AtlasCopco-AirCompressors.pdf

Instruction bookAtlas Copco Stationary Air Compressors ZH6000 - ZH10000 - Two-stage With PLC Controller Instruction book 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. Note: The PED instructions for this machine are included at the end of the book. Registration code: APC ZH>4000 2-stage / 38 / 991 2003-02 No. 2920 1485 00 This instruction book describes how to handle and operate the subject machine(s) to ensure safe operation, optimum working economy and long service life. Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the compressor in good repair. Keep the book available for the operator(s) and make sure that the compressor is operated and that maintenance is carried out according to the instructions. 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. The company reserves the right to make changes without prior notice. 2920 1485 00 1 Instruction book CONTENTS Page 1 LEADING PARTICULARS.........................................................................................................................................4 1.1 General description .............................................................................................................................................4 1.2 Air flow.................................................................................................................................................................8 1.3 Condensate drain system ...................................................................................................................................8 1.4 Oil system ...........................................................................................................................................................8 1.5 Cooling system (Fig. 1.3) ..................................................................................................................................14 1.6 Electrical system ...............................................................................................................................................14 1.7 Programmable Logic Controller - PLC..............................................................................................................15 1.7.1 Controlling the capacity of the compressor ................................................................................................15 1.7.2 Protecting the compressor .........................................................................................................................16 1.7.3 Monitoring components - service warning..................................................................................................18 1.7.4 Checking the start conditions .....................................................................................................................18 1.7.5 Controlling the lubricating oil system..........................................................................................................18 1.7.6 Start commands during minimum stop time...............................................................................................18 1.7.7 Automatic restart after voltage failure.........................................................................................................19 1.7.8 External compressor status indication .......................................................................................................19 1.7.9 BUS connection system .............................................................................................................................19 1.8 Control panel (Fig. 1.9) .....................................................................................................................................20 1.8.1 Display (1-Fig. 1.9) .....................................................................................................................................20 1.8.2 Control buttons/keys/pictographs/lamp (Fig. 1.9) ......................................................................................21 1.8.3 Pictographs below display (Fig. 1.10) ........................................................................................................22 1.8.4 Buttons below display (Fig. 1.10) ...............................................................................................................23 1.9 Menu-driven control programs ..........................................................................................................................25 1.9.1 Main screen ................................................................................................................................................25 1.9.2 Calling up the Main menu and other menus ..............................................................................................25 1.9.3 Returning to the Main menu and Main screen ...........................................................................................26 1.9.4 Screen saver ..............................................................................................................................................26 1.9.5 Main screen menu ......................................................................................................................................27 1.9.6 Configuration menu ....................................................................................................................................31 1.9.7 Settings menu.............................................................................................................................................32 1.9.8 Service menu..............................................................................................................................................38 1.9.9 Timer menu ................................................................................................................................................42 1.9.10 Saved data menu .....................................................................................................................................45 2 INSTALLATION .......................................................................................................................................................47 2.1 Dimension drawings (Figs. 2.1 and 2.2) ...........................................................................................................47 2.2 Installation proposal (Fig. 2.3)...........................................................................................................................49 2.3 Mounting of outlet piping ...................................................................................................................................52 2.3.1 Rubber compensator types ........................................................................................................................53 2.3.2 Alignment tolerances (Fig. 2.5) ..................................................................................................................54 2.4 Cooling water requirements ..............................................................................................................................54 2.4.1 Type of the system .....................................................................................................................................54 2.4.2 Cooling water parameters ..........................................................................................................................54 2.5 Pictographs .......................................................................................................................................................58 3 OPERATING INSTRUCTIONS ...............................................................................................................................59 3.1 Preparation for initial start-up............................................................................................................................59 3.2 Compressor control modes...............................................................................................................................60 3.3 Before starting...................................................................................................................................................61 3.4 Starting ..............................................................................................................................................................62 3.4.1 Routine starting ..........................................................................................................................................62 3.4.2 Starting after emergency stopping or shut-down .......................................................................................63 3.4.3 Number of motor starts...............................................................................................................................63 3.5 During operation................................................................................................................................................64 3.5.1 Checking the display ..................................................................................................................................65 3.6 Manual control of compressor operation ..........................................................................................................65 3.7 Stopping ............................................................................................................................................................66 3.8 Taking out of operation .....................................................................................................................................67 4 MAINTENANCE.......................................................................................................................................................68 4.1 Preventive maintenance schedule for the compressor 1) ...............................................................................68 2920 1485 00 2 Instruction book 4.2 Motor greasing ..................................................................................................................................................69 4.3 Lubricant specifications.....................................................................................................................................69 4.4 Storage after installation ...................................................................................................................................70 4.5 Service kits........................................................................................................................................................70 5 SERVICING PROCEDURES ..................................................................................................................................71 5.1 Air filters (Fig. 5.1).............................................................................................................................................71 5.2 Oil and oil filter change (Figs. 5.2 and 5.3) ......................................................................................................71 5.3 Demister (Fig. 5.5) ............................................................................................................................................73 5.4 PLC battery change (Fig. 5.6)...........................................................................................................................74 6 PROBLEM SOLVING ..............................................................................................................................................75 7 PRINCIPAL DATA ...................................................................................................................................................77 7.1 Readings on display (1-Fig. 1.9) 1)..................................................................................................................77 7.2 Programmable settings .....................................................................................................................................77 7.3 Circuit breakers - motor types...........................................................................................................................77 7.3.1 Circuit breakers ..........................................................................................................................................77 7.3.2 Motor types.................................................................................................................................................78 7.4 Compressor specifications................................................................................................................................78 7.4.1 Design conditions .......................................................................................................................................78 7.4.2 Limitations ..................................................................................................................................................78 7.4.3 Sound pressure level 3) .............................................................................................................................79 7.4.4 Specific data of 3.5 bar - 50 Hz compressors 2) .......................................................................................79 7.4.5 Specific data of 3.9 bar - 50 Hz compressors 2) .......................................................................................79 7.4.6 Specific data of 4.2 bar - 50 Hz compressors 2) .......................................................................................79 7.4.7 Specific data of 4.6 bar - 50 Hz compressors 2) .......................................................................................80 7.4.8 Specific data of 50 psi - 60 Hz compressors 2) ........................................................................................80 7.4.9 Specific data of 55 psi - 60 Hz compressors 2) ........................................................................................80 7.4.10 Specific data of 60 psi - 60 Hz compressors 2) ......................................................................................81 7.4.11 Specific data of 65 psi - 60 Hz compressors 2) ......................................................................................81 7.5 Conversion list of SI units into British/American units.......................................................................................81 8 PROGRAMMABLE SETTINGS ...............................................................................................................................83 8.1 Regulation settings - See section 1.9.7.1 .........................................................................................................83 8.2 Protection settings - See section 1.9.8.2 ..........................................................................................................83 8.3 Service settings - See section 1.9.7.3...............................................................................................................84 8.4 Settings for other parameters - See section 1.9.8.4 .........................................................................................84 9 Options.....................................................................................................................................................................85 2920 1485 00 3 1. 4.9. ZH6000 are 60 Hz compressors designed for following nominal working pressures: 50.5 stands for: Compressor type ZH10000 . 3.5. The variants with five capacities are: 4. 65 psig. The compressors are available either fully enclosed in a sound-insulated bodywork or on a base frame without bodywork. The compressors are driven by an electric motor. 1.3) Air filters Compressor core Blow-off valve Drive coupling Oil reservoir Auxiliary oil pump Electrical system (see section 1.2 and 1.5.9 bar(e) and 50. 55 psig.1 General description ZH6000 and ZH10000 two-stage are water-cooled centrifugal compressors which deliver oil-free. 4.2 and 4.2. Example of compressor designation ZH10000-1-3.6 bar(e) and 60. 55.1.6 bar(e).50 Hz Capacity size 1 Nominal working pressure 3. Six capacities are available for following pressure variants: 3. 60 and 65 psig.Instruction book 1 LEADING PARTICULARS 1.6) The compressor core comprises: Inlet guide vanes Gearbox First compressor element Intercooler Second compressor element Aftercooler Check valve Oil cooler Main oil pump 2920 1485 00 4 .5 bar(e) Main components (Figs. ZH10000 are 50 Hz compressors designed for following nominal working pressures: 3. pulsation-free air. 3. Instruction book 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Drive motor Actuator.1 Front view 2920 1485 00 5 . aftercooler Aftercooler Oil reservoir Fig. 1. blow-off valve Blow-off valve Coupling Check valve Air filters Compressed air outlet Cooling water outlet Auxiliary oil pump Cooling water inlet Condensate drains Condensate trap. Instruction book 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Air filters Inlet guide vanes Actuator.2 Rear view 2920 1485 00 6 . 1. inlet guide vanes First compressor element Second compressor element Drive motor Demister. oil reservoir Oil filter (dual oil filters are optional) Oil reservoir Condensate trap. intercooler Intercooler Thermostatic by-pass valve Oil cooler Auxiliary oil pump Cooling water inlet pipe Cooling water outlet pipe Fig. intercooler circuit Intercooler Aftercooler Oil cooler Auxiliary oil pump Motor. aftercooler circuit Thermostatic by-pass valve Water regulating valve. inlet guide vanes Inlet guide vanes First compressor element Water regulating valve.Instruction book 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Fig. 1. auxiliary oil pump Condensate trap.3 Core Gear casing Oil pump Positioner. aftercooler Cooling water inlet Cooling water outlet Compressed air outlet Blow-off valve 2920 1485 00 7 . 1. 1.Instruction book 1. 1.4) Oil demister (7-Fig. 1. Each trap is provided with a float valve to automatically drain condensate and a manual drain valve.3 Condensate drain system Two moisture traps are installed. 1.2) and blown through aftercooler (10-Fig.3).4) Strainer (2-Fig.1) towards the air net.2) Oil filter(s) (8-Fig.2 Air flow Air drawn through filters (1-Fig.1) to prevent condensate from entering the air outlet pipe.4 Oil system The system mainly includes: Oil reservoir (6-Fig.3). The cooled air is further compressed in second compressor element (5-Fig. 1.3) and check valve (5-Fig. 1 2 3 4 5 6 7 Oil filler cap Oil strainer Oil level sight-glass Oil drain valve Oil heater Oil reservoir Inspection cover.2) and discharged to intercooler (11-Fig. 1. 1.2) Thermostatic valve (7-Fig. 1. driven by electric motor (13) Oil cooler (13-Fig.2) Main oil pump (2-Fig. 1.3) 2920 1485 00 8 . 1. oil reservoir Fig. 1.4 Oil reservoir 1. 1. 1. driven by the main shaft Auxiliary oil pump (12-Fig.2) is compressed in first compressor element (4-Fig.2).2) and inlet guide vanes (2-Fig. 1. 1.4) Oil heater (5-Fig.2) to prevent condensate from entering the second compressor element and one downstream of the aftercooler (13-Fig. 1. 1. one downstream of the intercooler (11-Fig. 1. 1. If the permissive start conditions are not fulfilled. The heater is automatically controlled by the PLC (see section 1. and also in case the oil supply pressure should become too low.7. The thermostatic valve mixes heated oil from the reservoir and cooled oil from the oil cooler to maintain the temperature of the oil to the lubricating points as constant as possible. 2920 1485 00 9 . At starting.5). the compressor will not start (see section 3. oil is sucked up by the main oil pump from the reservoir through the strainer and is supplied to all bearings and gears.Instruction book During normal operation.7. Oil droplets are drained back to the oil reservoir. The operation of the auxiliary oil pump is automatically controlled by the Programmable Logic Controller (PLC . the temperature of the oil in the gearbox and the oil pressure are checked by the PLC.5) to ensure sufficient oil pressure during start-up and shutdown.see section 1. The heater will warm up the oil in the reservoir to the required minimum temperature. Oil fumes from the oil reservoir are sucked in by the oil demister and filtered inside the demister.3). Instruction book 2920 1485 00 10 . Instruction book 100 101 102 103a 103e 104 105 106 108 109a 109b 110 111 112 113 114a 114b 120 121 122 123a 123b 125 126 127 128 129 130 131 140 141 142 143 145 146 147a 147b 148 149 150 152a 152b 153 154 155 156 157 158 159 160 161 172 173 174 175 176 Air filters Air inlet silencer Joint Inlet guide vanes Actuator. auxiliary oil pump Non-return valve Oil demister Fan motor. oil demister Pressure control valve Oil reservoir heater Oil drain valve Non-return valve Flexible coupling Restriction Manual operated valve Drive motor Drive coupling Compensator Compensator Cooling water flow reverse valve (optional) Water shut-off valve (optional) Water regulating valve. intercooler Electronic condensate drain (optional) Flexible coupling Second compressor element Flexible coupling Aftercooler Condensate trap. intercooler circuit 2920 1485 00 11 . blow-off valve Silencer Condensate drain receiver Manual condensate drain valve Non-return valve Condensate drain receiver Manual condensate drain valve Non-return valve Oil reservoir Oil strainer Main oil pump Drive coupling. aftercooler Electronic condensate drain (optional) Check valve Compensator Flexible coupling Blow-off valve Actuator. inlet guide vanes Flexible coupling First compressor element Flexible coupling Intercooler Condensate trap. main oil pump Oil cooler Thermostatic by-pass valve Oil filter Dual oil filter (optional) Auxiliary oil pump Motor. intercooler (automatic drain is optional) Condensate drain level. transmitters. sensors Motor winding temperature protection (optional) Motor bearing temperature protection (optional) Only with electronic drain (optional) Only with anti-condensation heaters (optional) Atlas Copco installation Customer’s installation Water shut-off valve (optional) Cooling water flow reversing valve (optional) For compressors without starter. blow-off valve Solenoid valve. drive end (optional) Motor bearing temperature. 1.5 Instrument and piping diagram (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) Ventilation line Drain Air Oil Water Signal air Signal electrical Only with dual oil filter (optional) From transducers. non-drive end (optional) Vibration. inlet guide vanes Positioner. second compressor element Aftercooler outlet temperature Oil reservoir temperature Gearbox oil supply temperature Cooling water inlet temperature Drive motor inlet temperature Motor winding temperature U1-U2 (T1-T4) (optional) Motor winding temperature V1-V2 (T2-T5) (optional) Motor winding temperature W1-W2 (T3-T6) (optional) Motor bearing temperature. second compressor element Delivery air pressure Gearbox oil pressure Anti-condensation heater (optional) Air inlet temperature.Instruction book 177 180 180a Water regulating valve. aftercooler (automatic drain is optional) Oil level Oil level Air filter pressure drop DP element 2 nozzle pressure DP element 2 pressure Oil filter pressure drop Outlet pressure. first compressor element Vibration. cooling water shut-off (optional) Fig. second compressor element Positioner. current transformer XA-SA to be supplied by customer Sleeve bearings only 2920 1485 00 12 . aftercooler circuit Programmable Logic Controller User interface Transducers/Sensors/Timers/Positioners/Solenoid valve KSH02 KSH41 KSH48 KSH49 KSH93 LSHL17 LSHL28 LSL42 LSLL42 PDT02 PDT19 PDT20 PDT46 PT22 PT29 PT49 R96 TT18 TT29 TT43 TT44 TT51 TT60 TT95a TT96a TT97a TT98 TT99 VP10 VP20 Y2 Y3 Y51 Air filter lifetime Oil demister lifetime Oil filter lifetime Oil lifetime Drive motor regreasing time Condensate drain level. Instruction book 2920 1485 00 13 . 1.6 Air-oil-water flows 1.Instruction book A B C D E F G H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Air inlet Air Air outlet Oil Water inlet Water Water outlet Condensate Air filters Air inlet silencer Inlet guide vanes First compressor element Intercooler Second compressor element Oil filter Pressure control valve Aftercooler Check valve Blow-off valve Silencer Oil demister Oil reservoir Oil reservoir heater Oil strainer Main oil pump Auxiliary oil pump Non-return valve Oil cooler Thermostatic by-pass valve Fig. 1. aftercooler (10) and oil cooler (11) with cooling water.3) Motor for fan of oil demister (1-Fig.5 Cooling system (Fig. 5. 1. 1.11) with Programmable Logic Controller Compressor control panel (Fig.9) Pressure.5) Drive motor (6-Fig.2) Motor for auxiliary oil pump (13-Fig.3) A piping system is provided to supply the intercooler (9). Following flow regulating valves are provided: downstream of the intercooler (8) downstream of the aftercooler (6) 1.1) 2920 1485 00 14 . vibration and oil level sensors (Fig.6 Electrical system The system mainly includes: Electric cubicle (Fig.2) Positioner.4) Positioner. blow-off valve (2-Fig. 1. 1. 1. 1. temperature. 1. 1.5) Oil heater (5-Fig. inlet guide vanes (3-Fig. AUTO-DUAL control system (option) The system is designed for applications with a large compressed air volume where the fluctuations in air demand are generally within the throttle range capability of the compressor. 1. the compressor will be switched to completely unloaded running. The compressor may be stopped after running completely unloaded for a programmed time period.11) Inlet guide vanes (4-Fig. The PLC takes into account a number of programmable settings such as the minimum stop time and maximum number of motor starts. the compressor will again run loaded. 2920 1485 00 15 .Instruction book 1. combined with occasional requirements for lower air flows. See also section 1.3) Blow-off valve (3-Fig.1) The PLC continuously regulates the capacity of the compressor from maximum air capacity to a minimum capacity by controlling the position of the inlet guide vanes and blow-off valve. The PLC will again regulate the position of the inlet guide vanes (IGV) as described above. If the net pressure drops below the programmed loading pressure. When the net pressure drops below a programmed pressure. The compressors are standard provided with the constant pressure control system. The PLC will regulate the position of the inlet guide vanes (IGV) to match the air delivery to the air consumption while maintaining the net pressure as close as possible to the programmed value (called Regulation setpoint).7. the inlet guide vanes (IGV) will be completely opened while simultaneously the blow-off valve (BOV) will be fully closed. the compressor runs unloaded. In case the net pressure should rise to a programmed pressure. Constant pressure control system (standard) The constant pressure control system is designed to continuously control the air output while keeping the net pressure fluctuations to a minimum. the inlet guide vanes (IGV) will close to their minimum open position while simultaneously the blow-off valve (BOV) will be opened completely.PLC .has following functions: Controlling the capacity of the compressor Protecting the compressor Monitoring components subject to service Checking the start conditions Controlling the lubricating oil system 1. the compressors may be provided with the AUTO-DUAL control system. 1. 1. As an option.1.1 Controlling the capacity of the compressor The system includes: PLC (Fig.PLC In general. the Programmable Logic Controller .9.7 Programmable Logic Controller .7. continuously regulating the air output as described above. The PLC will continuously regulate: the position of the inlet guide vanes (from 100 % open to a minimum open position) the position of the blow-off valve (from 100 % closed to a minimum closed position) The air delivery will be matched to the air consumption while the net pressure is maintained as close as possible to the programmed pressure setpoint. If the air consumption decreases causing the net pressure to exceed the programmed unloading pressure. 1.7) on the compressor control panel will blink to warn the operator. Check and remedy. Press button (F2-Fig. It remains possible to scroll through other screens after pressing Main menu button (F8-Fig. shut-down warning Warning Before starting any maintenance or repair. pressure or oil level exceeding the programmed shut-down warning level. including those mentioned in this book. 1.12).3. warning pictograph (Fig.9) to acknowledge this warning: the warning pictograph will light steadily and the message NEW WARNING will change into WARNING. They are connected in the control circuit of the PLC.2. Remark If more messages need to be shown on the display.7) will blink to warn the operator before the shut-down level is reached. 1. 1. The compressor is restarted automatically when the net pressure drops below the programmed loading pressure. Apply all relevant safety precautions.g. 1.9). Fig.7 Pictograph. 1.7. temperature.8) on the control panel will blink to warn the operator. 1. 1. the compressor is shut down and a pictograph (Fig.9) after which the reason for this warning will appear on display (1-Fig. In case of a shut-down warning: The warning pictograph (Fig. the messages will be displayed one after the other for a few seconds.1 Shut-down warning The shut-down warning level is a programmable setting below the shut-down level.9.7) is blinking. In case of a malfunction.7. 1. and afterwards to return to the Main screen (Fig. switch off the voltage and depressurize the compressor. 1. e. loading pressure.Instruction book The PLC takes into account a number of programmable settings such as the unloading pressure.: OIL SUPPLY TEMPERATURE NEW WARNING Press reset button (5-Fig. See also section 1. vibration and oil level sensors are provided on the compressor. The compressor is stopped when possible (depending on the setting of the maximum number of motor starts) to reduce the power consumption. 1.9) to check the gearbox oil temperature as well as other actually measured values. 1. If an abnormal operating condition arises. a pictograph (Fig. minimum stop time and maximum number of motor starts. The warning message disappears as soon as the warning condition disappears. pressure. stop the compressor. If the PLC detects a vibration.2 Protecting the compressor Several temperature. 2920 1485 00 16 . 9) to check the gearbox oil temperature as well as other values measured at the moment of shut-down. 1.9) to check which condition is not fulfilled to permit a restart.Instruction book 1.2. the PLC has a surge anticipation system.9). a safety margin to this surge line must be kept. The limit between stable and unstable operation is referred to as "surge line".: GEARBOX OIL TEMPERATURE NEW SHUTDOWN Press reset button (5-Fig. shut-down 1. 1.9) or button (F2-Fig. press OK button (F5-Fig. 2920 1485 00 17 . the messages will be displayed one after the other for a few seconds.g.9). pressure or oil level exceeding the programmed shut-down level. If not.2. The message COMPRESSOR IS NOT READY TO START appears.9) after which the reason for this shut-down will appear on display (1-Fig. See also section 6. this operating condition may cause damage to the compressor. Switch off the voltage and remedy. 1. the compressor will be stopped and the shut-down pictograph (Fig. See also section 1.12). rhythmic fluctuations of the discharge pressure. Press button (F2-Fig. e. 1. The compressor will also be shut down in case of: An overload or undervoltage at the drive motor Surging of the compressor (see section 1. 1.2 Shut-down If the PLC detects a vibration. To prevent surging.3) Failure of some important sensors In case of a shut-down: The shut-down pictograph (Fig. 1. To prevent the compressor from entering the unstable operating range. and afterwards to return to the Main screen (Fig.3 Surge control Surge is recognized by rapid. It remains possible to scroll through other screens after pressing Main menu button (F8-Fig.8 Pictograph.9) to acknowledge this shut-down: the shut-down pictograph will light steadily and the message NEW SHUTDOWN will change into SHUTDOWN. 1. 1. 1.8) is blinking. temperature.2.3. Remark If more messages need to be shown on the display. When the OK pictograph (5-Fig.8) will blink. 1. the compressor can be restarted (message COMPRESSOR IS READY TO START). 1.7. 1.7. Fig.10) lights up green or starts blinking. This is called the “control line” and is set up during commissioning. After remedying and disappearing of the shut-down condition. In case of prolonged unstable running.9. switch on the voltage and press reset button (5-Fig.7. 7.oil filter .3) When the compressor is not running and with key switch (9-Fig. the compressor will not start. 2920 1485 00 18 . switch off the voltage and replace the indicated component or take the necessary service action.7. the motor is prevented from restarting within a programmed time period which is set ex-factory at 240 seconds.7.4) Start and stop the auxiliary oil pump (12-Fig. If these conditions are not fulfilled.9.Instruction book 1.3 Monitoring components . See section 1.4 Checking the start conditions At starting the programmed permissive start conditions (such as the minimum temperature of the oil in the gearbox and minimum oil pressure) are checked. See section 3. the oil in the oil reservoir will be kept at the correct temperature by switching on and off the oil heater and the auxiliary oil pump will periodically circulate the oil. 1.3.10) is blinking.cooler approach temperatures (is the temperature difference over the cooler between the cooling water inlet and the compressed air outlet) . Switch on the voltage and reset the actual lifetime of the component. In case of a service warning: Pictograph (11-Fig.air filters Each input is compared to the programmed limits. 1.7. 1.9) in position local (11) or remote (12). i.service warning The PLC continuously monitors critical components subject to service: . 1. 1.3.9) and start the compressor.motor grease .PLC battery . A start command during this period is ignored.7.oil . Press reset button (5-Fig.6 Start commands during minimum stop time Minimum stop time After stopping. 1. 1. Exceeding these limits causes a message on the control display to warn the operator. Stop the compressor.oil demister . 1.5 Controlling the lubricating oil system The PLC automatically controls the lubricating oil system.e.: Energize the oil heater (5-Fig. 8 External compressor status indication Auxiliary contacts are provided for external compressor status indication: Indication Automatic operation Warning Shut-down Compressor running Permissive start OK Relay K6 K7 K8 K1 K9 Terminals on strip 1X4 51-52 53-54 55-56 59-60 61-62 Max. 2920 1485 00 19 . Automatic restarting after voltage failure is not allowed for medium-voltage motors.7. increased by the initiating time of the CPU (which takes about 35 seconds). load 2. the function can be activated.5 A / 230 V AC 2.9 BUS connection system As an option. If desired. Consult Atlas Copco. a BUS connection system can be provided to enable the controller to communicate with a plant monitoring system (through MODBUS or PROFIBUS connections). load 8 A / 230 V AC 8 A / 230 V AC 8 A / 230 V AC 8 A / 230 V AC 8 A / 230 V AC Indication Control mode OFF Control mode LOCAL Control mode REMOTE Switch S5 S5 S5 Terminals on strip 1X4 43-44 45-46 47-48 Max.Instruction book 1.7 Automatic restart after voltage failure For compressors leaving the factory. Consult Atlas Copco. 1.5 A / 230 V AC Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas Copco. 1.7.5 A / 230 V AC 2. The minimum stop time is taken into account. Warning If activated. the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period (between 0 seconds and 60 minutes). this function is made inactive.7. 9) A control panel is provided allowing the operator to communicate with the PLC.9) The alphanumeric display indicates: the compressor operating condition pressure. 1. The control panel includes: Start button (15) and stop button (17) Emergency stop button (13) Display (1) indicating the compressor operating condition. Voltage on lamp (7) Reset button (5) to reset a warning/shut-down/emergency stop condition Key switch (9) to select the required compressor control mode Keypad (3) and keys to enter or modify parameters (2. 1. 20 and 21) Fig.9 Control panel 1. a service need or a fault Illuminating pictographs (22) indicating the status of the compressor and explaining the functions of the corresponding buttons (F1 to F10) below the display. 4.1 Display (1-Fig.Instruction book 1. 1. temperature and vibration levels a service need a fault 2920 1485 00 20 .8.8 Control panel (Fig. 19. 8. Maintained-action push button to stop the compressor immediately in case of emergency. the oil will not be heated and not circulated. To scroll within a rectangular text box on a screen.8.2 Control buttons/keys/pictographs/lamp (Fig. 1. the oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). emergency stop button (13) remains active. Local control (remote control mode is made inactive): the compressor can only be controlled by the buttons on the control panel. Stop To switch to another rectangular text box on a screen. See section 1. To reset an active shut-down warning. To enter or modify parameters. After remedying the trouble. unlock the button by pulling it out (some compressors may have a button with arrow which must be turned anti-clockwise to unlock). shut-down. voltage on Pictograph Control mode switch To clear the last input during changing of parameters or to leave the text input line.2 Compressor off: the PLC will not react to any start/stop command.3.Instruction book 1. the oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). the auxiliary oil pump will remain running for about 10 minutes to cool down the compressor. motor overload condition. 10 11 Pictograph Pictograph 12 Pictograph 13 Emergency stop button Pictograph Start button Pictograph Stop button 14 15 16 17 18 19 20 21 22 Pictograph Arrow key Scroll keys Arrow key Pictographs 2920 1485 00 21 . Reset Lights up if the voltage is switched on. The oil will be kept on operating temperature as long as switch (9) is in the local (11) or remote (12) position. a service message or emergency stop condition.9) 2 3 4 5 6 7 8 9 Backspace key Keypad Return key Reset button Pictograph Lamp. To call up menus and to enter or modify parameters. To switch to another rectangular text box on a screen. Emergency stop To start the compressor Start To stop the compressor in a normal stop sequence (programmed stop): the compressor will run unloaded for about 15 seconds and then stop. Voltage on To select the compressor control modes: -compressor off -local control -remote control See section 3. Remote control (local control is made inactive): the compressor will only react to start/stop and manual load/unload commands by external switches. 4. 1. Lights up green if the compressor is not running but all start conditions to have a permissive start are fulfilled (see section 3.10) 1 2 3 3 3 3 4 5 Oil heater Shut-down Automatic operation Automatic operation Automatic operation Automatic operation Unloaded operation OK Lights up green when the oil heater is energized. Lights up green when the auxiliary oil pump is running. Indicates the function of button (F9).1) Blinks green indicating that the compressor may be started and stopped automatically by programmed time-based commands (see section 1.7. the pictograph lights up steadily.2/1. See section 1.9.3 Pictographs below display (Fig.7. 5 OK 6 7 8 9 10 11 Auxiliary oil pump Inlet guide vanes Main menu Next screen Sequencer Warning 2920 1485 00 22 . first the auxiliary oil pump will start and then the compressor will start. Lights up green if the compressor is controlled by the (optional) sequencer (consult Atlas Copco).Instruction book 1. after acknowledging by pressing button (F2). press button (F5) to check the reason. the pictograph lights up steadily (see sections 1.8.7. Blinks green if the auxiliary oil pump is not running before starting: when pressing start button (15-Fig.9. The heater is automatically controlled by the PLC.9) Blinks green indicating that the compressor may be started automatically after power failure (see section 1.3).3). after acknowledging by pressing button (F2). Indicates the function of button (F8). 1. Lights up steadily green indicating that the compressor is running in automatic operation mode (see section 1.1) Lights up green if the compressor is running in manual unloaded condition (see section 3.7) Blinks green indicating that the compressor is stopped after a period of unloaded running but will be started if the pressure drops below a programmed value (see section 1.8.4.8. Lights up green if it is allowed to adjust the position of the inlet guide vanes (only by Atlas Copco). See section 6. Blinks yellow in case one or more parameters exceed the shutdown warning level or service warning level. the permissive start conditions are not fulfilled.7.9). See section 1. Blinks red in case one or more parameters exceed the shutdown level or after emergency stopping.6).7. If the pictograph is not green illuminated. After scrolling through other screens. The compressor will remain running unloaded unless it is put in automatic operation again by pressing button (F3).9.Instruction book 1. The compressor is switched out of automatic operation (no capacity regulation by the PLC). Press this button before starting to check which start condition is not fulfilled. this button allows to return to the information on the warning screen.1). 1. To unload the compressor manually.13) of the compressor control programs (see section 1. see section 1. 1. To have the compressor controlled by the (optional) sequencer (if desired. To return to the information on the shut-down screen after scrolling through other screens. F5 F7 F8 F9 F10 OK Manual control of inlet guide vanes Main menu Next screen Sequencer Note: The functions of buttons (F1 up to F10) may vary depending on the chosen menu. 1 2 3 4 5 6 7 8 9 10 11 Oil heater Shut-down condition Automatic operation Unloaded operation Start conditions fulfilled Auxiliary oil pump Manual control of inlet guide vanes Main menu Next screen Sequencer Warning condition Fig.4 Buttons below display (Fig. To return to the main menu (Fig.10) F2 F2 F3 F4 Information in case of a warning Information in case of a shutdown Automatic operation Manual unload To check which parameter is causing the warning.7. To scroll down to the next screen. See section 3. control panel 2920 1485 00 23 . To set the compressor in automatic operation mode: the compressor is automatically controlled by the PLC (see section 1. To manually set the inlet guide vanes (this function is only accessible to Atlas Copco personnel).10 Pictographs and buttons.8. consult Atlas Copco). 1.3.9). 5V DC Vibration transmitters. 1. RUN/REM/PROG Input/output cards Terminal strips Fig.11 Electric cubicle.Instruction book B61 CPU F3/4/5/10 K6 K7 K8 K9 K13 K25 K27 K29 L1/2/3 Q1 Q25 Q27 Q29 T1 U2 VT10/20 Z1 1X2 1 2 3 4 5 Current transmitter. drive motor current Central processing unit Circuit breakers Auxiliary relay. oil heater R29 Terminals. compressor elements Line filter. 3-phase low voltage supply Circuit breaker. automatic operation Auxiliary relay. AC power Terminal strip Fuse Power supply Key. oil demister fan motor M27 Contactor. control circuit Circuit breaker. auxiliary oil pump motor M25 Circuit breaker. oil demister fan motor M27 Circuit breaker. auxiliary oil pump motor M25 Contactor. general warning Auxiliary relay. motor starter control Contactor. without starter (typical example) 2920 1485 00 24 . oil heater R29 Main transformer Power supply. general shut-down Auxiliary relay. permissive start OK Auxiliary relay. the display will automatically return to the Main screen.9.g. To select another menu: use scroll keys (22) to move symbol > to the left of the desired menu and then press return key (13). the Main menu (Fig. menu-driven control programs have been implemented in the PLC.8 Timer Saved data 1.9.g.9. 2920 1485 00 25 . pressure setpoint) and calling up information about the compressor starts and stops Protection: calling up the protection settings (e.9. Calling up shut-down and emergency stop data saved by the PLC.9. shutdown and shut-down warning settings) Service: modifying service warning settings and resetting the actual lifetime of a component after servicing Modifying settings (e. Password needed.8 1. 1.16.g.2/1. Programming time-based commands to start and stop the compressor automatically.2 Calling up the Main menu and other menus After pressing button (F8). If the buttons on the control panel are not used for about 4 minutes.9.9.Instruction book 1.8 1.5 1.7 Service 1. 1.9.9.10 Function Shows the six available control programs.9. shut-down warning and shut-down settings). Password needed. A simplified menu flow is shown in Figs.9 1. Function of control programs Program Main menu Main screen Configuration Settings Section 1.1 Main screen When the voltage is switched on.9. After about 30 seconds. Regulation: modifying the regulation settings (e.9.3 1. Surge history. display language and units of measurement. permissive start level for the oil temperature).7 1.15 and 1. Is the gateway to have access to these programs.9.12) is shown indicating the compressor status.13) is shown. The Main menu is the gateway to have access to these menus. a screen is shown indicating a test protocol. Calling up the actually measured data and the compressor status Programming the date. Password needed. 1. time.9.7 1. 1.g.9 Menu-driven control programs In order to facilitate programming and controlling of the compressor. the Main screen (Fig. The Main menu shows the six available control programs (called menus).6 1. 1. Modifying parameters (e. Press return key (13) to switch to the Main screen (Fig. 1.12).Instruction book 1.9. 1. 1. 1. Press button (F8) or button (F5) to return to the Main screen (Fig. Fig.13 Main menu 2920 1485 00 26 .3 Returning to the Main menu and Main screen To return from whatever menu to the Main menu (Fig. Press scroll keys (22) until symbol > is situated on the left of item MAIN SCREEN. 1.12).9. 1. press button (F8) until the Main menu is shown.4 Screen saver If the control panel buttons are not used for about 10 minutes. the screen saver will be activated: the Atlas Copco logo will slowly move over the screen.13).12 Main screen (typical example) Fig. 9.37 bar 4. Use button (F9) for scrolling down in the menu. Press return key (13) to select this menu. Calling up this menu 1 Press main menu button (F8). 1. 1. 2920 1485 00 27 .20 bar 2. see section 1.9.Instruction book 1.1) the gearbox oil pressure the outlet pressure at compressor element 2 the position of inlet guide vanes IGV (4-Fig. All values shown are typical examples.22 bar 3. the programmed time-based start and stop commands will be executed.5 Main screen menu Function The Main screen is used to call up the actually measured data as well as the compressor status.38 bar BOV % CLOSED 100 TIMER NOT ACTIVE COMP OUTLET PRESSURE PRESSURE SETPOINT OIL PRESSURE ELEMENT 2 OUTLET IGV % OPEN 100 COMPRESSOR IS LOADED LOCAL CONTROL This menu shows: the compressor outlet pressure the compressor setpoint (see section 1.14 shows all data which can be called up in the Main screen.9) 3 Fig. The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item MAIN SCREEN.7. Following menu appears (typical example): 3.3): the open position of the vanes is expressed in percentage the position of the blow-off valve: the closed position of the valve is expressed in percentage whether the compressor is controlled locally (start/stop and manual load/unload commands only possible by means of the buttons of the control panel) or controlled remotely (start/stop and manual load/unload commands only possible by means of external switches) the status of the Timer (if activated. 37 bar 4.50 micron NORMAL NORMAL NORMAL LOADED 2774 REGULATOR 3013 Fig.14 Main screen (all values shown are typical examples) 2920 1485 00 28 .50 micron 11.38 bar BOV % CLOSED 100 TIMER NOT ACTIVE -0.Instruction book COMP OUTLET PRESSURE PRESSURE SETPOINT OIL PRESSURE ELEMENT 2 OUTLET IGV % OPEN 100 COMPRESSOR IS LOADED LOCAL CONTROL AIR FILTER DP OIL FILTER DP OIL/CONDENSATE LEVEL OIL RESERVOIR TEMP GEARBOX OIL TEMPERATURE ELEMENT 2 INLET TEMP COMPRESSOR OUTLET TEMP COOLING H20 INLET TEMP COOLER 1 APPROACH AFTERCOOLER APPROACH DRIVE MOTOR INLET AIR DRIVE MOTOR CURRENT ELEMENT 1 VIBRATION ELEMENT 2 VIBRATION MOTOR OVERLOAD OIL PUMP OVERLOAD EQUIPMENT OVERLOAD HOURS RUNNING 3013 3.20 bar 2.02 bar 0.22 bar 3. 1.15 bar OK 58 °C 50 °C 37 °C 35 °C 28 °C 8 °C 7 °C 19 °C 55 A 7. Instruction book Fig. main screen – configuration – settings 2920 1485 00 29 . 1.15 Simplified menu flow. 1.Instruction book Fig. service – timer – saved data 2920 1485 00 30 .16 Simplified menu flow. Press button (F10): pictograph (Fig.17) will light up green. The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item CONFIGURATION. time.Instruction book 1. 1. 1.6 Configuration menu Function The Configuration menu is used to program the date. indicating that the date and time may be changed.18 Configuration menu Important If pictograph (Fig.17 Pictograph 3 Following menu appears (typical example): ENGLISH bar micron °C 14/03/1999 HOUR MINUTE << << << << >> >> >> >> 14:32:11 14 32 LANGUAGE IN USE PRESSURE UNITS VIBRATION UNITS TEMPERATURE UNITS SUNDAY YEAR MONTH DAY 1999 3 14 Fig. display language and units of measurement. Press return key (13) to select this menu. Fig. the date and time values are not accessible. 1. 1. Calling up this menu 1 Press main menu button (F8).9.17) is lit up red. 2920 1485 00 31 . 7. See Fig.9. If required. pressure setpoint) to call up information about the compressor starts and stops. To change the display language 7 8 Use arrow keys (21 or 23) until a vertical line is situated on the left of the << >> box. Press button (F10). day. Use scroll keys (22) to move symbol > to the left of line LANGUAGE IN USE and press return key (13).Instruction book To change the date and time 4 5 6 To change the year: use arrow keys (21 or 23) until a vertical line is situated on the left of the YEAR text box. use backspace key (12) to clear the last input or to leave the text input line. The indication of the day will automatically change after modifying the date. hours and minutes. Use scroll keys (22) to move symbol > to the line of the unit to be changed and press return key (13).9. the colour of the related pictograph will become red. 1.1 Regulation Submenu Function The Regulation submenu is used: to modify regulation settings (e.7 Settings menu This menu has three submenus. 1. Press return key (13).19. The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2920 1485 00 32 . Use the method described in step 4 to change the value for the month. 1 Press main menu button (F8). type a new value by means of keys (14) and press return key (13). indicating that the values are no longer accessible.g. 1. To change the units 9 10 Use arrow keys (21 or 23) until a vertical line is situated on the left of the << >> box. Instruction book 2 Press scroll keys (22) until symbol > is situated on the left of item SETTINGS. Press return key (13) to select this menu. Following menu appears: REGULATION PROTECTION SERVICE 3 Press scroll keys (22) until symbol > is situated on the left of item REGULATION. Press return key (13) to select this menu. Following menu appears (typical example): 4.20 bar 4.60 bar 0.60 bar 0.60 bar 3 3 06:00:0 0 17:15:0 0 1 1 >+ + + - PRESSURE SETPOINT MAX PRESSURE SETPOINT LOADING PRESSURE SETPOINT UNLOAD PRESS SETP STARTS ALLOWED/HOUR STARTS ALLOWED/DAY STARTED ON STOPPED ON STARTS THIS HOUR STARTS THIS DAY Fig. 1.19 Regulation submenu 05/03/99 05/03/99 This menu shows: The pressure setpoint The maximum pressure setpoint The loading pressure setpoint The unloading pressure setpoint The allowed starts/hour and starts/day The date and time the compressor was started/stopped The number of starts/hour and starts/day To change the pressure setpoint The PLC will maintain the net pressure as close as possible to the programmed pressure setpoint (see section 1.7.1). To increase the pressure setpoint: 4 Use scroll keys (22) until symbol > is situated on the left of symbol + on the PRESSURE SETPOINT line and press return key (13) until the desired value is reached. 2920 1485 00 33 Instruction book To decrease the pressure setpoint: 5 Use scroll keys (22) until symbol > is situated on the left of symbol - on the second line and press return key (13) until the desired value is reached. To change the unloading pressure setpoint The unloading pressure setpoint is the pressure increase with regard to the pressure setpoint at which the compressor is automatically switched to completely unloaded operation: Example: Pressure setpoint Unloading pressure setpoint Automatic complete unload at 6 4.20 bar 0.60 bar 4.80 bar Use scroll keys (22) to move symbol > to symbol + (on the third line, to increase the setting) or to symbol (on the fourth line, to decrease the setting ) and press return key (13) until the desired value is reached. To change the loading pressure setpoint The loading pressure setpoint is the pressure decrease with regard to the pressure setpoint at which the compressor is automatically switched back to loaded operation (with continuous regulation of the inlet guide vanes and blow-off valve): Example: Pressure setpoint Loading pressure setpoint Automatic switch to load at 7 4.20 bar 0.20 bar 4.00 bar Use scroll keys (22) to move symbol > to symbols + or - (on the fifth or sixth line) and press return key (13) until the desired value is reached. Important The PLC includes the function Stop after unloaded delay. This function is not activated ex-factory; if required, it can be activated by Atlas Copco. If activated, the compressor will be stopped in case it runs automatic completely unloaded for an uninterrupted period of 15 minutes (programmable). Pictograph (3) for automatic operation will blink indicating that the compressor will automatically restart when the net pressure decreases to the loading pressure setpoint. 2920 1485 00 34 Instruction book 1.9.7.2 Protection Submenu Function The Protection submenu is used to call up protection settings (e.g. shut-down and shut-down warning settings). See Fig. 1.20. 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item SETTINGS. Press return key (13) to select this menu. Following menu appears: REGULATION PROTECTION SERVICE 3 Press scroll keys (22) until symbol > is situated on the left of item PROTECTION. Press return key (13) to select this menu. Following menu appears (typical example): SHUTDOWN 1.00 bar OIL PRESSURE WARNING 1.60 bar This menu shows the shut-down warning settings and shut-down settings for the mentioned parameter. 2920 1485 00 35 Instruction book 4 Figure 1.20 shows all data which can be called up in the Protection submenu. Use button (F9) for scrolling down in the menu. All values shown are typical examples OIL PRESSURE WARNING 1.60 bar ELEMENT 1 VIBRATION WARNING 24.00 micron ELEMENT 2 VIBRATION WARNING 24.00 micron GEARBOX OIL TEMPERATURE WARNING 57.00 °C ELEMENT 2 INLET TEMPERATURE WARNING 52.00 °C SHUTDOWN 1.00 bar SHUTDOWN 27.00 micron SHUTDOWN 27.00 micron SHUTDOWN 63.00 °C SHUTDOWN 66.00 °C Fig. 1.20 Protection submenu (all values shown are typical examples) 1.9.7.3 Service Submenu Function The Service submenu is used to call up and modify service warning settings and to reset the actual lifetime of a component after servicing. See Fig. 1.21. 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2920 1485 00 36 Instruction book 2 Press scroll keys (22) until symbol > is situated on the left of item SETTINGS. Press return key (13) to select this menu. Following menu appears: REGULATION PROTECTION SERVICE 3 Press scroll keys (22) until symbol > is situated on the left of item SERVICE. Press return key (13) to select this menu. Following menu appears (typical example): OIL FILTER DP WARNING 1.00 bar This menu shows the programmed service warning pressure for the oil filter 4 Figure 1.21 shows all data which can be called up and reset in the Service submenu. Use button (F9) for scrolling down in the menu. All values shown are typical examples. To modify the service warning value 5 Use scroll keys (F9 and F10) until the parameter to be changed appears. 6 Use the - button (F1) to decrease or the + button (F2) to increase the service warning value. To reset the actual lifetime of a component after servicing 7 Replace the related component. 8 Use scroll keys (F9 and F10) until the actual lifetime of the related parameter appears. 9 Press reset key (F3). 2920 1485 00 37 00 bar AIR FILTER DP WARNING -0.00 hr AIR FILTER HOURS WARNING 8000.00 hr DRIVE MOTOR REGREASING WARNING 2000.21 Service submenu ACTUAL 5315 hr ACTUAL 5315 hr ACTUAL 1315 hr ACTUAL 5315 hr ACTUAL 13315 hr 1.00 hr OIL DEMISTER HOURS WARNING 24000.00 hr OIL FILTER HOURS WARNING 8000.00 hr Fig. 1.8 Service menu Function The Service menu is used: to modify settings.9. 2920 1485 00 38 .00 °C AFTERCOOLER APPROACH WARNING 20.Instruction book OIL FILTER DP WARNING 1. such as the oil permissive start level The service menu is password-protected.00 °C LUBE OIL HOURS WARNING 8000.05 bar COOLER 1 APPROACH WARNING 20. such as the shut-down warning and shut-down settings to call up the surge history to modify other parameters. See Fig.8. Press return key (13) to select this menu.60 bar 2920 1485 00 39 .Instruction book 1. Press return key (13) to select this menu. 1.8.00 bar OIL PRESSURE WARNING 1. COMMUNICATIONS SETUP and OPTIONS is protected by another password. Following six submenus are shown 3 MODIFY VALVES MODIFY SETTINGS SURGE HISTORY MODIFY PARAMETERS COMMUNICATIONS SETUP OPTIONS Important The access to submenus MODIFY VALVES.1 Calling up this menu 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item SERVICE.2 Modifying settings Function The Modify settings submenu is used to modify protection settings (shut-down warning and shut-down levels).22. Enter the password and press return key (13).9. The modifications in these submenus may only be carried out by Atlas Copco personnel. 1. 1 Press scroll keys (22) until symbol > is situated on the left of item MODIFY SETTINGS. Following menu appears (typical example): SHUTDOWN 1.9. Instruction book 2 Figure 1. Use button (F9) for scrolling down in the menu.00 °C 2920 1485 00 40 .22 shows all data which can be modified. 6 Use the + and . OIL PRESSURE WARNING 1.00 °C SHUTDOWN 66.22 Modify settings submenu Note: The figure shows all items spread over several screens. SHUTDOWN 1.00 °C ELEMENT 2 INLET TEMPERATURE WARNING 52. To change a shut-down setting 5 Use scroll keys (F9 and F10) until the parameter to be changed appears.00 bar SHUTDOWN 42.50 micron GEARBOX OIL TEMPERATURE WARNING 57.70 micron SHUTDOWN 42. Use button (F9) to scroll down through the screens.50 micron ELEMENT 2 VIBRATION WARNING 27.buttons (F1 and F2) to increase and decrease the warning value respectively.00 °C Fig.70 micron SHUTDOWN 63.buttons (F3 and F4) to increase and decrease the shut-down value respectively. 4 Use the + and . To change a shut-down warning setting 3 Use scroll keys (F9 and F10) until the parameter to be changed appears. All values shown are typical examples. 1.60 bar ELEMENT 1 VIBRATION WARNING 27. TIME BOV % CLOSED .23 Modify parameters submenu 3 To modify a setting. 3 Use button (F9) to consult the next case of surge.. 1. 2920 1485 00 41 ..T. 11:34:27 .8. PRIMARY RATING Fig.8.Instruction book 1.4 Modifying parameters Function The Modify parameters submenu is used to modify a number of parameters. Press return key (13) to select this menu. scroll to the parameter to be modified using keys (22) and increase or decrease the value using buttons (F4) and (F9) respectively. Press return key (13) to select this menu. Following menu appears (typical example): 01 06/03/1999 . Following menu appears (typical example): 25 °C 240 s 15 min 15 s 20 s 10 s 15 s 3 3 .9...1.8. 1..9. SURGE HISTORY DATE IGV % OPEN SURGE NUMBER History 01 stands for the most recent surge. Press scroll keys (22) until symbol > is situated on the left of item MODIFY PARAMETERS.9. 1 2 Consult section 1.8.9. OIL PERMISSIVE START MINIMUM STOP TIME STOP AFTER UNLOAD TIME VIBRATION DELAY AT START LOAD DELAY TIME OIL PRESS DELAY AT START DP AIR FILTER WARNING DELAY STARTS ALLOWED/DAY STARTS ALLOWED/HOUR C. If required. Press scroll keys (22) until symbol > is situated on the left of item SURGE HISTORY..1. use backspace key (12) to clear the last input or to leave the text input line..3 Checking surge history Function The Surge history submenu is used to display a number of data for each time surge should have occurred. 1 2 Consult section 1.. Instruction book 1. 1. 2920 1485 00 42 . The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 3 Press scroll keys (22) until symbol > is situated on the left of item TIMER.25.24 Timer menu 4 The pictographs on the display will change. 1.9 Timer menu Function The Timer menu is used to program time-based commands to start and stop the compressor automatically. see Fig.9.1 Calling up this menu 1 Press main menu button (F8). The first submenu appears (typical example): Fig.9. Press return key (13) to select this menu.9. 1. Press button (F5): pictograph (5-Fig.25) is lit up green.Instruction book 1 2 3 4 5 6 7 8 9 10 Enter Modify Change value Change value Timer active (green) or not active (white) Delete Save Main screen Scrolling down Scrolling up Fig. 1. Press + button (F4) or . the timer is active and the start/stop commands are not accessible. Press + button (F4) or . Check the programmed command on the screen: 2920 1485 00 43 . 1. 1. 1. pictograph (1-Fig.25 Timer pictographs 1. indicating that the data may be changed.25) will light up green.button (F3) until MONDAY appears on the third line of the screen.button (F3) until "6:15" appears on the third line of the screen. Example: The compressor should start on Monday at 06:15 o'clock and stop on Friday at 18:05 o'clock 1 2 3 4 5 6 Press input button (F1).9.2 To program start/stop commands Important If pictograph (5-Fig.button (F3) until "6:0" appears on the third line of the screen.25) will light up white. Press + button (F4) until the command START appears on the third line of the screen. Use scroll keys (22) to move symbol > to the DAY line. The message "ADD A NEW EVENT" appears and the EVENT number changes to "1".9. Use scroll keys (22) to move symbol > to the HOUR line. Use scroll keys (22) to move symbol > to the MINUTES line. Press + button (F4) or . Use scroll keys (22) to move symbol > to the START/STOP line. pictograph (1-Fig.9.9. pictograph (2-Fig. Press + button (F4) or . Use scroll keys (22) to move symbol > to the DAY line. 1. The message "ADD A NEW EVENT" appears and the EVENT number changes to "2". Check the programmed command on the screen: TIMER NOT ACTIVE NUMBER OF EVENTS PROGRAMMED EVENT: 2 STOP 14 15 16 FRIDAY 2 18:05 Press SAVE button (F7) to save this command.25) will light up green. 1.25 lights up white). Press + button (F4) until the command STOP appears on the third line of the screen. Press modify button (F2). message CHANGES SAVED appears. Use scroll keys (22) to move symbol > to the START/STOP line. message CHANGES SAVED appears. Save by pressing key (F7). Buttons (F9 and F10) allow to scroll through the programmed commands.9.9. Use scroll keys (22) to move symbol > to the MINUTES line. Press + button (F4) or .9. See section 1.Instruction book TIMER NOT ACTIVE NUMBER OF EVENTS PROGRAMMED EVENT: 1 START 7 8 9 10 11 12 13 MONDAY 1 6:15 Press SAVE button (F7) to save this command.button (F3) until "18:05" appears on the third line of the screen.9. see section 1. message MODIFY THE CURRENT EVENT appears.buttons (F3 and F4).9. see “Important” above. 2920 1485 00 44 . Use scroll keys (22) to select the item to be modified. Check that the timer function is not active (pictograph 5-Fig.1.9. Press + button (F4) or .5 to activate the timer.5 to activate the timer. 1.3 To modify a command 1 2 3 4 5 6 7 Call up the Timer submenu. See section 1. Use scroll keys (22) to move symbol > to the HOUR line. Press scroll buttons (F9 or F10) until the event to be modified appears on the third line of the screen.button (F3) until "18:0" appears on the third line of the screen. Modify as required using the + and . Press input button (F1). 1. message CHANGES SAVED appears.25) will light up green.button (F3) until FRIDAY appears on the third line of the screen. To de-activate the time schedule 3 Press timer on/off button (F5): pictograph (5-Fig.9. see section 1.5 to activate the timer.1 To activate the time schedule 2 Press timer on/off button (F5): pictograph (5-Fig. 1. 1.5 To activate/de-activate the programmed time schedule Warning The start and stop commands are only carried out after activating the schedule. pictograph (6-Fig.9. Save by pressing key (F7).9. the compressor is started and stopped according to the schedule even if it was stopped manually. After activating. See section 1.9.9. message CHANGES SAVED appears. Check that the timer function is not active (pictograph 5-Fig.9.4 To delete a command 1 2 3 4 5 6 Call up the Timer submenu.9. message DELETE THE CURRENT EVENT appears. 1.25) lights up green indicating that the programmed timer functions are active. Calling up this menu 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2920 1485 00 45 .1.25 lights up white). see section 1. 1 Call up the Timer submenu.9. 1. Press delete button (F6). 1.Instruction book 1. message TIMER ACTIVE will appear (also on the Main screen). see “Important” above. Press scroll buttons (F9 or F10) until the event to be deleted appears on the third line of the screen.10 Saved data menu Function The Saved data menu is used to call up the 3 last shut-down and emergency stop data saved by the PLC. message TIMER NOT ACTIVE will appear (also on the Main screen).9.9.25) will light up green.25) lights up white indicating that the programmed timer functions are not active. 1.9. ) related to the shut-down..Instruction book 2 Press scroll keys (22) until symbol > is situated on the left of item SAVED DATA.. A screen appears showing information (date. time.. 2920 1485 00 46 . Press return key (13) to select this menu. Following menu appears: LAST SHUTDOWN <1> LAST SHUTDOWN <2> LAST SHUTDOWN <3> LAST EMERGENCY STOP <1> LAST EMERGENCY STOP <2> LAST EMERGENCY STOP <3> Note: (1) stands for the last event. (2) stands for the second-last event. … 3 Use scroll keys (22) to move through the screen until symbol > is situated on the left of the desired item and press return key (13). 1 Dimension drawings (Figs.Instruction book 2 INSTALLATION 2.1 Dimension drawing. 2. compressor with bodywork 2920 1485 00 47 .2) (1) (2) (3) (4) (5) Compressed air outlet Cooling water outlet Cooling water inlet Motor cooling air inlet for closed motor (IP55) Motor cooling air outlet for open motor (IP23) (6) (9) (4) (5) (7) (8) (10) (1) (2) (3) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (23) TWO STAGE (22) THREE STAGE (24) (21) THREE STAGE (22) TWO STAGE (23) (24) 9823 2462 00/1 52436D Fig.1 and 2. 2. intercooler. G ½" Manual drain. intercooler 1. G ½" Automatic drain.2 Dimension drawing. G ½" Automatic drain. standard motors Open motor 1RA3 (IP23) Closed motor 1LA4 (IP55) THREE STAGE (22) TWO STAGE (23) (24) (19) (20) 9823 2462 00/1 52437D Fig. compressor without bodywork 2920 1485 00 (25) 48 . G ½" Manual drain. aftercooler. aftercooler. 2. 1 G ½" Not for two-stage standard and threestage hot air Not for two-stage hot air Air and water connections Compressed air outlet three-stage Compressed air outlet two-stage Water inlet and outlet Free space in canopy Cubicle For 10kV motors only Main terminal box connection Ventilation. intercooler 2. intercooler 2. blow-off silencer Manual drain. G ½" Automatic drain.Instruction book (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (27) (26) (17) (18) (19) (20) (21) (22) (28) (29) (23) (24) (25) (26) (27) (28) (30) (22) THREE STAGE (31) (29) (30) (23) TWO STAGE (24) (11) (12) (13) (14) (15) (16) (17) (18) (31) Motor cooling air outlet for closed motor (IP55) Motor cooling air inlet for open motor (IP23) Blow-off out Compressor air inlet For hot air only Condensate drains Automatic drain. 2. 2.2 Installation proposal (Fig.Instruction book 2.3) (1) (2) (1) (2) (3) (4) (5) (6) (7) (8) (9) 9823 2494 00 52421D (1) Totally open zone next to delivery pipe (2) Minimum free area (3) Minimum corridor width (4) Ventilation proposals (5) Motor side (6) Compressor side (7) Closed motor IP54 (8) Open motor IP23 (9) No canopy Fig.3 Installation proposal (typical example) 2920 1485 00 49 . The valves must be provided locally. The drain pipes must not dip into the water of the collector.1 bar) length of delivery pipe in m inner diameter of the delivery pipe in mm absolute pressure at the compressor outlet in bar(a) free air delivery of the compressor in l/s 3. Install a water inlet and outlet valve. The required ventilation capacity to limit the compressor room temperature can be calculated as follows: Qv = Qv = N = dT = 0. An isolating switch must be installed near the compressor. Recommended minimum distance between the top of the compressor and the ceiling is 150 cm for ventilation and lifting. Position of the control panel. The valve must be provided locally. Position of the medium voltage cable entry. Position of the low voltage cable entry. Connect the valve to the air net. The pressure drop over the delivery pipe can be calculated as follows: dp = (L x 450 x Qc1.2 for the compressor limitations. 8. The air velocity through the grids should be limited to 5 m/s. 2920 1485 00 50 . as well as drain valves. It is also recommended to install a 1” nipple in the water inlet and outlet pipes. Connect the inlet and outlet valves to the water net. The installation must be earthed and protected against short circuits by fuses in all phases. Lay out the drain piping towards the condensate collector. 2. Description Install the compressor on a level floor suitable for taking the weight of the compressor.4. Consult section 7.1 N / dT required ventilation capacity in m /s shaft input of the compressor in kW temperature rise over ambient in °C 3 5. 9. Check that the electrical connections correspond to the local codes. Fit the manual condensate drain valves (5 and 7-Fig. 4.1).1 mm. 1. See also section 2. It is strongly recommended to provide a funnel for each drain pipe to allow visual inspection of the condensate flow. Position of the condensate drain valves. 6. The strainers have to be suitable for the cooling water flow. 7b.3 for alignment tolerances. It is recommended to provide a strainer in the water inlet for filtering particles larger than 0. Remove the covers from the water inlet and outlet pipes. The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor is avoided. 3.85) / (d5 x P) dp L d P Qc = = = = = pressure drop (recommended maximum = 0.3 for alignment tolerances. Remove the cover from the air outlet pipe of the compressor and install the compressed air outlet valve. See also section 2.Instruction book Ref. 7a. Instruction book (1) (2) (4) (8) (3) (5) (6) (7) 9823 1514 43/1 52563D (1) (2) (3) (4) (5) (6) (7) (8) Customer's installation. medium voltage supply Customer's installation. low voltage supply Control voltage Compressor motor PT100 Protection in bearings (optional) PT100 Protection in windings (optional) Motor heater (optional) To be installed by customer 2920 1485 00 51 . The compensator must not carry the weight of the customer pipe.3). 3-phase low voltage supply Drive motor Motor. motor winding temperature V1-V2 (T2-T5) (optional) Motor winding temperature W1-W2 (T3-T6) (optional) Spare.Instruction book F6 F21 K13 K21 K25 K27 K29 L1/2/3 M1 M25 M27 Q1 Q25 Q27 Q29 R29 R96 T1 T61 TT95a TT95b TT96a TT96b TT97a TT97b TT98 TT99 1X1 1X2 1X3 Undervoltage relay (customer's installation) Overload relay. auxiliary oil pump Fan motor. For the design of piping and supporting structures. EN 13480 or ASME 16. use an approved standard code (e.g. The compensators that are used are not suitable to carry the pressure thrust load. The allowable alignment tolerances for the different compensators are listed in the table below. 2920 1485 00 52 . motor auxiliary oil pump Circuit breaker. Adequate supporting of the piping system shall be provided to avoid weight load on the compensator. oil demister Circuit breaker.3 Mounting of outlet piping Atlas Copco ZH6000-10000 compressors with aftercooler are equipped with rubber compensators on the air and water connections. demister fan motor Circuit breaker. motor winding temperature U1-U2 (T1-T4) (optional) Motor winding temperature V1-V2 (T2-T5) (optional) Spare. See section 2. motor starter control Starter. AC power distribution Terminal strip. oil demister fan motor M27 Contactor. 2. oil heater R29 Terminals. drive end (optional) Motor bearing temperature. 2. drive motor (customer's installation) Contactor. to customer's installation Earth bolt Fig. oil heater Oil reservoir heater Anti-condensation heater (optional) Main transformer Motor current transformer/transmitter 4-20mA (customer's installation) Motor winding temperature U1-U2 (T1-T4) (optional) Spare.3. These compensators can cope with some minor misalignment (Fig.1. Make sure to adequately support and anchor the piping system. compressors without starter 2.5) when the customer pipe end is mounted. auxiliary oil pump motor M25 Contactor.4 Voltage supply connections. motor winding temperature W1-W2 (T3-T6) (optional) Motor bearing temperature. drive motor (customer's installation) Auxiliary relay. The piping system at customer side must be designed to fulfil the stated tolerances (both static and during operation). non-drive end (optional) Terminal strip. control circuit Circuit breaker.5/B31. 5) 140 135 140 140 2920 1485 00 53 .Instruction book (1) (2) (3) (4) (5) (6) (7) (8) Pipe end customer Pipe end Atlas Copco Lateral alignment Angular alignment Atlas Copco side Customer side Customer air outlet pipe Compressor Fig.3. 2.5 Mounting of outlet piping 2.1 Rubber compensator types Compensator part number DIN 1621 3098 00 1619 3120 07 ANSI 1621 8114 00 1621 9293 00 Diameter (in) 3 8 3 8 EL (mm) minimum (Fig.5) 115 120 115 115 EL (mm) maximum (Fig. 2. 2. The adhesion of scaling depositions and their effect are different on different materials. but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the saturation pH value (pHs). Due to the evaporative effect in the cooling tower. 2. In the latter case. Important: Design the piping and supporting structures in function to fulfil the requirements as stated. or a circulating system with a cooling tower.Instruction book 2. solids and gases typically found in cooling water in interaction with different materials.1 Type of the system Closed system In a closed system. 2. 2. the composition of the water that enters the cooler must be considered.4. 2. No general recommendation can encompass the effects of all combinations of the various compounds.pH Where: pH = measured pH (at room temperature) of water sample pHs= pH at saturation 2920 1485 00 54 . Open system An open system is a pass-through system.3.2 Alignment tolerances (Fig.4 Cooling water requirements The cooling water quality must meet certain minimum requirements. the total alkalinity.4. the total solids concentration and the temperature. The saturation pH value is determined by the relationship between the calcium hardness. and not the composition of the make-up water. The Rysnar Index is calculated as follows: RSI = 2*pHs . much higher concentrations of ions can be obtained in the circulating water than in the make-up water. This recommendation is a general guideline for acceptable coolant quality. the same cooling water is circulating through a system without contact with air.5) Maximum allowed tolerance on lateral alignment: 0 ± 5 mm The pipe ends must be mounted in such a way that they are in-line (no angular misalignment is allowed).2 Cooling water parameters The Rysnar stability index (RSI) The Rysnar Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate. Total Dissolved solids (mg/l) 50 – 300 400 .1 0.11.22 23 .0.21 22 .9 2.1 1.0 1.5 2.38 1.27 28 .2 2.12 .37 38 .8 .4 2.4 1.9 2.2 2.55 56 .1.24 .54 0.20 2.6 .5 2.6 1.7 2.88 0.3 2.1 2.8 1.26 0.0 1.3 2.71 72 .0 . C and D are found in the table below.34 35 .10 1.870 880 .50 51 .44 0.3 1.2.4 2.69 70 .4 2.0 7. B: depends on the highest cooling water temperature (°C).0 2. The values from A.5.56 .0.70 0.54 .1 2.87 88 .20 .46 .9 3.22 0.1000 Temperature A 0.8.0 D 1.690 700 .7 1.4 1.80 B 2. For ZH-units take: T = 65°C C: depends on the calcium hardness (ppm CaCO3).34 0.80 .2 .174 175 .8 14.7 1.430 440 .8 0.4 5.63 64 .270 280 .6 1.110 111 .4.1.0 The interpretation of the values obtained is: RSI < 6 boiler scale formation RSI 6 – 7 neutral water RSI > 7 corrosive water 2920 1485 00 55 .5 2.13 14 .8 1.6 2.4 1.54 3.7.43 44 .17 18 .7 1.138 138 .22 .31 32 .Instruction book The pHs is calculated by using: pHs = (9.5 1.6 0.2.1.11 12 . D: depends on the HCO3.2 2.concentration or M-alkalinity (mval/l).0 2.36 .0.78 2.2 .20.9 1.27 28 .340 350 .3 + A + B) .0.6 2.76 1.13 14 .6 1.1000 C 0.0. B.5 1.5 1.8 2.0 1.3 2.28 .2 1.3.0.7 0.0 11.0 .8 9.0.3 1.220 230 .2 Ca-hardness (ppm CaCO3) 10 .56 57 .17 18 .13.17.1 2.8 1.1 1.(C + D) A: depends on the total solids concentration (mg/l).72 .9 1.550 560 .90 .40 .6 M-Alkalinity (mval/l) 0.2 1.40 4.44 45 .2 (°C) 0-1 2-6 7-9 10 .3 1.6 17.6 .78 . 3 < RSI < 6.5 Tendency of the water Very high scale formation High boiler scale formation Action Water cannot be used Regular control and descaling operation necessary Water treatment not necessary Occasional inspection recommended Water treatment not necessary Occasional inspection recommended Water treatment not necessary Occasional inspection recommended Regular control necessary.5.9 4. use of corrosion inhibitor required Water should not be used 5. Cooling water showing good RSI conditions can still be unsuitable due to other factors.1 < RSI < 11 RSI > 11 Neutral water Slight corrosion at higher temperature Strong corrosion Very strong corrosion Very strong corrosion in complete water system This table indicates that distilled or demineralised water should never be used.0 9.6 < RSI < 6.9 < RSI < 7.0 < RSI < 5. In a closed system.Instruction book A more detailed interpretation follows below: RSI RSI < 3. The RSI is only indicating the equilibrium of scaling – descaling. use of corrosion inhibitor recommended Regular control necessary. the following limits apply: TDS < 3000 mg/l (<3800 µS/cm) For an open system. the RSI index should be between 5.2 Slight boiler scale formation 6.5 7.5 Total Dissolved solids (TDS) This is the sum of all ions in the water. as their RSI is >11.6 < RSI < 9.6 and 7. From the table above. the following limits apply: TDS < 750 mg/l (< 960 µS/cm) 2920 1485 00 56 . or it can be estimated from the electrical conductivity.8 6.8 < pH < 8. pH The effect of pH is already calculated in the Rysnar index. but the pH itself has some additional limitations: 6. otherwise contact a specialist. It can be derived from the dry residue after evaporation (but not including suspended solids). No oil. In open systems the sum of the squares of these values must not exceed 85. For recirculating systems with proper controls and treatment. lower limits should be used.5 ppm should not be exceeded. Their concentration should be limited: Closed cooling system: Chlorides < 500 ppm Open cooling system: Chlorides < 150 ppm However.5 ppm Copper < 1 ppm Iron and Manganese < 1 ppm Organics No algae. Suspended solids Non-soluble particles. if the water is scaling.should be >1 Ammonia < 0.000.Instruction book Chlorides (Cl-) Chloride ions will create pitting corrosion on stainless steel. Sulphates (SO4--) Closed cooling system: Sulphates < 400 ppm Open cooling system: Sulphates < 150 ppm Carbonate hardness Closed cooling system: 50-1000 ppm CaCO3 Open cooling system: 50-500 ppm CaCO3 HCO3. Free chlorine (Cl2) Continuously. size < 1mm. For shock treatments./ SO42. Note that the sulphate value must include any sulphite present. a level of 0.000. < 10 ppm Remark Chloride and sulphate are interactive. 2920 1485 00 57 . (See The Rysnar stability index (RSI)). the sum of the squares may be up to 520. a maximum limit of 2 ppm for maximum 30 minutes/day applies. 25. 1.6 Pictographs. 2. condensate drains 1 2 Cooling water outlet Cooling water inlet Fig. aftercooler Automatic condensate drain.10 and 1. intercooler Automatic condensate drain.5 Pictographs See also Figs. 1.Instruction book 2.9. water 2920 1485 00 58 . aftercooler Manual condensate drain. blow-off silencer Manual condensate drain.7 Pictographs. 2. intercooler Fig. 1 2 3 4 5 Condensate drain. Avoid any obstruction or liquid lock by sagging of the pipe.11) for correct connection (a label is stuck on the transformer). Check that the cooling water drain valves (customer's installation) in the inlet and outlet piping are closed. Close the condensate drain valves (5 and 7-Fig. The compressor can also be lifted after inserting beams in the slots. Fit the centre part of the drive coupling using new bolts (4-Fig. 1. 6. Check the rotation of drive motor (1-Fig. Never install valves in this pipe. The lifting equipment must be placed in such a way that the compressor will be lifted perpendicularly. Lift smoothly and avoid twisting. 12. In this case. A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect the compressor against corrosion.4) is closed and the drain plug (2) is fitted. precautions must be taken.1).1) while the compressor is coasting to a stop: the correct rotation direction is counter-clockwise when looking at the drive end shaft of the motor. 10. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame.4).11 and 2.5 mbar. 11. A sticker dealing in short with the operation is delivered with the compressor. Make sure that the forks protrude from the other side of the frame. See section 4. consult Atlas Copco. Remove the centre part of the drive coupling (4-Fig. 1.3. Open the water inlet and outlet valves (customer's installation). Operating conditions If the ambient or air inlet temperatures can be beyond the limitations stated in section 7. 3. and also if operating in other extreme conditions.1 Preparation for initial start-up 1. Make sure that the beams cannot slide and that they protrude from the frame equally. as well as the flow regulating valves (2 and 4-Fig. See section 7. 1.4. 1. Check that key (3-Fig. 7. 8. 5. If not provided. The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. Remove the plates.3 for the values of the circuit breakers and motor types. check that oil is visible in the bearing sight-glasses. 14. For drive motors equipped with sleeve bearings. Have the drive motor alignment checked by an Atlas Copco representative. stick warning labels next to the control panel and also on both sides of the compressor on an obvious place inside the bodywork indicating that the compressor is automatically controlled (started and stopped) by the PLC.11) of the CPU is in position RUN and check the setting of circuit breakers (Q1/25/27/29-Figs. 3. 2.1). Consult section 7.3). switch off the voltage and reverse two incoming electric lines. 13. Fit it next to the control panel.2). Consult section 2 for the dimension drawings and installation proposal. The maximum pressure drop over this pipe is 0. 3. 4. If wrong. 3.3. Start the drive motor and stop it immediately. Check the voltage selecting wires at transformer (T1-Fig.Instruction book 3 OPERATING INSTRUCTIONS Safety precautions The operator must apply all related safety precautions including those mentioned in this book. 3. 9. Check that the oil reservoir is filled with oil to the full mark of sight-glass (3-Fig. The outlet of the demister may be ducted outside of the bodywork. 2920 1485 00 59 . 1.1). Check for water flow. Check that the drain valve in the water inlet pipe (1-Fig. 1. 3. 2920 1485 00 60 .4). 3. Check that the auxiliary oil pump (7-Fig. 19. Switch on the voltage and put key switch (17) in position local (vertical position). whether the oil heater is activated (pictograph 1 is lit up green). Check the rotation of fan motor (1-Fig. Remote control mode (local control is made inactive): The compressor will only react to start/stop and manual load/unload commands by external switches. take out the key after selecting the required mode. Wait until the starting conditions are fulfilled (see section 3.3) starts running (pictograph 6 is lit up green) (or starts after a period of time.5) of the demister: the correct rotation direction is clockwise when looking at the drive end shaft of the motor. 20. 17. The oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). 1. if the oil temperature is below 38 °C. Have the tuning of inlet guide vanes (3-Fig.Instruction book 15. switch off the voltage and reverse two incoming electric lines at circuit breaker (Q25-Figs. if wrong. 1.8.3) of the oil pump: the correct rotation direction is clockwise when looking at the drive end shaft of the motor.3) and blow-off valve (1) checked by an Atlas Copco representative. controlled by the PLC).11 and 2. 3. To avoid unauthorized switching over to another control mode. Emergency stop button (18) remains active.3): pictograph (5) is lit up green or blinks to indicate that the compressor may be started. 16. Check the rotation direction of the motor (8-Fig. Local control mode (remote control mode is made inactive): The compressor can only be controlled by the buttons on the control panel. Check. Have the settings programmed in the PLC checked by an Atlas Copco representative. 18. 5.11 and 2. If wrong.2 Compressor control modes Key switch (17) allows the operator to select three control modes: 24 Compressor off: The PLC will not react to any start/stop command. The oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). 3. 3. See section 1. switch off the voltage and reverse two incoming electric lines at circuit breaker (Q27-Figs.4). The oil will not be heated and not circulated. 25 26 Important The PLC will only react to a new control mode if the new position of the control mode switch is maintained for 3 seconds. 3. If these conditions are not fulfilled (pictograph 5 is not lit up green). Open the air outlet valve.2 bar(e). 3.2) which must be in the green range or above. 4. the settings have not been disturbed. See section 4.1). 1. For drive motors equipped with sleeve bearings. immediately after pressing the start button. if necessary.3). with the correct type of oil. If the cooling water was drained (see section 3. 3. the oil pressure must exceed 0.7): close the drain valve (1-Fig. It is recommended to keep key switch (17) in the position local control (vertical position) or remote control (switched to the right) to keep the oil heater energized and the auxiliary oil pump operative (started and stopped by the PLC). Close condensate drain valves (5 and 7-Fig. the compressor will not start. Check the oil level (3-Fig. 2920 1485 00 61 . check that oil is visible in the bearing sight-glasses.4) in the water inlet pipe and fit the drain plug (2) fit the drain plugs (6-Fig.Instruction book 3.7. Open the water flow regulating valves (2 and 4-Fig. See section 1.3) underneath all coolers Open the water inlet valve and outlet valve.3 Before starting Attention Before starting the compressor. after previous operation. a message indicating the fault will appear on display (11). after pressing button (F5). 5. 3.5. 2. 3.3. 6. the oil temperature must exceed 25°C. Opening of these valves can be overlooked if. Top up. 3. 3): the closed position of the valve is expressed in percentage whether the compressor is controlled locally (start/stop and manual load/unload commands only possible by means of the buttons of the control panel) or controlled remotely (start/stop and manual load/unload commands only possible by means of external switches) the status of the Timer (if activated. 3. the programmed time-based start and stop commands will be executed. 7. After 20 seconds (programmable).9) 4. the main screen is shown. aftercooler condensate drain Condensate drain.4 Starting 3.9.Instruction book 1 2 3 4 5 6 7 8 Air outlet Water outlet Water inlet Automatic drain outlet. Automatic operation pictograph (3) will light up. If the compressor is not ready to start. intercooler condensate drain Condensate drain valve. If any. regulate the water flow with the compressor running loaded using valves (2 and 4-Fig. 6. intercooler condensate drain Automatic drain outlet.1 Air. 3.4 for the cooling water temperature and pressure. see section 1. Consult section 7.3): the open position of the vanes is expressed in percentage the position of blow-off valve (1-Fig. consult section 6.8. See section 1. Check whether any warnings or shut-down conditions (indicated by pictograph 2) exist. Check the cause and remedy.3). pictograph (6) will go out. Switch on the voltage. 5. 2. 3.1. aftercooler condensate drain Condensate drain valve.7) the gearbox oil pressure the outlet pressure at compressor element 2 the position of inlet guide vanes (3-Fig. consult section 1. The screen shows: the compressor outlet pressure the compressor setpoint (see section 1. blow-off silencer Fig.4. Normally.9.3) should automatically turn off after the compressor has reached full operating speed. Auxiliary oil pump (7-Fig. Press reset button (16) to clear any alarm.3). 3. The compressor starts running in unloaded condition. Check that voltage on lamp (15) lights up. Press start button (19). 2920 1485 00 62 . and for the cooling water consumption. the compressor starts running loaded. If necessary.7. Check that permissive start pictograph OK (5) lights up or blinks (see section 1. 3. water and condensate drain connections 3.1 Routine starting 1. 3. switch off the voltage and depressurize the compressor. See section 8. oil reservoir Fig. After remedying the fault.Instruction book 3. unlock the emergency stop button by pulling it out.3 Number of motor starts In automatic operation. press reset button (16) and restart the compressor as described above.4.2 Starting after emergency stopping or shut-down Press emergency stop button (18) (if not yet done so).4. the PLC limits the number of motor starts. 3.2 Oil reservoir 2920 1485 00 63 . 1 2 3 4 5 6 7 Oil filler cap Oil strainer Oil level sight-glass Oil drain valve Oil heater Oil reservoir Inspection cover. 3.4. it may restart automatically. aftercooler circuit Inlet guide vanes Water regulating valve.3 View of coolers 3. To put the compressor back into automatic operation. intercooler circuit Vent plugs Drain plugs Auxiliary oil pump Motor. 3. See below. press button (F3). To unload the compressor manually.Instruction book 1 2 3 4 5 6 7 8 Blow-off valve Water regulating valve. press button (F4). Check the readings on display (11). When pictograph (3) is lit up. Check that condensate is drained through the automatic drain outlets (4 and 6-Fig. 2. 2920 1485 00 64 . auxiliary oil pump Fig.5 During operation 1. 3. 4.1) (the amount depends on the ambient and operating conditions). starting and stopping of the motor is automatically controlled: when the motor is stopped. 3. Pictograph (4) lights up and pictograph (3) goes out. 2. To avoid unauthorized switching over to another control mode.Instruction book Important 1. starting and stopping of the motors is automatically controlled by the PLC. the compressor can be unloaded manually by pressing button (F4): the compressor is switched out of automatic operation and remains running unloaded (unless button F3 is pressed). repair or adjustment.7. the motor is prevented from restarting within a programmable time period which is set exfactory at 240 seconds (called minimum stop time). 3. Consult section 1.2. Press button (F3) to switch the compressor to automatic operation again (automatic capacity regulation controlled by the PLC).1 for automatic restart after a long period of automatic completely unloaded operation section 1.8. 2920 1485 00 65 . Regularly check the display (11) for readings and messages. Pictograph (3) is lit up green. the compressor main screen is shown. See section 3. See also: section 1. Normally.7 for automatic restart after power failure section 1.7. the compressor runs in automatic operation: the PLC controls the capacity and operation of the compressor.9 for time-based start and stop commands.1. The PLC will only react to a new control mode if the new position of control mode switch (17) is maintained for 3 seconds.4. If the motor is stopped and automatic operation pictograph (3) is lit up or blinking.7. take out key (17) after selecting the required mode.5. Warning Before carrying out any maintenance. 3. If required. See also section 3.6 Manual control of compressor operation Normally. press emergency stop button (18). stop the compressor.9. 2. A start command during this period is ignored. 3. Always check the display and remedy the trouble if pictograph (2) is blinking or lit up.9. Pictograph (3) lights up and pictograph (4) goes out.1 Checking the display 1.3 for explanation of the pictograph section 1. switch off the voltage and depressurize the compressor. After stopping. press emergency stop button (18). drain the cooling system: remove drain plug (2-Fig. 3. Close the cooling water inlet valve. Close the air outlet valve. 3. 5.7 Stopping 1. Press stop button (20). Open condensate drain valves (5 and 7-Fig. If the compressor is installed in a room where freezing temperatures are expected.7. unlock the emergency stop button by pulling it out. 3.Instruction book 3. The compressor will follow a programmed stop sequence (run unloaded for some seconds. See section 1. 3. 1 2 Water drain valve Water drain plug Fig.1). after which it will stop).3) underneath all coolers Attention It is recommended to keep key switch (17) in position local control (vertical position) or remote control (switched to the right) to keep the oil heater energized and the auxiliary oil pump operative (started and stopped by the PLC).4) in the water inlet pipe and open the drain valve (1) remove the drain plugs (6-Fig. 3. Pictograph (2) starts blinking. To stop the compressor immediately in case of emergency. 6.5.4 Water piping 2920 1485 00 66 . 2. After remedying the trouble. 4. Disconnect the cooling water pipes from the compressor. Close the air outlet valve and stop the compressor. Shut off and depressurize the part of the air net which is connected to the outlet valve. 5.8 Taking out of operation At the end of the service life of the compressor. proceed as follows: 1. 4. oil and condensate circuits. 6. Disconnect the compressor air outlet pipe from the air net. Switch off the voltage and disconnect the compressor from the mains. Drain the water. 2920 1485 00 67 .Instruction book 3. Disconnect the compressor condensate piping from the condensate drain net. 3. 2. In servicing. O-rings and washers. have cleaned if necessary Have inlet guide vanes. Safeguard against unintentional "switch-on".2 See notes below table 1 5 2 4 3 Operation Check operation of inlet guide vanes and blow-off valve Check for warnings Check oil level Check display readings Check that condensate is discharged from automatic drains Manually drain condensate drain receivers after stopping Check programmed settings Check for water.2 5.2 3. Read the related section before taking maintenance measures.1 3. press stop button (20). change oil if necessary Change oil filter Check oil strainer.1 Preventive maintenance schedule for the compressor 1) The schedule contains a summary of the maintenance instructions.1 5. press emergency stop button (18).1 5. including those mentioned in this book. Apply all relevant safety precautions.7 8 4. Period 2) Daily " " " " " Weekly " " " 6-monthly " " Yearly " " " " " " " Running hours 2) 8 8 8 24 24 4000 8000 8000 8000 8000 8000 See section 1. clean if necessary Check operation of oil demister Check coolers.7 3. 4.1 5. oil or air leaks Check for abnormal noise Drain condensate from air receiver.2 5. The "longer interval" checks must also include the "shorter interval" checks.Instruction book 4 MAINTENANCE Warning Before starting any maintenance or repair. switch off the voltage and depressurize the compressor. if installed Grease motor bearings Check pressure drop over oil demister pipe (if ducted away) Remove air filters and inspect. clean or replace if necessary Clean compressor Replace air filters Have oil analysed. blow-off valve and check valve inspected Have motor alignment checked 2920 1485 00 68 .3 7. replace all removed gaskets. wait until the compressor has stopped. This is special lubricant for ZH compressors ensuring optimum bearing lubrication. 4. shut-down and alarm functions. 2920 1485 00 69 .2): Type: Use Atlas Copco Roto-Glide grease. The amount of condensate depends on the working and environmental conditions. In very dusty surroundings it may be necessary to check the air filters more frequently. 4. 5. Interval: The grease interval is 2000 operating hours or more.2 Motor greasing For motors with roller bearings (section 7. Attention: Never mix different greases.Instruction book Period 2) " " 2-Yearly 3-Yearly Notes 1. The amount discharged from the intercooler is low in relation to the condensate flow from the aftercooler.4 5.3 Lubricant specifications Use Atlas Copco Roto-H Plus. Consult Atlas The interval depends on the ambient temperatures. Running hours 2) 16000 24000 See section 5. Any leak should be attended to immediately. 2. 4. Consult the motor data plate. Consult Atlas Copco if in any doubt. This lubricant can be ordered in following quantities: All markets – except for USA and Canada 19 l can 208 l drum For USA and Canada 5 gal can 55 gal drum 2908 8509 00 2908 8510 00 2908 8507 00 2908 8508 00 Attention: Do not mix Roto-H Plus with Roto-H or other lubricants.3 See notes below table - Operation Have regulating system. 3. sensors and electrical components checked Have compressor inspected by Atlas Copco Change PLC battery Replace cartridge of oil demister Level should be in green range or above. Copco.3. 4. protective measures must be taken. If the compressor is going to be stored without running from time to time.5 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. Protect the compressor in case the ambient temperature can be beyond the limitations (see section 7. and run the compressor for about 15 minutes.Instruction book 4.4 Storage after installation Open condensate drain valves (5 and 7-Fig. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Footnotes chapter 4 1) Use only authorized parts. 2920 1485 00 70 . 4. If in any doubt. Keep the compressor room well-ventilated and the compressor clean.1). depending on the environmental and working conditions of the compressor. especially the service intervals. Close the valves after draining. 3. If key switch (17) is left in the compressor lock mode (switched to the left).2). Consult Atlas Copco. consult Atlas Copco. switch over to local or remote position once a week. 2) Whichever interval comes first. wait until the starting conditions are fulfilled (pictograph 5 lights up or blinks). The local Atlas Copco Sales Company may overrule the maintenance schedule. Keep key switch (17) in local (vertical position) or remote (switched to the right) control mode to keep the oil warm and pumped around preventing the internal system from rusting. Filter change for optional dual oil filters (Fig. clean the strainer. Remove the filters (2). Loosen venting plugs (2) of the left filter until the venting holes are visible. an appropriate pre-filter of the dry type should be installed. 2.2) and fit a new one.2 Oil and oil filter change (Figs. Fill the compressor sump to the full mark of sight-glass (3) with oil as specified in section 4.1 Air filters (Fig.3 (approx. See section 1.1) 1. 4.3. 1 2 Cover Air filters Fig.5) and fit the cover. Remove the filter (Fig. 5. Remove the cover (1) and clean the filter chamber. 2. 5. 5.9. If necessary.3) and check oil strainer (2). 4. the right filter is in operation and vice versa. 2920 1485 00 71 . 5. 5. Remove inspection cover (7-Fig. Never install damaged or clogged filters. Assume that the right filter is in operation and needs to be changed: 1. 5.9. 5. Remove filler plug (1-Fig.Instruction book 5 SERVICING PROCEDURES 5. 220 l).3. 3. Stop the compressor and switch off the voltage. Switch handle (1) in line with handle (3) to fill the left filter with oil and to vent it.1 Air filters 5. 5. 3. Switch on the voltage. 7.3).7. Take care that no dirt drops into the filter box. 2.7. 6.2 and 5. Reset the service warning and the actual running hours of the oil to 0. Drain the compressor sump by opening drain valve (4). Run the compressor until warm. Install the new filters (see section 4. 6. The filters must be serviced as soon as the service warning appears on the display or yearly. In dusty operating conditions where it will be necessary to replace the filters too frequently.3) 1. Stop the compressor and switch off the voltage. Switch on the voltage. 5. Reset the service warning and the actual running hours to 0 as described in section 1. reset the service warning and the actual running hours of the oil filter to 0. Reinstall the cover. Close the valve after draining.4) When handle (3) is switched to the left (and handle 1 perpendicular to handle 3). Replace the seals on the venting plugs. close the venting plugs. the left filter is in operation.Instruction book 3.2 Oil filter 1 2 3 4 5 6 7 Oil filler plug Oil strainer Oil level sight-glass Oil drain valve Oil heater Oil reservoir Inspection cover. Switch handle (3) to the right. 5. Switch handle (1) until it is perpendicular to handle (3). 5. When oil flows out the venting holes.3 Oil reservoir 2920 1485 00 72 . Remove the right filter and fit a new one (torque 35 Nm). 4. 5. oil reservoir Fig. Fig. Stop the compressor and switch off the voltage. 3.Instruction book 1 2 3 Handle Venting plugs Handle Fig. Loosen the clamp ring and remove the upper part (2) of the demister.9.5) 1. Fit the new gasket and filter cartridge into the upper part of the demister and screw in the bolt underneath the cartridge to fix it.3. 6. 4. Reset the service warning and the actual running hours to 0 as described in section 1.3 Demister (Fig. Note A demister element kit can be ordered: part number 1621 8651 00. 5. 5. Unscrew the bolt underneath the filter cartridge and take out the cartridge and gasket.4 Dual oil filters 5. Reinstall the upper part (2) of the demister and tighten the clamp ring. Switch on the voltage.7. 2920 1485 00 73 . 5. 2. 2.6 CPU 2920 1485 00 74 . 5.6) 1. 1 2 3 CPU card Battery Grip Fig. 5. Reinstall CPU card (1). 5. 5. Press grips (3) and take out CPU card (1). 3. Remove battery (2) and place the new one within one minute.4 PLC battery change (Fig. Make sure that all electrical supplies are switched off and that the power cannot be switched on.5 Oil demister 5. 4.Instruction book 1 2 Fan motor Upper part of demister Fig. Switch on all electrical supplies and restart the compressor. 2 Press reset button (16) See section 1. Check for sensor failure.7.Instruction book 6 PROBLEM SOLVING Warning Before starting any maintenance or repair.5. including those mentioned in this book. oil heater overload and auxiliary oil pump motor overload Set key switch (17) in position local (vertically) or remote (switched to the right) The number of programmed starts has been exceeded (see section 8. Press reset button (16) See section 1. Apply all relevant safety precautions.4). switch off the voltage and depressurize the compressor. Faults and suggested remedies 1 The compressor is not ready to start (pictograph 5 remains out) Press OK button (F5). wait until the compressor has stopped.7. Examples of messages: Message E. Wait for timer to expire LOCKED MODE STARTS ALLOWED/HOUR STARTS ALLOWED/DAY MINIMUM STOP TIME 2920 1485 00 75 .4). press stop button (20). Wait for timer to expire The minimum stop timer is running (set exfactory at 240 s). Wait for timer to expire The number of programmed starts has been exceeded (see section 8. press emergency stop button (18).STOP BUTTON COMPRESSOR SHUTDOWN PRESS RESET GEARBOX OIL TEMPERATURE Action Release emergency stop button (18) by pulling it out. Safeguard against unintentional "switch-on". Instruction book 2 Pictograph (2) is blinking Consult section 1.2 3 a a b b c c 4 a a b b c c 5 Air temperature above normal Inlet temperature too high due to bad room ventilation or recirculation of cooling air Improve ventilation of compressor room Insufficient cooling water flow Check and increase cooling water flow Insufficient cooling or restriction in cooling water system due to formation of scale or settling down of dirt Consult Atlas Copco Excessive vibration and noise Unstable operation of drive motor Have vibration level measured and motor inspected. Consult Atlas Copco Alignment altered Have compressor/motor re-aligned. Consult Atlas Copco Formation of coke on the bearings Have bearings inspected by Atlas Copco Surge problems Consult Atlas Copco 2920 1485 00 76 .7. 2 Programmable settings A number of regulation settings and protection settings are programmable.4 Oil heater Q29 A 3. 58 °C approx.7 2.3 bar(e) slightly above outlet pressure below 0.8 2. 1.4 up to 7.7 2.Instruction book 7 PRINCIPAL DATA 7.0 5.5 11. See section 8. compressor element 2 Aftercooler outlet temperature Approach temperature.11 approx.0 2920 1485 00 77 . 2.7 2.1 Circuit breakers Low voltage supply V 230 400 500 220-230 380 440-460 575 Frequency Hz 50 50 50 60 60 60 60 Approval IEC IEC IEC CSA-UL CSA-UL CSA-UL CSA-UL Main circuit Q1 A 11.6 0. compressor element 2 see 7.4. gearbox Outlet pressure.1 Readings on display (1-Fig.0 0.4. reservoir Oil temperature.4.4 up to 7.11 see 7.5 2.5 4.7 Auxiliary oil pump Q25 A 4.motor types 7.05 bar below 1 bar approx.7 2.2 Oil demister fan Q27 A 1.3 Circuit breakers .2 4.1 2.4.3.0 0.8 3. gearbox Inlet temperature.4 1.5 0.0 3. intercooler Approach temperature. compressor element 2 DP air filter DP oil filter Oil temperature.8 2.9) 1) Outlet pressure Setpoint pressure Oil pressure. compressor element 1 Vibration level.6 5.2 1.0 5.6 0. 7. aftercooler Cooling water inlet temperature Drive motor cooling air inlet temperature Drive motor current Vibration level. 50 °C sum of cooling water inlet and cooler approach temperatures sum of cooling water inlet and cooler approach temperatures below 20 °C below 20 °C below 35 °C below 50 °C depends on motor type 5 to 15 micrometer 5 to 15 micrometer 7.7 2. 4.4.4 Compressor specifications 7.3-5-5.3-5-5.3-5-5.5-6-6.3.5-6-6.5-6-6.6 kV 700 hp / 2.3-5-5.3-3-3.6 kV 710 kW / 10 kV 600 hp / 2.3-4.2 Limitations Maximum setpoint pressure Maximum air inlet temperature Minimum air inlet temperature Maximum ambient temperature Minimum ambient temperature Maximum cooling water outlet temperature Maximum cooling water inlet temperature Maximum cooling water pressure Minimum cooling water pressure bar(e) °C °C °C °C °C °C bar(e) bar(e) see sections 7.6 kV 710 kW / 3-3.4.3-4.3-4.3-5-5.4 up to 7.4 up to 7.3-4.3-3-3.16-6-6.5-6-6.5-6-6.3-4.3-3-3.3-3-3.4.6 kV 560 kW / 3-3.6 kV 900 hp / 2.6 kV 630 kW / 3-3.4.1 Design conditions Absolute inlet pressure Relative air humidity Air inlet temperature Nominal effective working pressure Cooling water inlet temperature Motor shaft speed .16-6-6.3-4.60 Hz versions bar(a) % °C bar(e) °C r/min r/min 1 60 35 see sections 7.3-4.11 40 -10 40 5 50 35 5 2 2920 1485 00 78 .6 kV 800 hp / 2.2 Motor types Motor IP 55 500 kW / 3-3.6 kV 630 kW / 3-3.3-4.6 kV 800 hp / 2.7 2980 3575 7.6 kV 700 hp / 2.16-6-6.6 kV 630 kW / 10 kV 710 kW / 3-3.11 26.3-3-3.16-6-6.50 Hz versions Motor shaft speed .3-3-3.3-5-5.6 kV 560 kW / 3-3.5-6-6.6 kV Motor type 1LA4 354-2 1LA4 400-2 1LA4 402-2 1LA4 450-2 1LA4 404-2 1LA4 450-2 1LA4 352-2 1LA4 354-2 1LA4 400-2 1LA4 402-2 Motor type 1RA3 350-2 1RA3 352-2 1RA3 354-2 1RA3 354-2 1RA3 314-2 1RA3 350-2 1RA3 350-2 1RA3 352-2 Bearing type Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Sleeve bearings Roller bearings (optional: sleeve bearings) Sleeve bearings Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) 7.3-3-3.Instruction book 7.4.16-6-6.5-6-6.16-6-6.6 kV 600 hp / 2.16-6-6.5-6-6.3-5-5.16-6-6.3-5-5.6 kV Motor IP 23 500 kW / 3-3.6 kV 900 hp / 2.3-3-3. 5 220 ZH10000 -3 3.2 bar 4.3 Sound pressure level 3) Sound pressure level.4.2 36 630 62 0. approx.6 220 ZH10000 -4 3.6 220 ZH10000 -4 4.2 bar NA NA NA NA NA NA NA 2920 1485 00 79 .6 220 ZH10000 -4 3.9 34 560 52 0.9 3.4.3 3.3 3.9 bar 4. without bodywork dB(A) dB(A) 70 81 7.2 37 710 66 0.50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.9 bar 4.5 34 500 49 0.9 38 710 69 0.2 bar .2 bar 4.5 36 630 58 0.5 Specific data of 3.Instruction book 7.7 220 ZH10000 -6 4.5 bar 3.7 220 ZH10000 -6 3.5 220 ZH10000 -2 3.8 220 7.7 220 ZH10000 -5 4.4.6 4.9 35 560 55 0.3 3.6 220 ZH10000 -5 3.5 37 630 61 0.9 bar . Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) °C kW m³/hr bar l ZH10000 -1 3.9 3.9 3.7 220 ZH10000 -6 3.50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.9 3.6 220 ZH10000 -5 3. with bodywork Sound pressure level.6 4. approx.9 3.5 38 710 69 0.2 bar 4.6 Specific data of 4.2 34 500 49 0.5 35 560 54 0.2 bar 4.6 4.9 bar 4.5 220 ZH10000 -2 3.4 Specific data of 3.9 bar 4.2 35 630 57 0.9 37 710 64 0.5 34 500 47 0.9 34 500 49 0.5 bar 3.5 bar 3.5 bar 3.4.8 220 7.9 bar 4.6 4.6 220 ZH10000 -3 3.6 220 ZH10000 -3 4.5 bar 3.9 bar 4.3 3.5 bar 3.5 bar . approx.3 3.3 3.50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.6 4.2 bar 4.9 3.2 34 560 53 0.5 220 ZH10000 -2 4.9 36 630 59 0. Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) °C kW m³/hr bar l ZH10000 -1 4. Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) °C kW m³/hr bar l ZH10000 -1 3. 9 3.6 bar NA NA NA NA NA NA NA 7.5 220 ZH10000 -2 4.5 220 ZH60002 50 psi 3.7 220 ZH10000 -5 4.6 220 ZH10000 -4 4.3 3.50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.6 220 ZH60003 55 psi 4. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) °C hp m³/hr bar l ZH60001 50 psi 3.9 3. approx.5 35 700 54 0.60 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.7 220 ZH60006 55 psi 4.1 4.9 Specific data of 55 psi .6 220 ZH60004 50 psi 3.3 3.60 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) °C hp m³/hr bar l ZH60001 55 psi 4.5 37 800 62 0.9 3.4.3 3.5 34 600 47 0.6 bar 5.5 36 800 58 0.6 bar 5.5 220 ZH60003 50 psi 3.5 220 ZH60002 55 psi 4.6 36 710 64 0.1 4.9 38 900 69 0.6 37 710 69 0.6 bar 5.1 4.6 bar 5.6 220 ZH10000 -3 4.9 3.6 bar .4.4.9 37 800 64 0.6 35 630 59 0.3 3.7 Specific data of 4.6 220 ZH60004 55 psi 4.5 34 600 49 0.1 4.9 35 700 55 0.9 36 800 59 0.8 220 2920 1485 00 80 . Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) °C kW m³/hr bar l ZH10000 -1 4.9 34 700 52 0.6 220 ZH60005 50 psi 3.6 bar 5. approx.6 34 560 54 0.8 220 ZH10000 -6 4.9 3.3 3.7 220 ZH60006 50 psi 3.8 220 7. approx.1 4.9 34 600 49 0.5 38 900 69 0.3 3.9 3.8 Specific data of 50 psi .6 220 ZH60005 55 psi 4.6 34 560 51 0.Instruction book 7. ft x °C = (32 + 1.6 34 700 54 0.5 Conversion list of SI units into British/American units 1 bar = 14. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) °C hp m³/hr bar l ZH60001 60 psi 4.60 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.504 psi 1 g = 0.205 lb 1 km/h = 0.11 Specific data of 65 psi .035 oz 1 kg = 2. approx.4.401 in wc 1 N = 0.4.10 Specific data of 60 psi .2 35 800 57 0.8 x) °F 5) 2920 1485 00 81 .341 hp (UK and US) 1 l = 0.6 220 ZH60004 65 psi 5.1 4.2 34 700 53 0.6 220 ZH60003 60 psi 4.6 4.2 37 900 66 0.6 4.6 35 800 59 0.1 4.7 220 ZH60006 60 psi NA NA NA NA NA NA NA 7.6 4.1 4.6 220 ZH60003 65 psi 5.315 cfm 1 mbar = 0.Instruction book 7.8 220 ZH60006 65 psi NA NA NA NA NA NA NA 7.7 220 ZH60005 60 psi 4.1 4.225 lbf 1 Nm = 0.60 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature.6 37 900 69 0.2 34 700 49 0.281 ft 1 mm = 0.5 220 ZH60002 65 psi 5.039 in 1 m3/min = 35.264 US gal 1 l = 0.7 220 ZH60005 65 psi 5.6 34 700 51 0.621 mile/h 1 kW = 1.035 cu.6 4.2 36 800 62 0.6 36 900 64 0.6 220 ZH60004 60 psi 4.ft 1 m = 3. approx.1 4.5 220 ZH60002 60 psi 4.6 4. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) °C hp m³/hr bar l ZH60001 65 psi 5.738 lbf.220 Imp gal (UK) 1 l = 0. 20°C air inlet temperature and 20°C water inlet temperature. 5) A temperature difference of 1°C = a temperature difference of 1. 2920 1485 00 82 . With a tolerance of 3 dB. 6) Rated at 40°C and service factor 1.15. 4) At temperature rise of 10°C. 3) According to PNEUROP PN8NTC2.2 under free field conditions at 1 m. 7) Rated at 40°C and service factor 1. 1 bar absolute inlet pressure. 2) At design conditions.8°F.Instruction book Footnotes chapter 7 1) At nominal working pressure. 9 3.9 1. element 2 (PT22) -shut-down warning level -shut-down level Air inlet temperature.0 1.8 4.9 49.5 bar 50 Hz / 3.0 1.1 30.0 °C °C 50 53 52 66 65 66 °C °C 50 58 57 63 62 63 micrometer micrometer 10 24.5 5 -1 3 8.2 bar 50 Hz / 4. compressor element 1 (VP10) -shut-down warning level -shut-down level Vibration.4 3. compressor element 2 (VP20) -shut-down warning level -shut-down level Oil level (LT42) -shut-down warning level -shut-down level Factory setting Maximum setting bar(e) bar(e) 1.4 49.1 30.7 4.1 Minimum setting Setpoint pressure (PT29) 50 Hz / 3.6 bar 60 Hz / 50 psi 60 Hz / 55 psi 60 Hz / 60 psi 60 Hz / 65 psi Loading pressure setpoint (PT29) 5) Unloading pressure setpoint (PT29) 5) Factory setting Maximum setting bar(e) bar(e) bar(e) bar(e) bar(e) bar(e) bar(e) bar(e) bar bar 2 2 2 2 2 2 2 2 -0.5 l l --- 179 150 --- 2920 1485 00 83 .1 3.7.6 3.1 Regulation settings .9 4.2 0.5 3.9.Instruction book 8 PROGRAMMABLE SETTINGS 8.1 4. element 2 (TT18) -shut-down warning level -shut-down level Gearbox oil temperature (TT44) -shut-down warning level -shut-down level Vibration.2 3.See section 1.5 -0.4 49.See section 1.0 0.2 4.6 0.9 bar 50 Hz / 4.8.6 1.6 5.5 micrometer micrometer 10 24.2 Minimum setting Gearbox oil pressure (PT49) -shut-down warning level -shut-down level Air outlet pressure.9 49.8 47.2 Protection settings .3 4.8 47.1 1.6 3.6 1.2 4.9.9 4.0 0.5 bar(e) bar(e) 0 1. cooler 1 (TT18/51) Approach temperature. Consult the motor data plate.4 Settings for other parameters .4 Minimum setting Delay at start for oil pressure 1) Delay at start for vibration 1) Delay at start for air filter pressure drop 1) Delay at signal for approach temperature Number of starts per hour Number of starts per day Load delay time (DOL starter) Minimum stop time Stop after unloaded delay 5) Start failure.7 1 1 1 1 1 1 Factory setting 20 20 -0.See section 1.5 s s min °C bar(e) Footnotes chapter 8 1) 2) 3) 4) 5) Is the time period after starting during which the signal is ignored.8. Recommended interval: 2000 running hours ore more.1.3 Service settings .2 Maximum setting 25 25 120 255 15 24 99 255 60 40 0. See section 1.10 1.7.9.See section 1.3 Minimum setting Approach temperature.03 0.5 2) 2) 2) 3) 4) 2) 8. In case the function Stop after unloaded delay is activated by Atlas Copco.9.05 1 8000 8000 8000 24000 2000 8000 Maximum setting 100 100 -0. gearbox oil temperature (TT44) Start failure. Recommended interval: 3-yearly or 24000 running hours.7. aftercooler (TT29/51) Air filter pressure drop (PDT02) Oil filter pressure drop (PDT46) Oil lifetime (KSH49) Oil filter lifetime (KSH48) Air filter lifetime (KSH02) Oil demister lifetime (KSH41) Drive motor regreasing time (with roller bearings) (KSH93) Drive motor regreasing time (with sleeve bearings) (KSH93) °C °C bar bar hr hr hr hr hr hr 15 15 -0. gearbox oil pressure (PT49) s s s s 6 6 5 15 1 1 20 20 10 20 0 Factory setting 10 15 15 30 3 24 20 240 15 25 0. Recommended interval: yearly or 8000 running hours.Instruction book 8.9. 2920 1485 00 84 . This option includes a galvanic protection of the PLC analog input card. vibrations…). 2920 1485 00 85 . remote pressure set point. NOISE INSULATING BODYWORK For compressors with this option a noise level of 70 dB(A) can be met. 2.) and allows access to operating parameter values (pressures. Temperature read-out on display is provided. HOT AIR VERSION The compressors can be delivered without aftercooler for hot air delivery. 1.4). This option includes the anti-condensation power supply and its control.) and allows access to operating parameter values (pressures. vibrations…). aftercooler and oil cooler in order to clean the coolers without dismantling the cooler bundles. 2. Temperature read-out on display is provided. AUTOMATIC WATER SHUT-OFF VALVE An automatic water shut-off valve (175-Fig.5) may be provided loose for reversing the water flow through the intercooler.7). Alarm and shut-down levels are handled by the control system. REMOTE PRESSURE SET POINT This option allows the operator to adjust the pressure set point remotely by means of a 4-20 mA signal to be delivered by the user. 1. This option allows the operator to command the compressor remotely (start/stop... TT96a and TT97aFig. COOLING WATER REVERSE FLOW VALVE A cooling water reverse flow valve (174-Fig. 1. This option includes the wiring of the sensors from the auxiliary terminal box of the main motor to the controller. MODBUS INTERFACE A Modbus interface can be provided in order to communicate with external control systems. MOTOR BEARING TEMPERATURE PROTECTION Temperature probes (PT100) can be embedded in the bearings of the drive motor (TT98 and TT99-Fig. This option allows the operator to command the compressor remotely (start/stop.. ELECTRONIC CONDENSATE DRAIN TRAPS Electronic drain traps may be provided instead of float valve condensate drain traps (109b and 114b-Fig.5). MOTOR ANTI-CONDENSATION HEATER An anti-condensation heater (R96-Fig. Alarm and shut-down levels are handled by the control system.. DUAL OIL FILTERS Dual oil filters can be delivered to replace the oil filter during operation without stopping the compressor.7) can be mounted inside the main motor housing in order to avoid condensation during motor standstill. temperatures.Instruction book 9 Options ANSI FLANGES The flanges on the air pipes and cooling water pipes can be provided with ANSI flanges instead of DIN flanges. This option includes the electronic drain power supply and the high level condensate detection in case of drain trap malfunction MOTOR WINDING TEMPERATURE PROTECTION Temperature probes (PT100) can be embedded in the windings of the drive motor (TT95a. the discharge compensator is made of stainless steel and is delivered loose. 2.5) may be provided loose to shut-off the system when the compressor is not in operation. This option includes the wiring of the sensors from the auxiliary terminal box of the main motor to the controller. temperatures. PROFIBUS DP INTERFACE A Profibus DP interface can be provided in order to communicate with external control systems. In this case. remote pressure set point. the option for the MODBUS interface shall be added. However.Instruction book DH+ COMMUNICATION PORT For DH+ communication. ES MILLENIUM CONNECTIVITY The PLC based control system is prepared for connection to a master controller ES3000. MAIN DRIVE MOTOR WITH SLEEVE BEARINGS This option includes the motor with sleeve bearings and the forced-feed lubrication from the compressor oil system. the DH+ port located on the CPU shall be used and the DH+ option activated in the PLC software settings. 2920 1485 00 86 . content 261. Parts of article 3.3 of 97/23/EC are subject to good engineering practice. Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of article I. section 3. Aftercooler : Cat III Design pressure 10 bar(e). .3.6. 1. Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC according to article I.Product : ZH 6000-10000 This is a pressure assembly of cat III according to 97/23/EC. content 299 l Design code : ASME section VIII div. The following pressure bearing parts are of category higher than I : Intercooler : Cat III Design pressure 10 bar(e).5 l Design code : ASME section VIII div. section 3. 1. Instruction book Notes: 2920 1485 00 88 . ............. )s h a l lb e durably marked............ I ti s s t r i c t l yf o r b i d d e nt od w e l lo rs t a yi nt h er i s kz o n eu n d e ral i f t e dl o a d ....t h a tc a nl e a dt oi n t e r n a lf i r eo re x p l o s i o n ...... Capacity ... As a further safeguard.e s p e c i a l l yw i t hr e g a r dt os a f e t y............................ P l a c et h eu n i tw h e r et h ea m b i e n ta i ri sa sc o o la n dc l e a na sp o s s i b l e .......t h eu n i ts h a l lb e a ra no b v i o u ss i g n r e a d i n g : DANGER: This machine is remotely controlled and may start without warning. Installation...... a sign stating "This machine may start without warning" s h a l lb ea t t a c h e dn e a rt h e instrument panel......... When operating this unit....... N e v e ro b s t r u c tt h ea i ri n l e t ............................. Atlas Copco compressor instruction book: ................ the following safety directions and p r e c a u t i o n sa r eo fs p e c i a li m p o r t a n c e .............................................................................. 7 ........ Pipework or other parts with a temperature in excess of 80 degrees celsius and which may be accidentally touched by personnel in normal operation shall be guarded or insulated. Processing of any other gas requires a d d i t i o n a ls a f e t yp r e c a u t i o n st y p i c a lt ot h ea p p l i c a t i o nw h i c ha r en o ti n c l u d e dh e r e i n . 2920 1377 03 1 / 2 .....t h es t r i c t e ro ft h et w os h a l la p p l y... These precautions are general and cover several machine types and equipment... C a r e s h a l lb et a k e nt om i n i m i z et h ee n t r yo fm o i s t u r ew i t ht h ei n l e ta i r...... Atlas Copco compressor parts list: ........ W ear a safety helmet when working in the area of overhead or lifting equipment. Atlas Copco air dryer instruction book: ........... I na d d i t i o nt on o r m a ls a f e t yr u l e sw h i c hs h o u l db eo b s e r v e dw i t hs t a t i o n a r y air compressors and equipment............ E v e r yp r e s s u r ev e s s e lo ra u x i l i a r yi n s t a l l e do u t s i d e t h eu n i tt oc o n t a i na i ra b o v ea t m o s p h e r i cp r e s s u r es h a l lb ep ro t e c t e d b yap r e s s u r e r e l i e v i n gd e v i c eo rd e v i c e sa sr e q u i r e d . SAFETY PRECA U T I O N S To b e read attentively and acted accordingly before i n s t a l l i n g ... electric motor: ........... F i r s ts t a r t u pd a t e : ...... the operator must employ safe working practices and observe all related local work safety requirements and ordinances......... 8 ...................................... 9 .............. L o o s eo rp i v o t i n gp a r t ss h a l lb es e c u r e l yf a s t e n e db e f o r el i f t i n g ...............t h ec o n n e c t e d p i p em u s tb ef r e eo fs t r a i n ................... Any blanking flanges...... 1 3 ........... Atlas Copco logbook: ......O WNERSHIP DA TA Compressor type: ............................ hence some statements may not apply to the unit(s) described i nt h i sb o o k . 4 ................ Delivery date: ....... On units with automatic start-stop system......................e t c ............. A t l a sC o p c oa i rd r y e rp a r t sl i s t : ......... competent personnel..... Dryer gearbox . Telephone: ......... competent personnel..............o p e r a t i n go r repairing the unit..........t e m p e r a t u r e s .... I fa n ys t a t e m e n ti nt h i sb o o k .. Address: ............................ E n s u r et h a tt h ed i s c h a rge pipe from the compressor to the aftercooler.. 5 ..... 1 0 ....... P a r t s : ................ L i f t i n ga c c e l e r a t i o na n dr e t a r d a t i o ns h a l lb ek e p tw i t h i ns a f el i m i t s ... The aspirated air shall be free from flammable fumes or vapours........... Never remove or tamper with the safety devices. 11 .......... 2 ..................... maintenance and repair shall only be performed by authorized... Contact persons: S e r v i c e : .............................. Motor serial No.... Printed Matter Nos....... guards or insulations f i t t e do nt h eu n i t ....... U n i ts e r i a lN o ..p a i n ts o l v e n t s .... Capacity: ............. 1 2 .. g ...........t h ef o l l o w i n gd i r e c t i v e sa r es p e c i a l l ys t r e s s e d : 1 ....................................... Service Plan: ......... Local Atlas Copco Representative Name: ...... caps and desiccant bags shall be removed before connecting up the pipes. Te l e x : ........................................................ N oe x t e r n a lf o r c em a yb ee x e r t e do nt h ea i ro u t l e tv a l v e ...as u i t a b l en o t i c e s h a l lb ea ff i x e dt ot h es t a r te q u i p m e n t .................... Unit serial No.......: ..................................... A i rd r y e rt y p e : ............... These recommendations apply to machinery processing or consuming air or inert gas................................d r y e r : .. Distribution pipes and connections shall be of correct size and suitable for the working p r e s s u r e ..... E-mail .......... Motor type: ....................... P a r t sa n da c c e s s o r i e ss h a l lb er e p l a c e di fu n s u i t a b l ef o rs a f e o p e r a t i o n . 3 ...... (continued on inside of cover) Installation Apart from general engineering practice in conformity with the local s a f e t yr e g u l a t i o n s .. In multiple compressor systems manual valves shall be installed to isolate each compressor...... Selected lubricants Compressor: .... Other high-temperature pipework shall be clearly marked.................... N o r m a lr a t i n g s( p r e s s u r e s .... A compressor or air dryer shall be lifted only with adequate equipment i nc o n f o r m i t yw i t hl o c a ls a f e t yr u l e s ....................... 6 ... a i rd r y e ro ra i rn e ti sf r e et oe x p a n du n d e rh e a ta n dt h a ti ti sn o ti n contact with or close to flammable material..... Bearing grease type....................t i m es e t t i n g s ...................... N o n r e t u r nv a l v e s( c h e c kv a l v e s )s h a l ln o t b er e l i e du p o nf o ri s o l a t i n gp r e s s u r es y s t e m s ....... I fn e c e s s a r y............. trained............ A i rc o o l e du n i t ss h a l lb ei n s t a l l e di ns u c haw a yt h a ta na d e q u a t e f l o wo fc o o l i n ga i ri sa v a i l a b l ea n dt h a tt h ee x h a u s t e da i rd o e sn o t r e c i r c u l a t et ot h ei n l e t .................... plugs... The owner is responsible for maintaining the unit in a safe operating c o n d i t i o n ........................................................... operation........................................ d o e sn o t c o m p l yw i t hl o c a ll e g i s l a t i o n .. e .. To t h i se n d ...... compressor: ................................................... persons switching on remotely controlled u n i t ss h a l lt a k ea d e q u a t ep r e c a u t i o n st oe n s u r et h a tt h e r ei sn oo n e checking or working on the machine.. Owner's machine No.... i n s t a l las u c t i o nd u c t .: ................................ I fr e m o t ec o n t r o li si n s t a l l e d ...................... Any modification on the compressor or air dryer shall only be performed in agreement with Atlas Copco and under supervision of authorized. A r r a n g et h ea i ri n t a k es ot h a tl o o s ec l o t h i n go fp e o p l ec ann o tb e s u c k e di n ......... c . 8 . Do not remove any of. 7 . In case of refrigerant contact with t h es k i n .e t c . to warm up a workroom. 1 0 . M a k es u r et h a tn ot o o l s .e n s u r et h a tt h eo p e ne n di sh e l ds e c u r e l y. The u n i t ss h a l lb eg r o u n d e da n dp r o t e c t e da g a i n s ts h o r tc i r c u i t sb yf u s e s . Protect hands to avoid injury from hot machine parts. will be disclaimed by Atlas Copco. A i ro u t l e tv a l v ea n da i rn e t . The following safety precautions are stressed when handling r e f r i g e r a n t : a . A free end will whip and may cause injury. Take positive p r e c a u t i o nt oe n s u r et h a tt h eu n i tc a n n o tb es t a r t e di n a d v e r t e n t l y.d on o ts t a rt "s h a l lb ea t t a c h e dt ot h es t a r t i n ge q u i p m e n t .T h ee l e c t r i c a lc o n n e c t i o n ss h a l lc o r r e s p o n dt ot h el o c a lc o d e s .i f excessive. the main power supply is switched off and the machine has cooled down.t e m p e r a t u r e sa n dt i m es e t t i n g sa r ec o r r e c t and that the control and shut-down devices function correctly. All maintenance work. do so with extreme caution and use eye protection.l o o s ep a r t so rr a g sa r el e f ti no ro nt h eu n i t . e v e ni f not expressly mentioned in this book. Never weld on.e . Every time the separator element is renewed. or tamper with. 2 9 2 01 3 7 70 3 2 / 2 .h o s e s . g . Never use frayed.p i p e s . g . Oil tanks must be completely purg e d . eff e c t i v e l yi s o l a t et h e u n i tf r o ma l ls o u r c e so fp r e s s u r ea n dr e l i e v et h ee n t i r es y s t e mo f p r e s s u r e . f S a f e t yv a l v e sa n do t h e rp r e s s u r e r e l i e fd e v i c e sa r en o to b s t r u c t e d b yd i r to rp a i n t g . or by non-observance of ordinary caution and due c a rerequired in handling. 2 . Make sure that all sound-damping material. e. Keep dirt away by covering the parts and exposed openings with a c l e a nc l o t h . i si ng o o d c o n d i t i o n .n e v e rt e a ro ff o rr e m o v et h el a t t e r . Never weld or perform any operation involving heat near the oil system. 1 . damaged or deteriorated hoses. f r e eo fw e a ro ra b u s e 8 . When using it to clean equipment. the sound-damping material. 9 .e t c .b ys t e a m c l e a n i n g . M a k es u r et h a tah o s ei s f u l l yd e p r e s s u r i z e db e f o r ed i s c o n n e c t i n gi t . Never operate the units when there is a possibility of taking in flammable or toxic fumes. before carrying out such operations.s p a r k a r r e s t o r s . When blowing t h r o u g hah o s eo ra i rl i n e .e . the machine shall be stopped but no inspection covers shall be opened b e f o r es u ff i c i e n tc o o l i n gt i m e h a se l a p s e d . on the bodywork a n di nt h ea i ri n l e ta n do u t l e ts y s t e m so ft h ec o m p r e s s o r. A l le l e c t r i c a ll e a d sa r es e c u r ea n di ng o o do r d e r . 2 . Use only the correct tools for maintenance and repair work. 1 3 . Keep all bodywork doors shut during operation. I fd a m a g e d . A l l re s p o n s i b i l i t yf o r any damage or i n j u ryre s u l t i n gf rom neglecting these precautions. Always wear special gloves. Never use caustic solvents which can damage materials of the air net. Check that the working area i sa d e q u a t e l yv e n t i l a t e d . maintenance or repair. We a re a r protectors when opening a door. flush abundantly with fresh water over the clothing until all r e f r i g e r a n ti sf l u s h e da w a y .c o u p l i n g s . the compressed air must b ea d e q u a t e l yp u r i f i e da c c o r d i n gt ol o c a ll e g i s l a t i o na n ds t a n d a r d s . p r e s s u r ev e s s e l s . People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear protectors. F o rb r e a t h i n ga i rq u a l i t y. electrical and regulating components.a l l o w a n c eh a st ob em a d ef o re x t r as a f e t yp r e c a u t i o n s . I f removed. e . 7 .SAFETY PRECA UTIONS 1 4 . 4 . 6 . All guards are in place and securely fastened b . 1 2 .i fr e q u i r e d . 4 . P e r i o d i c a l l yc h e c kt h a t : a . Take safety precautions against toxic vapours of cleaning l i q u i d s . 9 . b .a r ei ng o o dr e p a i r. 5 . 11 . There are no leaks d .i . or in any way modify. I fl i q u i dr e f r i g e r a n tc o n t a c t s t h es k i nt h r o u g hc l o t h i n g . Before removing any pressurized component.g. v a l v e s . If warm cooling air from compressors is used in air heating systems. Use only genuine spare parts.t h i st oa v o i dt h er i s ko fs p o n t a n e o u si g n i t i o no ft h eo i l vapour when air is admitted.g.m a n i f o l d s . Use only the correct t y p ea n ds i z eo fh o s ee n df i t t i n g sa n dc o n n e c t i o n s . 3 . other than routine attention. Never play with compressed air.I ft h eg r o u n di sn o tl e v e lo rc a nb es u b j e c tt ov a r i a b l ei n c l i n a t i o n . Whenever there is an indication or any suspicion that an internal part of a machine is overheated. g .r i n s et h es k i nw i t hw a t e r. Scrupulously observe cleanliness during maintenance and repair. A l lf a s t e n e r sa r et i g h t e .t op r e v e n tm o i s t u r ef r o me n t e r i n gt h e m . A i rh o s e ss h a l lb eo fc o r r e c ts i z ea n ds u i t a b l ef o rt h ew o r k i n gp r e s s u r e . Never use flammable solvents or carbon tetrachloride for cleaning p a r t s . 1 5 .e t c . e. The doors may be opened for short periods only. operating. N e v e ru s ei tt oc l e a nd i r tf r o my o u r c l o t h e s .g. C o n s u l t Atlas Copco. check t h a to p e r a t i n gp r e s s u r e s . polycarbonate bowls. 1 5 . Note: W i t hs t a t i o n a r ym a c h i n eu n i t sd r i v e nb ya ni n t e r n a lc o m b u s t i o n e n g i n e . N e v e ro p e r a t et h eu n i t sa tp r e s s u r e sb e l o wo ri ne x c e s so ft h e i rl i m i t r a t i n g sa si n d i c a t e do nt h eP r i n c i p a lD a t as h e e t . In addition.e . e . 1 4 . a i rf i l t e r. Protect the motor. g .r e p l a c ei tb yg e n u i n e Atlas Copco material to prevent the sound pressure level from increasing.s e c u r e and not rubbing c . e. during d r a i n i n go fo i l .g.t oc a r r yo u tc h e c k s .t h e ns e e km e d i c a lf i r s ta i d . check that the coupling guard of the compressor drive shaft h a sb e e nr e i n s t a l l e d . a warning sign bearing a legend such as "work in progre s s . A l lh o s e sa n d / o rp i p e si n s i d et h eu n i ta r ei ng o o dc o n d i t i o n .u s eb r e a t h i n gp r o t e c t i o n . D on o ta p p l yi tt oy o u rs k i no r d i r e c ta na i rs t r e a ma tp e o p l e . Never inhale refrigerant vapours. Before clearing the unit for use after maintenance or overhaul. Maintenance Maintenance and repair work shall only be carried out under supervision o fs o m e o n eq u a l i f i e df o rt h ej o b . The compressor is not considered as capable of producing air of b r e a t h i n gq u a l i t y. e t c . examine the discharg e p i p ea n dt h ei n s i d eo ft h eo i ls e p a r a t o rv e s s e lf o rc a r b o nd e p o s i t s . shall only be undertaken when the unit is stopped.p r e s s u r ev e s s e l .w h e ns t e a m c l e a n i n g . take precautions against air pollution and possible contamination of the breathing air. e. Always wear safety glasses. 3 . (continued) 5 . c o n s u l t Atlas Copco.p a p e ro rt a p e . Operation 1 . 6 . Never use a light source with open flame for inspecting the interior o fam a c h i n e . the deposits should be removed.f u e l l i n gc a r e .