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Instruction book
Atlas Copco Stationary Air Compressors
ZT55-ZT75-ZT90
ZR55-ZR75-ZR90
Instruction book
From following serial number onwards: AIF-077 519
Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium.
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 meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines
Important
This book must be used together with the related User manual for Elektronikon® regulator, Printed Matter
No. 2920 1478 xx.
No. 2920 1452 02
(Replaces 2920 1452 01)
Registration code: APC Z55-90 / 38 / 994
2003-3
www.atlascopco.com
2920 1452 02
1
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Related Manuals for Atlas Copco ZT55-ZT75-ZT90
Summary of Contents for Atlas Copco ZT55-ZT75-ZT90
- Page 1 ZR55-ZR75-ZR90 Instruction book From following serial number onwards: AIF-077 519 Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium. 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.
- Page 2 Follow all applicable safety precautions, amongst others those mentioned in this book. Repairs must be carried out by trained personnel from Atlas Copco who can also be contacted for any further information. In all correspondence mention the type and the serial number, shown on the data plate.
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Page 3: Table Of Contents
Instruction book 1 LEADING PARTICULARS......................... 5 1.1 General description..........................5 1.2 Air flow (Figs. 1.6 and 1.7)........................ 10 1.3 Condensate drain system (Figs. 1.6, 1.7 and 1.8)................11 1.3.1 Description ..........................11 1.3.2 Testing the electronic water drain ....................11 1.4 Oil system ............................ - Page 4 Instruction book 7.1 Readings on display (Fig. 1.12) ......................56 7.2 Settings of safety valves ........................56 7.3 Settings of circuit breakers - fuses..................... 56 7.4 Compressor specifications......................... 58 7.4.1 Reference conditions ........................58 7.4.2 Limitations ........................... 58 7.4.3 Specific data, ZR - 7.5 bar - 50Hz....................58 7.4.4 Specific data, ZR - 8.6 bar - 50Hz....................
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Page 5: Leading Particulars
Instruction book 1 LEADING PARTICULARS 1.1 General description ZR55-ZR75-ZR90 and ZT55-ZT75-ZT90 are two-stage screw compressors, driven by an electric motor. The compressors deliver oil-free, pulsation-free air. ZR compressors are water-cooled, whereas ZT compressors are air-cooled. ZR/ZT Full-Feature compressors are additionally provided with an air dryer which removes moisture from compressed air. - Page 6 Instruction book Air filter Air outlet Silencer Aftercooler Oil cooler Daa Automatic condensate outlet, aftercooler Automatic condensate outlet, intercooler Low-pressure compressor element Drive motor SVh High-pressure safety valve Low-pressure safety valve Emergency stop button Load/no-load valve Silencer Cooling water inlet WO Cooling water outlet Loading solenoid valve Flange, connection to MD dryer...
- Page 7 Instruction book Air filter By-pass valve Oil cooler Oil drain valve, gear casing EWDa Electronic water drain, aftercooler EWDi Electronic water drain, intercooler Moisture trap, aftercooler Moisture trap, intercooler Drive motor Oil filter Oil level sight-glass High-pressure safety valve Low-pressure safety valve Loading solenoid valve Fig.
- Page 8 Instruction book Air filter Aftercooler Intercooler Low-pressure compressor element Load/no-load valve Loading solenoid valve Dryer Throttle valve, regeneration air inlet Electronic water drains (EWD) Rotor drive assembly Fig. 1.3 Rear view, ZR90 Full-Feature 2920 1452 02...
- Page 9 Instruction book Air filter By-pass valve Pre-aftercooler Aftercooler Intercooler Oil cooler High-pressure compressor element Low-pressure compressor element EWDi Electronic water drain, intercooler Oil filler cap Moisture trap, intercooler Drive motor Low-pressure safety valve Loading solenoid valve Flange, moisture trap intercooler Fig.
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Page 10: Air Flow (Figs. 1.6 And 1.7)
Instruction book Air filter Pre-aftercooler Aftercooler Intercooler Oil cooler EWDa Electronic water drain, aftercooler Moisture trap, aftercooler High-pressure safety valve Load/no-load valve Plate Vent plug, oil cooler Drain plug, oil cooler Fig. 1.5 Rear view, ZT90 1.2 Air flow (Figs. 1.6 and 1.7) Pack compressors Air drawn through filter (AF) is compressed in low-pressure compressor element (El) and discharged to intercooler (Ci). -
Page 11: Condensate Drain System (Figs. 1.6, 1.7 And 1.8)
Instruction book Full-Feature compressors 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 aftercooler(s) (Ca for ZR and Ca1 and Ca2 for ZT) towards the air dryer. - Page 12 Instruction book Checking the alarm signal Press the test button for at least 1 minute. Check that the alarm LED flashes. Release the test button. 2920 1452 02...
- Page 13 Instruction book Fig. 1.6 Flow diagram/regulating system, ZR 2920 1452 02...
- Page 14 Instruction book Fig. 1.7 Flow diagram/regulating system, ZT 2920 1452 02...
- Page 15 Instruction book Air filter Plunger Silencer Chamber Air outlet valve (customer’s installation) Diaphragm Aftercooler Valve for (+) connection, pressure difference Pre-aftercooler gauge Aftercooler Valve for (-) connection, pressure difference Intercooler gauge Elektronikon regulator Throttle valve, regeneration inlet air Oil cooler Shut-off valve, hot regeneration inlet air Check valve Strainer...
- Page 16 Instruction book Inlet Collector Sensor Pilot valve Diaphragm Outlet Fig. 1.8 Electronic water drain Fig. 1.9 Drain frequency during alarm condition 2920 1452 02...
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Page 17: Oil System
Instruction book Fig. 1.10 Control panel, electronic water drain 1.4 Oil system ZR compressors (Fig. 1.6) Oil is circulated by pump (OP) from the sump of the gear casing through cooler (Co) and filter (OF) towards the bearings and timing gears. Valve (BV-Fig. 1.2) opens if the oil pressure should rise above a given value. -
Page 18: Elektronikon Control System
Instruction book F3/4 Circuit breakers, control circuit Circuit breaker for electronically controlled automatic condensate drains Overload relay, drive motor Auxiliary relay, loading Line contactor Star contactor Delta contactor Circuit breaker, control circuit Main transformer Transformer, control circuit Power supply terminals 1X4/5/6/7 Terminal strips Fig. -
Page 19: Protecting The Compressor
The regulator has a built-in function to automatically restart the compressor when 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 Atlas Copco. Warning If activated and provided the module was in the automatic operation mode, the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period. -
Page 20: Control Panel
Instruction book 1.8 Control panel Fig. 1.12 Control panel Ref. Designation Function Start button Push button to start the compressor. LED (8) lights up indicating that the Elektronikon regulator is operative. Display Indicates messages concerning the compressor operating condition, a service need or a fault. -
Page 21: Function Keys (5-Fig. 1.12)
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 Mainscreen To return from a menu to the main screen (Fig. 1.13) Menu Starting from the main screen (Fig. - Page 22 Instruction book Warning Before connecting external equipment, stop the compressor and apply all safety precautions as mentioned in section 4. 2920 1452 02...
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Page 23: Installation
Instruction book 2 INSTALLATION 2.1 Dimension drawings Fig. 2.1 Dimension drawing, ZR 2920 1452 02... - Page 24 Instruction book Fig. 2.2 Dimension drawing, ZR Full-Feature 2920 1452 02...
- Page 25 Instruction book Fig. 2.3 Dimension drawing, ZT 2920 1452 02...
- Page 26 Instruction book Fig. 2.4 Dimension drawing, ZT Full-Feature 2920 1452 02...
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Page 27: Installation Proposals (Figs. 2.5 And 2.8)
Instruction book Text on Figs. 2.1up to 2.4 Voltage supply entry Compressed air outlet Cooling air inlet Opening for transportation 4 slotted holes for horizontally pulling out of container only Cooling air outlet Hole pattern ducting Automatic drain, aftercooler Automatic drain, intercooler (10) Compressed air outlet, compensator (11) Mass (12) Water in/out, compensator... - Page 28 If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30 Pa. Common ducting for several compressors is not allowed. For detailed information regarding ventilation proposals, contact your Atlas Copco Service Centre. Lay out the drain piping from automatic condensate outlets (EWD) towards the condensate collector.
- Page 29 Instruction book Fig. 2.5 Installation proposal, ZR 2920 1452 02...
- Page 30 Instruction book Fig. 2.6 Installation proposal, ZR Full-Feature 2920 1452 02...
- Page 31 Instruction book Fig. 2.7 Installation proposal, ZT 2920 1452 02...
- Page 32 Instruction book Fig. 2.8 Installation proposal, ZT Full-Feature 2920 1452 02...
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Page 33: Electric Cables
Instruction book Text on Figs. 2.5 up to 2.8 (1) Minimum free area (2) Ventilation proposals 2.3 Electric cables Mains + earth cable 50Hz IEC Compressor Voltage Supply cables ZR/ZT55 200V 2x (3 x 70 + 35) mm² ZR/ZT55 230V 2x (3 x 70 + 35) mm²... - Page 34 Instruction book 60Hz IEC Compressor Voltage Supply cables ZR/ZT75 200V 2x (3 x 120 + 70) mm² ZR/ZT75 220-230V 2x (3 x 95 + 50) mm² ZR/ZT75 380V 3 x 120 + 70 mm² ZR/ZT75 440-460V 3 x 95 + 50 mm² ZR/ZT75 575V 3 x 70 + 25 mm²...
- Page 35 Instruction book Fig. 2.9 Electrical connections Text on Fig. 2.9 (1) Customer's installation (2) Compressor motor, 440-460V 60Hz (3) Compressor motor, all voltages except for 440-460V 60Hz (4) Warning (5) Shut-down (6) Only for ZT 200-230V (7) Motor heater (8) Thermistor protection (9) Only for ZT 380-575V (10) Fan motor, external dryer.
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Page 36: Cooling Water Requirements
Instruction book 2.4 Cooling water requirements 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. This recommendation is a general guide line for acceptable coolant quality. - Page 37 Instruction book Total Dissolved Temperature Ca-hardness M-Alkalinity solids (mg/l) (°C) (ppm CaCO (mval/l) 50 - 300 0 - 1 10 - 11 0.20 - 0.22 400 - 1000 2 - 6 12 - 13 0.24 - 0.26 7 - 9 14 - 17 0.28 - 0.34 10 - 13...
- Page 38 Instruction book The RSI only indicates the equilibrium of scaling – descaling. Cooling water showing good RSI conditions can still be unsuitable due to other factors. From the table above, the RSI index should be between 5.6 and 7.5; otherwise, contact a specialist. The effect of pH is already calculated in the Rysnar index, but the pH itself has some additional limitations: Z-units 6.8 <...
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Page 39: Pictographs (Figs. 2.10 And 2.11)
Instruction book Organics No algae. No oil. Suspended solids Non-soluble particles, size < 1mm. < 10 ppm 2.5 Pictographs (Figs. 2.10 and 2.11) Start Scroll keys Tabulator key Voltage on Alarm Automatic operation Stop S2 Emergency stop Fig. 2.10 Pictographs on control panel Automatic condensate outlet, intercooler Automatic condensate outlet, aftercooler 10 Warning: under tension... -
Page 40: Operating Instructions
Instruction book 3 OPERATING INSTRUCTIONS Safety precautions The operator must apply all related safety precautions including those mentioned in this book. Ambient conditions Consult section 7 for the limitations with regard to the ambient conditions and altitude operation. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame. - Page 41 Instruction book Transport support (painted red), to be removed Fig. 3.2 Gear casing transport support, ZR 2920 1452 02...
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Page 42: Initial Start-Up
Instruction book Transport bolt, to be removed Transport supports (painted red), to be removed Transport support (painted red), to be removed Figs. 3.3 Transport supports for gear casing and coolers, ZT 3.1 Initial start-up 1. Read the User manual for Elektronikon® regulator to familiarize yourself with all regulator functions. 2. -
Page 43: Before Starting
Instruction book On ZR Full-Feature, the inlet and outlet valves of the cooling water circuit of the regeneration cooler must be opened completely. 9. Check that the gear casing is filled with oil: oil must be visible in sight-glass (SG-Fig. 3.4). 10. -
Page 44: Starting (Fig. 1.12)
Instruction book 2. On ZR, 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 valve has not been disturbed. By-pass valve Oil drain valve, gear casing Oil filler cap Oil filter Oil level sight-glass... -
Page 45: During Operation (Fig. 1.12)
3. The display will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded. Carry out the service actions of the indicated plans or replace the component and reset the relevant timer. Consult your Atlas Copco Customer Centre. See also section 4.1. -
Page 46: Taking Out Of Operation
Instruction book 6. For ZR, 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 the drain plugs: 2-Fig. - Page 47 Instruction book High-pressure compressor element Water drain plug (painted green) Fig. 3.6 Water drain plug, HP compressor element (ZR compressors only) Water drain plug, oil cooler Fig. 3.7 Water drain plug, oil cooler (ZR compressors only) 2920 1452 02...
- Page 48 Instruction book DP2/3 Water drain plugs (painted green) Cooler block Fig. 3.8 Water drain plugs, cooler block (ZR compressors only) 2920 1452 02...
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Page 49: Maintenance
(see section 4.1.4) 4.1.2 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 50: Service Agreements
Elektronikon regulator. When reaching a level, a message will appear on the screen. After carrying out all service actions, the interval timers are to be reset using the key "Reset" in menu "Service". Consult your Atlas Copco Customer Centre. -
Page 51: Storage After Installation
Copco parts while keeping the maintenance budget low. All service kits are mentioned in the relevant Parts Lists. Atlas Copco Roto-Z oil Atlas Copco Roto-Z oil can be ordered in following quantities: Quantity Ordering number 20-litre can 2908 8501 01... -
Page 52: Servicing Procedures
5.3 Safety valves Testing The valves can be tested on a separate compressed air line. If a valve does not open at the pressure specified in section 7.2, consult Atlas Copco. Warning Never run the compressor without safety valves. No adjustments are allowed. -
Page 53: Problem Solving
Check water temperature and increase cooling water flow On ZR, restriction in cooling water system due to formation of scale or settling down of dirt Consult Atlas Copco Condensate is not discharged from condensate traps during operation Discharge flexible clogged... - Page 54 Aftercooler air outlet temperature too high On water-cooled compressors, check cooling water inlet temperature and increase water flow. If temperature cannot be decreased sufficiently, consult Atlas Copco On air-cooled compressors, clean cooler externally. If temperature cannot be decreased sufficiently, consult Atlas Copco...
- Page 55 Instruction book 11 Condensate only discharged when test button is pressed Sensor dirty Clean sensor Air pressure below minimum pressure Increase air pressure 12 EWD continuously discharges air Control air blocked Check and correct as necessary Sensor dirty Clean sensor 2920 1452 02...
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Page 56: Principal Data
Instruction book 7 PRINCIPAL DATA 7.1 Readings on display (Fig. 1.12) Outlet pressure bar(e) Depends on pressure setpoint Maximum working pressure bar(e) See section 7.4 7.2 Settings of safety valves Low-pressure safety valve bar(e) High-pressure safety valve for ZT/ZR90 7.25 bar 60Hz bar(e) 11.0 compressors... - Page 57 Instruction book ZR/ZT55 380V 3.08 ZR/ZT55 440-460V 3.08 ZR/ZT55 575V 2.37 60Hz IEC Compressor Voltage F21 (A) Q25 (A) Q41 (A) Q1 (A) Fuses Type 2 gG (A) ZR/ZT75 200V 16.5 5.28 ZR/ZT75 220-230V 14.9 5.28 ZR/ZT75 380V 3.08 ZR/ZT75 440-460V 3.08 ZR/ZT75...
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Page 58: Compressor Specifications
Instruction book 7.4 Compressor specifications 7.4.1 Reference conditions Absolute inlet pressure bar(a) Nominal working pressure bar(e) See below Relative air humidity Air inlet temperature °C Cooling water inlet temperature °C 7.4.2 Limitations Maximum air inlet temperature °C Minimum air inlet temperature °C Maximum cooling water temperature at inlet (at temperature rise of °C... -
Page 59: Specific Data, Zr - 10 Bar - 50Hz
Instruction book - Pack bar(e) - Full-Feature bar(e) 8.35 8.35 8.35 Power input at maximum working pressure - Pack 61.5 83.4 96.7 - Full-Feature 61.1 82.9 96.0 Oil capacity Sound pressure level 1) dB(A) Cooling water consumption - Pack (temperature rise of 15°C) - Full-Feature (temperature rise of 10°C) 7.4.5 Specific data, ZR - 10 bar - 50Hz Unit... -
Page 60: Specific Data, Zr - 10.4 Bar - 60Hz
Instruction book - Pack bar(e) - Full-Feature bar(e) 8.75 8.75 8.75 Power input at maximum working pressure - Pack 66.5 89.9 106.3 - Full-Feature 66.0 89.3 105.6 Oil capacity Sound pressure level 1) dB(A) Cooling water consumption - Pack (temperature rise of 15°C) - Full-Feature (temperature rise of 10°C) 7.4.8 Specific data, ZR - 10.4 bar - 60Hz Unit... -
Page 61: Specific Data, Zt - 10 Bar - 50Hz
Instruction book - Pack 64.1 88.3 103.7 - Full-Feature 65.1 89.2 104.4 Oil capacity Sound pressure level 1) dB(A) 7.4.11 Specific data, ZT - 10 bar - 50Hz Unit ZT55 ZT75 ZT90 Nominal working pressure bar(e) Maximum working pressure - Pack bar(e) - Full-Feature bar(e) -
Page 62: Specific Data, Zt - 10.4 Bar - 60Hz
Instruction book 7.4.14 Specific data, ZT - 10.4 bar - 60Hz Unit ZT55 ZT75 ZT90 Nominal working pressure bar(e) Maximum working pressure - Pack bar(e) 10.4 10.4 10.4 - Full-Feature bar(e) 10.15 10.15 10.15 Power input at maximum working pressure - Pack 68.6 97.1... - Page 63 Atlas Copco compressor instruction book: ....Atlas Copco air dryer instruction book: ......
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Questions and answers
Причины перегрев 1 ступени компрессор ZT 75. Температура поднимается до 225гр и уходит в аварию. На улице 32гр плюс. Компрессор стоит в помещении.
Possible causes of overheating in the first stage of the Atlas Copco ZT 75 compressor, with temperatures reaching 225 degrees, include:
1. Blocked or insufficient cooling water flow, especially in open or closed cooling systems.
2. High ambient temperature exceeding 40°C.
3. Malfunctioning temperature sensors.
4. Faulty motor leading to overload.
5. Thermistor protection failure.
6. Inadequate ventilation or fan motor overload.
7. Dirty or clogged intercooler.
These issues can cause the compressor to exceed programmed shut-down temperature levels.
This answer is automatically generated
@Mr. Anderson Компрессор безмасляный, охлождение у него воздушное.
Добрый день. На панельке высветился значок красный и надпись ТРЕВОГА КОНВЕРТЕРА компрессор ZT90 безмасляный. В данный момент работает ZT75 без частотного регулирования а ZT90 стоит в ожидании когда если давление снизится на ZT75 то он включится в работу автоматически. Вопрос про ZT90 , почему высветился статус ТРЕВОГА КОНВЕРТЕРА? Где искать причину, что сделать? Спасибо за ответ.