Atlas Copco ZT 55 VSD Instruction Book
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Atlas Copco ZT 55 VSD Instruction Book

Atlas Copco ZT 55 VSD Instruction Book

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API797429
ZT 55 VSD
Instruction book

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  • Page 1 API797429 ZT 55 VSD Instruction book...
  • Page 3 Atlas Copco ZT 55 VSD API797429 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 Additional safety precautions..................5 ........................... 5 AFETY ICONS ......................5 ENERAL SAFETY PRECAUTIONS ................... 6 AFETY PRECAUTIONS DURING INSTALLATION ....................7 AFETY PRECAUTIONS DURING OPERATION ................9 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR .......................10 ISMANTLING AND DISPOSAL General description......................
  • Page 5 Instruction book 3.12 ......................38 ONTROLLER SETTINGS MENU 3.13 ..........................41 CCESS LEVEL Installation........................43 ........................43 NSTALLATION WARNINGS ........................44 IMENSION DRAWINGS ........................46 NSTALLATION PROPOSAL ........................48 LECTRIC CONNECTIONS ..........................51 ICTOGRAPHS Operating instructions....................54 .........................54 PERATION INTRODUCTION ..........................54 NITIAL START ............................56 TARTING ..........................
  • Page 6 Instruction book ..................66 DJUSTMENT OF THE INTERCOOLER PRESSURE ..........................66 OTOR GREASING ..........................66 AFETY VALVES Faults and remedies..................... 68 Principal data........................ 70 ........................70 EADINGS ON DISPLAY ........................71 LECTRIC CABLE SIZE ......................75 ETTINGS OF SAFETY VALVES ....................75 VERLOAD RELAY AND FUSE SETTINGS ........................

  • Page 7: Additional Safety Precautions

    Instruction book Additional 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. The Variable Speed Drive is equipped with a Safe Torque Off function, triggered by the emergency stop button. The Safe Torque Off function has the immediate effect that the drive can not supply any torque-generating energy. The drive is reliably torque-free. This state is monitored internally in the drive.

  • Page 9: Safety Precautions During Operation

    Instruction book The operator has to make sure that the machine is stopped and depressurized and that the electrical isolating switch is open, locked and labelled with a temporary warning before any maintenance or repair. As a further safeguard, persons switching on or off remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine.
  • Page 10 Instruction book 2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully depressurized before disconnecting it. 3.

  • Page 11: Safety Precautions During Maintenance Or Repair

    Instruction book Safety precautions during maintenance or repair 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 12: Dismantling And Disposal

    Instruction book If damaged, replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing. 20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls. 21. Only if applicable, the following safety precautions are stressed when handling refrigerant: •...
  • Page 13 Instruction book Disposal of other used material Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation. API797429...

  • Page 14: General Description

    Instruction book General description Introduction General description The VSD (Variable Speed Drive) machines are two-stage rotary tooth compressors, driven by an electric motor. The compressors deliver oil-free air. ZT are air-cooled and ZR are water-cooled. By continuously matching the speed of the drive motor to the air demand, the VSD compressor optimizes energy consumption and reduces the operating pressure band.

  • Page 15: Air Flow

    Instruction book Air outlet valve Emergency stop button Elektronikon regulator Condensate drains Converter cabinet Front view, Pack Outlet valve Aftercooler Intercooler Oil cooler High-pressure compressor element Oil filler plug Cooling fan Compressor drive motor Fan motor Oil filter (not shown) Oil level sight glass Emergency stop button Elektronikon...

  • Page 16: Condensate Drain System

    Instruction book the blow-off silencer (US). The check valve (CV) prevents that compressed air downstream of the check valve is blown off. References used in all flow diagrams Air inlet Oil flow Air outlet Refrigerant gas Air flow Water flow Refrigerant fluid References used for the compressor Ref.

  • Page 17: Oil System

    Instruction book Electronic water drains, typical example The drains are connected to the side panel of the compressor as shown in the next figure: Condensate drain connections Ref. Designation Ref. Designation Automatic drain, aftercooler Automatic drain, dryer (FF units) Automatic drain, intercooler Manual drain, dryer (FF units) Manual drain, intercooler Manual drain, regeneration cooler IMD...

  • Page 18: Cooling System

    Instruction book The oil system is equipped with a valve that opens if the oil pressure rises above a given value. The valve is located before the oil filter housing. Cooling system Figures: see section Air flow. ZT compressors are provided with an air-cooled oil cooler (Co), an intercooler (Ci) and an aftercooler (Ca).
  • Page 19 Instruction book Converter cabinet F1/2 Fuses Contactor F7/8/9 Fuses Fan motor protection Main contactor Transformer Contactor Elektronikon regulator Contactor Emergency stop button Frequency converter RFI filter Inductor API797429...

  • Page 20: 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 21 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 22: 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 23: 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 API797429...
  • Page 24 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 25 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 26 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 API797429...

  • Page 27: 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 28: 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 29: 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 30 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 31: 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 32 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 33: 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 34 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 35: 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 36: 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 37: 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 38 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 39 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 40: 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 41 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 42 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 43: 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 44 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 45: Installation

    • Working with machinery controlled by a frequency converter requires special safety precautions which depend on the type of network (TN, TT or IT). Consult Atlas Copco. • Thermal insulation should be provided to offer protection against the high temperature of the air outlet valve and air delivery pipe.

  • Page 46: Dimension Drawings

    Instruction book Dimension drawings Dimension drawing, ZT 37/55 VSD compressor, metric units Reference Description Electrical cable passage Cubicle cooling air inlet Cubicle cooling air outlet API797429...
  • Page 47 Instruction book Reference Description Compressed air outlet ANSI flange, optional Valve rotation Anchor pads 4x, optional Cooling air outlet of coolers and motor Dryer cooling air outlet, optional ID or IMD cooling air inlet, optional Mainswitch (intern), optional Motor cooling air and compressor air inlet Automatic drain, intercooler Automatic drain, aftercooler Prepared for automatic drain ID or IMD or breather...

  • Page 48: Installation Proposal

    Instruction book Installation proposal Compressor room example Installation proposal API797429...
  • Page 49 To preserve the protection degree of the electric cubicle and to protect its components from dust from the environment, it is mandatory to use a proper cable gland when connecting the supply cable to the compressor. In case of an IT network, consult Atlas Copco. 8. Safety valve API797429...

  • Page 50: Electric Connections

    Instruction book 9. Cooling water supply (only for ZR compressors): Water flow and pressure to be adjusted depending upon local conditions. For cooling water quality see Cooling water requirements. For maintenance purpose the cooling water in- and outlet have to be provided with shut-off valves. Note All pipes must be connected stress-free to the compressor unit.
  • Page 51 Instruction book install the following earth-leakage detection device: BENDER RCMA 470LY with external current transformer. • Network type TT: In case of TT-systems, safety regulations mostly impose 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.
  • Page 52 Instruction book Reference Compressor Solenoid valve, throttle Solenoid valve, breather Reference Starter cubicle Compressor control module F1...Fx Fuses Overload relay, fan motor (IT-versions) Overload relay, compressor motor Line contactor Star contactor Delta contactor Circuit breaker, fan motor Remote start/programmed stop Emergency stop Emergency stop remote Remote load/unload button (fixed speed compressors)

  • Page 53: Pictographs

    Instruction book Reference Analog and digital input expansion module (IO2) Auxiliary relay, general warning Not used Auxiliary relay, motor running Auxiliary relay, forced intercooler Auxiliary relay, compressor loaded Not used Not used Not used Reference Optional equipment R1, K34 Drive motor thermistor protection, shutdown R2, K35 Drive motor thermistor protection, warning R96/R97...
  • Page 54 Instruction book Reference Name Automatic condensate outlet, intercooler Automatic condensate outlet, aftercooler Warning: under tension Read Instruction book before starting the compressor Lock out/ tag out API797429...
  • Page 55 Instruction book Reference Name Before connecting the compressor electrically, consult the Instruction book for the motor rotation direction (fixed speed compressors) Torques for steel (Fe) or brass (CuZn) bolts Consult the Instruction book for lubrication instructions Switch off the voltage before removing the protecting cover inside the electric cabinet Oil the gaskets, screw on the filters and tighten by hand (approx.

  • Page 56: Operating Instructions

    Instruction book Operating instructions Operation introduction Warning The operator must apply all relevant safety precautions. Ambient conditions Consult Limitations for operation 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 57 Instruction book Example of transport fixations Also remove the 2 extra fixation bolts (7) on the roof. 5. Check the oil level: the level should be between the 2 lines on the sight-glass (SG). Add oil via the filler plug (FC) if necessary. See Oil specifications for details about the oil to be used. Detail of crankcase with oil filler plug (FC) and sight glass (SG) 6.

  • Page 58: Starting

    Arrow (1) on the gear casing indicates the correct rotation direction. If the rotation direction is wrong, contact Atlas Copco. On air-cooled compressors, check also the rotation direction of the fan motor (FN). The cooling air must be blown through the outlet grating on the roof.

  • Page 59: During Operation

    Instruction book When the compressor is stopped and automatic operation sign (4) is alight, the compressor may start automatically. If the timer function is active, the compressor may start automatically, even if it was stopped manually. During operation API797429...
  • Page 60 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. • Regularly check the actual compressor status by pressing the arrow down key from the main screen.

  • Page 61: Stopping

    Instruction book Stopping Elektronikon regulator 1. Press the test button on top of all electronic drains to discharge the condensate. See Air dryer on Full-Feature. 2. Press the stop button (6) of the Elektronikon regulator: the compressor will stop and the sign for automatic operation (4) will go out.

  • Page 62: Maintenance

    • Follow all relevant instructions given in the section Safety precautions. 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.

  • Page 63: Service Kits

    Consult the Spare Parts List for part numbers. Service agreements Atlas Copco Customer Centres have a range of service agreements to suit your needs: • An Inspection plan. • A Preventive maintenance plan. • A Total responsibility plan.

  • Page 64: Service Plan

    Specific requirements for compressors equipped with a frequency converter Depending on the duration of the storage, a special procedure is necessary to switch on the power in order not to damage the capacitors of the frequency converter. Contact Atlas Copco. API797429...
  • Page 65 Instruction book Forming of the capacitors in function of the storage time Ref. Storage time Required action Storage period < 1 year No action required Storage period between 1 and 2 years Prior to energizing, connect to voltage for 1 hour Storage period between 2 and 3 years Prior to energizing, form according to the...

  • Page 66: Servicing Procedures

    Instruction book Servicing procedures Air filter (AF) Location of the air filter Procedure Step Action Stop the compressor and switch off the voltage to the compressor. Remove the inlet silencer cover and remove the filter element. Clean the cover. Discard the old filter element. Install a new filter element and reposition the inlet silencer cover.

  • Page 67: Oil And Oil Filter Change

    Instruction book Oil and oil filter change Control panel Oil system components Oil filler plug (FC), sightglass (SG) and oil drain valve (Dmo) Procedure Step Action Run the compressor until warm. Press stop button (6). Wait until the compressor has stopped, press the emergency stop button and switch off the voltage to the compressor.

  • Page 68: Adjustment Of The Intercooler Pressure

    The bearings of the fan motor are greased for life. Contact your Customer Centre for the replacement interval of the motor bearings. Compressor drive motor (M1) Recommended grease: Atlas Copco Roto Glide Amber, 16 g per bearing. Contact your Atlas Copco Customer Centre. Do not mix greases of different types.
  • Page 69 Instruction book • Never run the compressor without safety valves. • No adjustments are allowed. API797429...

  • Page 70: Faults And Remedies

    Condensate is not discharged Discharge flexible clogged Check and correct as necessary from condensate traps during operation Electronic water drain Consult Atlas Copco malfunctioning LED's of electronic water drain do Compressor is running unloaded LED's will light up when the not light up compressor is loaded again.
  • Page 71 Instruction book Condition Fault Remedy Air pressure below minimum Increase air pressure pressure EWD continuously discharges air Control air blocked Check and correct as necessary Sensor dirty Clean sensor API797429...

  • Page 72: 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) See section Compressor data API797429...

  • Page 73: Electric Cable Size

    Instruction book Electric cable size Attention • An isolating switch and the required fuses must be installed before the compressor. This is indicated on the connection diagram as "customer's installation". The required type and maximum size of the fuses are described below.
  • Page 74 Instruction book Cable configuration Single supply cables Parallel supply cables Phase supply cables (Only valid for Y-D versions) Parallel phase supply cables (Only valid for Y-D versions) API797429...
  • Page 75 Instruction book (1): Power distribution panel (2): Compressor starter panel Fuse calculations for cUL, CSA and UL: The indicated fuse size is the maximum fuse size in order to protect the motor Cable sizing according to UL The table below indicates the current carrying capacities of cables for commonly used installation methods, according to standard UL 508A.
  • Page 76 Instruction book • Install fuses which are smaller than or equal to the Max. fuse values from the technical data sheets or instruction manual • Size of the PE cable • Use the maximum allowed ampacity of the selected supply cables and compare with the value in the table below according to UL508A Ampacity Size of PE...

  • Page 77: Settings Of Safety Valves

    Set pressure 60 Hz Intercooler safety valve 54 psig High-pressure safety valve 160 psig Overload relay and fuse settings Type Approval Setting Q15/F15 ZT 55 VSD UL/cUL Reference conditions Reference Unit Value Absolute inlet pressure bar(a) Relative air humidity Air inlet temperature ˚C...

  • Page 78: Compressor Data

    Note: if the compressor is to operate at an altitude of more than 1000 m above sea level, it is possible that the maximum pressure and/or the maximum speed must be decreased. Consult Atlas Copco. Compressor data ZT 55 VSD Nominal working pressure bar(e) Maximum working pressure, Pack...

  • Page 79: Instructions For Use

    Instruction book Instructions for use Instructions This vessel can contain pressurized air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed pulsation damper and must be operated within the limits specified on the data plate. No alterations must be made to this vessel by welding, drilling or other mechanical methods without the written permission of the manufacturer.

  • Page 80: Pressure Equipment Directives

    Instruction book Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to category Part number Description Medium Pressure Volume P x V Lifecycle PED Class 0830 1008 32 Safety valve 3.7 bar 2x10...

  • Page 81: 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 API797429...
  • Page 82 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. API797429...
  • Page 84 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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