directives

    Instruction book Pressure equipment directives Parts of article 4.3 of 2014/68/EU are subject to Sound Engineering Practice (SEP). Parts of category I according to 2014/68/EU are integrated into the machine and fall under the exclusion of article 1.2, (f)(i). Parts subject to the Simple Pressure Vessel Directive 2014/29/EU are excluded from 2014/68/EU according to article 1.2 (c).

  • Page 77: Documentation

    Instruction book Documentation Declaration of conformity Typical example of a Declaration of Conformity document (1): Manufacturer (2): Applicable directives (3): Standards used (4): Technical file holder AIF999999...
  • Page 78 Instruction book (5): Contact address of the manufacturer On the Declaration of Conformity, the harmonized and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity is part of the documentation that is supplied with this device. AIF999999...
  • Page 80 This is what we call - Sustainable Productivity. Atlas Copco Airpower Oil-free Air Division, Boomsesteenweg 957, 2610 Wilrijk, Belgium Phone: +32 (0)3 870 21 11 Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.

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