Atlas Copco Stationary Air Compressors

ZR315-8,6-60VSD

Instruction Book
Serial Number: S990476 01 v00
Customer: POLAR BREWERIES, VENEZUELA

Copyright 2005, 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.

www.atlascopco.com

2005-11
Instruction Book

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. Record all operating data, maintenance work
effected, etc. in an operator's logbook available from Atlas Copco. 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.

OWNERSHIP DATA

Compressor type: ............................................................ Unit serial No. compressor:........................

Air dryer type: .................................................................. Unit serial No. dryer: ..................................

Motor type:....................................................................... Motor serial No.:.........................................
Delivery date:................................................................... First start-up date: ......................................
Service Plan:.................................................................... Owner's machine No.: ................................

Selected lubricants
Compressor: .................................................................... Capacity: ....................................................
Bearing grease type, electric motor:................................
Dryer gearbox .................................................................. Capacity: ....................................................

Printed Matter Nos.

Atlas Copco compressor instruction book: ...................... Atlas Copco air dryer
Atlas Copco compressor parts list: .................................. instruction book: .........................................
Atlas Copco logbook:....................................................... Atlas Copco air dryer parts list: ..................

Local Atlas Copco Representative

Name: ..............................................................................
Address:...........................................................................
Telephone:................................... Contact persons: Service:.......................................................
Telex: ........................................... Parts: ..........................................................
E-mail address.............................

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Important notes:

A) Operation instructions and Spare parts lists of Non-Atlas Copco components

Although any document that was delivered with the part is shipped with the machine, paper documents are
often lost or put aside.

Documentation of parts used in this machine fabricated by other manufacturers than Atlas Copco can best
be found on their internet website. (i.e. flow control products, motors, regulators …)
Most of them have a documentation sub-website where all information can be found.

If you have difficulties to find the information contact your Customer Centre.

B) Paint

If the unit is delivered with:

- customer specified top colour for canopy and/or frame
- other powder coating thicknesses
- semi-offshore coating or offshore painting

Spare parts of these items will be delivered in standard Atlas Copco grey for the canopy and standard black
for the frame. (Spare part numbers of standard parts are printed in the Spare parts list.)

C) Hydrostatic witnessed parts

If the unit is delivered with hydrostatic witnessed parts, spare part numbers of not witnessed standard parts
are printed in the Spare parts list.
To overcome long delays by ordering spare parts, partnumbers of hydrostatic witnessed parts will not be
supported.

D) Service Kits

In the Spare parts list only standard Service kits are printed. Service kits of special parts will not be
supported.

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CONTENTS

CONTENTS ....................................................................................................................................................... 4
SAFETY PRECAUTIONS ................................................................................................................................. 6
1 LEADING PARTICULARS..................................................................................................................... 9
1.1 General description .......................................................................................................................... 9
1.2 Air system ........................................................................................................................................ 10
1.3 Condensate drain system .............................................................................................................. 12
1.4 Electronic water drains (EWD)....................................................................................................... 13
1.5 Cooling system ............................................................................................................................... 15
1.6 Oil system ........................................................................................................................................ 16
1.7 Electrical system............................................................................................................................. 17
2 PLC-Regulator ........................................................................................................................................ 18
2.1 Controlling the compressor speed – reducing power consumption......................................... 18
2.2 Protecting the compressor ............................................................................................................ 20
2.3 Service warning............................................................................................................................... 20
2.4 Control panel ................................................................................................................................... 20
2.5 Emergency stop button .................................................................................................................. 22
2.6 Status data / window....................................................................................................................... 22
2.7 Compressor condition data / (status) area................................................................................... 23
2.8 Measured data ................................................................................................................................. 25
2.9 Changing language......................................................................................................................... 26
2.10 Pressure setpoint ........................................................................................................................ 26
2.11 Modifying parameters, use of touch screen keyboard............................................................ 27
2.12 Modifying protection settings .................................................................................................... 27
2.13 Service screen / settings ............................................................................................................ 27
2.14 Screen blanked, power failure.................................................................................................... 28
2.15 Service plans ............................................................................................................................... 28
2.16 Programmable settings............................................................................................................... 29
2.16.1 Regulation settings & parameters.............................................................................................. 29
2.16.2 Protection settings ..................................................................................................................... 29
3 Installation............................................................................................................................................... 31
3.1 Dimension drawing ......................................................................................................................... 31
3.2 Flow diagram ................................................................................................................................... 32
3.4 Installation proposal ....................................................................................................................... 33
3.5 Electric connections ....................................................................................................................... 35
3.6 Electrical diagram ........................................................................................................................... 38
3.7 Electric cables ................................................................................................................................. 41
3.8 Cooling water requirements........................................................................................................... 41
3.9 Pictographs...................................................................................................................................... 44

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4 Operating instructions........................................................................................................................... 45
4.1 Operation introduction ................................................................................................................... 45
4.2 Initial start-up................................................................................................................................... 45
4.3 Before starting................................................................................................................................. 49
4.4 Starting............................................................................................................................................. 50
4.5 During operation ............................................................................................................................. 52
4.6 Stopping........................................................................................................................................... 52
4.7 Taking out of operation .................................................................................................................. 53
5 Maintenance............................................................................................................................................ 54
5.1 Maintenance warnings.................................................................................................................... 54
5.2 Preventive maintenance schedule ................................................................................................ 54
5.3 Motor greasing ................................................................................................................................ 55
5.4 Storage after installation ................................................................................................................ 55
5.5 Service kits ...................................................................................................................................... 55
5.6 Oil specifications ............................................................................................................................ 56
6 Adjustments and servicing procedures............................................................................................... 57
6.1 Air filters........................................................................................................................................... 57
6.2 Oil and oil filter change .................................................................................................................. 58
6.3 Safety valves ................................................................................................................................... 59
7 Problem solving...................................................................................................................................... 60
7.1 Faults and remedies ....................................................................................................................... 60
8 Technical data......................................................................................................................................... 61
8.1 Readings on display ....................................................................................................................... 61
8.2 Settings of safety valves ................................................................................................................ 61
8.3 Circuit breakers and fuses ............................................................................................................. 61
8.4 Reference conditions...................................................................................................................... 61
8.5 Limitations ....................................................................................................................................... 61
8.6 Compressor data............................................................................................................................. 62
8.7 Compressor specifications ............................................................................................................ 62
8.7.1 General information ................................................................................................................... 62
8.7.2 Performance data ...................................................................................................................... 62
8.8 Special mechanical items............................................................................................................... 64
8.9 Cubicle with PLC controlled regulator, Frequency Converter and IL77 operating panel....... 66
8.9.1 General ...................................................................................................................................... 66
8.9.2 Front panel apparatus................................................................................................................ 66
8.9.3 Start interlock / shutdown circuits / regulation / auxiliary circuits............................................... 67
8.9.4 I/O circuits .................................................................................................................................. 67
8.9.5.Interfaces to Customer .................................................................................................................... 68
9 Pressure equipment directives ............................................................................................................. 69

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SAFETY PRECAUTIONS
To be read attentively and acted accordingly before installing, operating or repairing the unit.

All responsibility for damage or injury resulting from neglecting these precautions, or non-observance of
the normal caution and care required for installation, operation, maintenance and repair, even if not
expressly stated, will be disclaimed by Atlas Copco.

General precautions

1. The operator must employ safe working practices and observe all related local work safety requirements
and regulations.
2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,
specialised personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality,
the compressed air must be adequately purified according to local legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurise the compressor. In addition, the
power isolating switch must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with local safety regulations.
Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the
risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a
safety helmet when working in the area of overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating:

DANGER: This machine is remotely controlled and may start without warning.

10. The machines must be installed in such a way that an adequate flow of cooling air is available and that the
exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
11. The electrical connections must correspond to the local codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the compressor.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return
valves (check valves) must not be relied upon for isolating pressure systems.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be
protected by a pressure-relieving device or devices as required.

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15. Pipework or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high-temperature pipework
must be clearly marked.
16. If the ground is not level or can be subject to variable inclination, consult the Atlas Copco Customer Centre.

Precautions during operation

1. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
2. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is
no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or
particles.
4. Never operate the machine below or in excess of its limit ratings.
5. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to
carry out routine checks. Wear ear protectors when opening a door.
6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
7. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair,
free of wear or abuse
8. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
9. Do not remove any of, or tamper with, the sound-damping material.
10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall
be protected by a pressure-relieving device or devices as required.

Precautions during maintenance or repair

1. Always wear safety glasses.

2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is
no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
7. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
8. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
9. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and
exposed openings with a clean cloth, paper or tape.
10. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify,
pressure vessels.
11. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.

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12. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
13. Make sure that no tools, loose parts or rags are left in or on the machine.
14. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been
reinstalled.
15. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
16. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam-cleaning.
17. Make sure that all sound-damping material, e.g. on the bodywork and in the air inlet and outlet systems of
the compressor, is in good condition. If damaged, replace it by genuine Atlas Copco material to prevent the
sound pressure level from increasing.
18. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
19. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required,
use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical
first aid.
20. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

Note:
Some precautions are general and may not apply to your machine.

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1 LEADING PARTICULARS
1.1 General description

PLC

Figure 1 General view (typical example) of ZR315 VSD

Ref. Name
AO Compressed air outlet
PLC PLC regulator cabinet
SVh Safety valve, high pressure
SVl Safety valve, low pressure
WI Cooling water inlet
WO Cooling water outlet

The ZR315 VSD-unit is a water-cooled, two-stage, electric motor driven screw compressor which deliver oil-free,
pulsation-free air. The VSD (Variable Speed Drive) optimise energy consumption and reduce the operating
pressure band by regulating the motor speed.

The compressor is enclosed in a sound-insulated bodywork and includes mainly:

• Air filter
• Low-pressure compressor element
• Intercooler
• High-pressure compressor element
• Aftercooler
• Water separators
• Electric motor
• Drive coupling
• Gear casing
• PLC-regulator
• Safety valves

PLC-regulator
In general, the PLC-regulator has following functions:
- Controlling the motor speed (Variable Speed Drive), reducing the power consumption and pressure band.
- Protecting the compressor
- Monitoring components - service warning

See further section 2.

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1.2 Air system

Flow diagram

Flow diagram

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Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca Aftercooler
Ci Intercooler
Co Oil cooler
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
MTa Moisture trap, aftercooler
MTi Moisture trap, intercooler
OF Oil filter
OP Oil pump

Description

• Air drawn through filter (AF) is compressed in low-pressure compressor element (El).
• The compressed air is discharged to intercooler (Ci).
• The cooled air is further compressed in high-pressure compressor element (Eh) and discharged through
silencer (AS) and aftercooler (Ca). A check valve (CV) is fitted downstream of the silencer.
• The compressed air leaves the compressor via the air outlet (AO).

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1.3 Condensate drain system

Description

Figure 2 Front view

Two condensate traps are installed: one downstream of the intercooler to prevent condensate from
entering the compressor element and one downstream of the aftercooler to prevent condensate from
entering the air outlet pipe. The condensate traps are connected to condensate drain receivers (DRi and
DRa respectively).
The condensate traps have an automatic condensate outlet, see section 1.4

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1.4 Electronic water drains (EWD)

EWD 330

Drain frequency of EWD 330

1 Inlet
2 Supply line
3 Pilot valve
4 Diaphragm
5 Sensor
6 Collector
7 Valve seat
8 Outlet

The condensate enters the Electronic Water Drain (EWD) via inlet (1) and accumulates in collector (6). A capacitive
sensor (5) continuously measures the liquid level.

On the EWD 330, pilot valve (3) is activated as soon as the collector is filled up to a certain level. Diaphragm (4)
opens outlet (8), discharging the condensate.

When the collector has been emptied, the outlet closes quickly without wasting compressed air.

When the controller registers a malfunction, the red alarm LED on the control panel of the EWD starts flashing, a
warning appears on the display of the regulator and the electronic drain valve will automatically change to the
alarm mode, opening and closing the valve according to a sequence as shown above. This condition continues
until the fault is remedied. If the fault is not remedied automatically, maintenance is required.

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Functional test on the EWD

Control panel of EWD

Briefly press the TEST button and check that the valve opens for condensate discharge
Checking the alarm signal
• Press and hold the test button for at least 1 minute.
• Check that the alarm LED flashes.
• Check that a warning is generated on the display of the regulator.
• Release the test button.

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1.5 Cooling system

Flow diagram

Cooling system
The cooling water flows through oil cooler (Co), the cooling jackets of high-pressure compressor element (Eh) and
low-pressure compressor element (El) as well as through intercooler (Ci) and aftercooler (Ca).

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1.6 Oil system

Flow diagram

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Reference Name
AF Air filter
AO Air outlet
AS Silencer
BV By-pass valve
Ca Aftercooler
Ci Intercooler
Co Oil cooler
CV Check valve
Eh High-pressure compressor element
El Low-pressure compressor element
MTa Moisture trap, aftercooler
MTi Moisture trap, intercooler
OF Oil filter
OP Oil pump

Description
Oil is circulated by pump (OP) from the sump of the gear casing through cooler (Co). The oil passes through oil
filters (OF) towards the bearings and timing gears. Valve (BV) opens if the oil pressure should rise above a given
value.

1.7 Electrical system

1 Electric cabinet
2 Frequency converter cabinet
3 PLC
Kxx Interface relais
1Xx Terminal strip
K2 Contactor
Q1 Circuit breaker
Fx Circuit breaker
S10 Service switch main drive

Figure 3 Electric cabinet

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2 PLC-Regulator
In general, the PLC-regulator has following functions:
- Controlling the motor speed (Variable Speed Drive), reducing the power consumption and pressure band.
- Protecting the compressor
- Monitoring components - service warning

Figure 4 Mainscreen

2.1 Controlling the compressor speed – reducing power consumption

The regulator matches the air delivery to the air consumption keeping the net pressure fluctuations very low.
The regulator will continuously vary the motor speed, maintaining the net pressure as close as possible to the
programmed pressure setpoint. As the air consumption decreases, the motor speed decreases as well as the
power consumption.

Unloading

If the motor is running at minimum speed and the net pressure rises to a value equal to the sum of the programmed
pressure setpoint and the programmed unload offset, the load/no-load valve will close in order to unload the
compressor.

If the compressor continues to run unloaded without interruption for 150 seconds, the regulator will stop the motor.
The regulator will restart the compressor when the net pressure drops below the pressure setpoint.

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When the net pressure drops below the pressure setpoint within this period of 150 seconds, the load/no-load valve
will fully open and the motor speed will increase to match the air delivery to the air consumption.

Ref. Designation
(1) Pressure
(2) Direct stop offset
(3) Set-point
(4) Motor speed
(5) Minimum
(6) Time
(7) Load
(8) Unload
(9) Stop
(10) Unload offset

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Direct stopping
In case the net pressure should rise to a value equal to the sum of the programmed pressure setpoint and the
programmed direct stop offset, the compressor will be unloaded and stopped.

The regulator will restart the compressor when the net pressure drops below the pressure setpoint.

2.2 Protecting the compressor

Shutdown and motor overload
Several temperature and pressure sensors are provided on the compressor. If one of these measurements
(temperature at LP element outlet, at HP element inlet, at HP element outlet, intercooler pressure, oil temperature
as well as oil pressure) exceeds the programmed shutdown level, the compressor will be stopped. This will be
indicated in the status area at the bottom of the mainscreen.
The compressor will also be stopped in case of overload of the drive motor.
Consult the section “Maintenance” and remedy the trouble.
Shutdown warning
If the regulator detects a temperature or pressure programmed warning shutdown level, this will be indicated in the
status area at the bottom the mainscreen to warn the operator before the shutdown level is reached.

2.3 Service warning

A number of service operations are grouped (called Level A, B, C, ...). See section “Maintenance”.

2.4 Control panel

Figure 5 Control panel 1

A control panel is provided allowing the operator to communicate with the PLC. The mainscreen is equipped with a
touch screen.

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Parts and functions

Reference Designation Function

Button to select “stand-alone” operation of the compressor, locally

1 Local
controlled.

2 Remote Button to select remote operation.

Button to start the compressor. The status window on top of the control
3 Start display will indicating that the regulator is operative (Automatic
operation/Compressor loaded).

Button to stop the compressor. Regardless if the selection is in “Local”

4 Stop
or “Remote”. Pressing this button will not stop the compressor
immediately, if the compressor is running in “loaded” mode, it will be put
in “unloaded” mode and the compressor stops after a set time. When a
shutdown circuit is active, the compressor will stop immediately. The
status window on top of the control display will indicating that the
regulator is not-operative (Automatic operation/Compressor stopped).

Button to put the compressor in “loaded” mode when the working

pressure is lower then unloading pressure. The status window on top of
5 Normal
the control display will indicate : Automatic Operation/loaded, Load in …
sec or Will load when pressure drops loading pressure Standby).

Button to manually unload the compressor. The status window on top of

6 Unload
the control display will indicate : Automatic Operation/Manual unloaded).

7 Reset To reset an active motor overload, shutdown or service message or

an emergency stop
Button, to activate that “setpoint 1” must be used. (see also section
8 Main
“Pressure setpoint”)

Button, to activate that “setpoint 2” must be used. (see also section

9 Standby
“Pressure setpoint”)

Button to force purging of electronic water drains. The status window on

11 Forced Drain
top of the control display will indicate : Forced drain … sec.

Display on top of the Control panel. Indicates messages concerning the

Status Window
compressor operations.

Display at the bottom of the Control panel. Indicates messages

Status Area concerning the compressor operating condition, a service need or a
fault.

Button to stop the compressor immediately in case of emergency.

S2 Emergency stop button
After remedying the trouble, unlock the button.

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2.5 Emergency stop button

In case of emergency, press button (S2) to stop the
compressor immediately.
Warning:
Before starting any maintenance or repairs, wait

until the compressor has stopped and open the

isolating switch (customer's installation) to switch

off the voltage to the compressor.

Close the air outlet valve and open the manual

condensate drain valve to depressurize the air
system.

Apply all relevant Safety precautions.

Figure 6 Emergency stop

2.6 Status data / window

Warning: Before starting any maintenance or repairs, press the stop button, wait until the compressor has
stopped, press the red emergency stop button and open the isolating switch (customer's
installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.

Figure 7 Status window

Function

The Status window gives information regarding the operation status of the compressor.

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Possible messages:

“Ready to start” This message is shown when:

“Automatic Operation /Compressor Loaded”
“Load in … sec”
“Automatic Operation / Stopped”
“Compressor will start in … sec”
“Programmed stop in … sec”
“Running Unloaded / Will stop in … sec”
“Ready to start in … sec”
“Programmed stopped / Ready to start”
• No “warning-or shutdown” circuit is activated.
• The “reset” button is pressed.
• The “emergency stop” push button is unlatched
• The compressor is stopped for a longer period than
the start delay time.
As soon the compressor is started, the “automatic operation”
message is displayed.
When the maximum working pressure is reached, the
compressor is put in “unloaded” mode. The compressor
remain running for 150 seconds. When the compressor is
stopped after running out of this idling time, this message is
displayed.
To assure building up of oil pressure, the compressor can’t be
directly loaded, therefore a timer is built in. 15 seconds after
pressing the “Start” button the compressor can be loaded.
By pressing the “Stop” (=programmed stop) button, the
compressor will be put in “unloaded” mode and after 3
seconds the compressor will stop.
After stopping the compressor, restart is not possible within
20 seconds (=minimum stop time). After this time the
compressor will be “ready to start”.

Other messages are:

• Automatic Operation / Manual unloaded
• Emergency stopped / Ready to start
• Will load when pressure drops loading pressure Main
• Unlatch Emergency stop push button
• Start not possible / Remote selected
• Will load when pressure drops loading pressure Standby
• Force drain … sec

See also section 8.9.

2.7 Compressor condition data / (status) area

Warning: Before starting any maintenance or repairs, press the stop button, wait until the compressor has
stopped, press the red emergency stop button and open the isolating switch (customer's
installation) to switch off the voltage to the compressor.
Close the air outlet valve and depressurize the air system.

Figure 8 Status area

Function

The Status area window gives information regarding the status of the compressor protection functions
(shutdown, shutdown warning and service warning).

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A shutdown message exists

• In case of a shutdown due to too high temperature at the outlet of the Low pressure compressor
element:

Ack Time in Time Last Node Value Alarm Extension Field 1 Alarm Extension Field 2

18:06:31,218 18:06:31,218 FIX TSHH11 TSHH11

The shutdown setting can be found by clicking on the sensor indication on the Mainscreen.

Figure 9 Warning & Shutdown settings TT11

Shutdown reset
• Switch off the voltage and remedy the trouble. After remedying and when the shutdown condition has
disappeared, switch on the voltage and press the “Reset” button.
• The message will blink on the screen. To stop the blinking, press on the area under “Ack” of
acknowledgment.
• To delete the message in the status area press again on the area under “Ack”.
• Press the start button to restart the compressor.

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A shutdown-warning message exists

A shutdown warning level is a programmable level below the shutdown level.
• If a shutdown warning exists, the status area screen will change into a screen similar to the one below:

Ack Time in Time Last Node Value Alarm Extension Field 1 Alarm Extension Field 2

18:06:31,218 18:06:31,218 FIX TSH11 TSH11

• The message will blink on the screen. To stop the blinking press on the area under ‘Ack’ of
acknowledgment.
• If necessary, stop the compressor by means of stop button and wait until it has stopped.
• Switch off the voltage, inspect and remedy.
• The warning message will “not” disappear automatically as soon as the warning condition disappears.
• Pressing ‘Reset’ is necessary, to report the PLC of the remedy.
• To delete the message in the status area, press again on the area under ‘Ack’.

2.8 Measured data

Main screen

Figure 10 Mainscreen
The information regarding the actually measured data is displayed on the mainscreen at the sensor
indication.

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2.9 Changing language

Mainscreen top

Figure 11 Mainscreen top

By touching the ‘English’ or ‘Venezuelan flag’ button at the top left corner of the mainscreen, the display
language can be changed from English into Spanish.

2.10 Pressure setpoint

Control panel 2

Figure 12 Control panel 2

To check the pressure setpoint, touch the ‘Pressure Setpoint’ button in the 2nd control panel at the right
corner on the bottom of the mainscreen.

A new window will be displayed:

Figure 13 Setpoint screen

There are two setpoints programmed. The operator can if desired select the 1st or second programmed
setpoint, by pressing the “Main” and ‘Standby’ button in the 1st control panel.
The 1st setpoint is programmed as ‘Pressure setting main’, the second as ‘Pressure setting standby’.

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2.11 Modifying parameters, use of touch screen keyboard

Mainscreen top

Figure 14 Mainscreen top

By touching the keyboard button at the right top corner of the mainscreen, a keyboard window will be
displayed, so it’s possible to adapt i.e. the setpoint settings.

2.12 Modifying protection settings

Modifying of shutdown, shutdown warning, delay’s parameters, is not customer accessible. Consult Atlas
Copco in case any of these parameters should be changed.

The Atlas Copco service engineer will use the login button on the control panel 2 (See Figure 16)

2.13 Service screen / settings

Figure 15 Service screen

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Shutdown, shutdown warning, delay’s levels and parameters are grouped together in a Service screen
window that can be viewed by pressing the service button of the 2nde control panel.

Figure 16 Control panel 2

2.14 Screen blanked, power failure

When a power-failure of the screen occurs, the PLC is still controlling the compressor. The control panel is
due to inaccessibility of the touch screen unavailable. The only way to stop the compressor is by pressing
the emergency stop button. (see Figure 6)

2.15 Service plans

Service actions to be carried out are grouped in plans called Service level A, B, C or D. When reaching an
interval, “NO” message will appear on the screen indicating which Service plans are to be carried out.

Service plans Intervals

Service plan I Every 2000 running hours
Service plan A Every 4000 running hours
Service plan B Every 8000 running hours
Service plan C Every 16000 running hours
Service plan D Every 40000 running hours
Service plan E Every 60000 running hours

Service actions according to Intervals

Service plan I 2000 running hours
Service plan A and I 4000 running hours
Service plan I 6000 running hours
Service plan A and B and I 8000 running hours
Service plan I 10000 running hours
Service plan A and I 12000 running hours
... ...

Consult your Atlas Copco Customer Centre for service actions. (see also section Maintenance)

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2.16 Programmable settings

2.16.1 Regulation settings & parameters
Regulation settings & parameters

Minimum Factory Maximum

setting setting Setting
Pressure Setting Main bar 3.5 7.00 8.6
Pressure Setting Standby bar 3.5 7.00 8.6
Indirect Stop (offset) Level bar 0.1 0.3 1.5
Direct Stop (offset) Level bar 0.3 1.0 1.5
Loading Delay sec 15 15 20
Minimum Stop Time sec 10 20 255
Programmed Stop Time sec 0 3 20
Idling Stop Time sec 150
Forced Drain Duration (Manual Drain Test) sec 0 10 60

Special Note : Settings deviating from std-settings are printed in "Italic"

2.16.2 Protection settings

Minimum Factory Maximum

setting setting Setting
Delivery Air Pressure Warning bar 0 8.8 8.8
Delivery Air Pressure Shutdown bar 8.8 8.9 8.9
Dp Air Filter Service Warning bar -0.050 -0.044 -0.044
Delay At Signal, Dp Air Filter sec 0 60 255
Dp Air Filter Shutdown Minimum bar -0.065 -0.065 -0.044
Oil Pressure Warning bar 1.0 1.3 1.9
Oil Pressure Shutdown bar 1.0 1.2 1.9
Delay At Start, Oil Pressure sec 15 15 20
Delay At Signal, Oil Pressure sec 10 10 12
Intercooler (Pressure), Warning bar -0.70 -0.65 -0.65
Intercooler (Pressure), Shutdown bar -0.70 -0.70 -0.65
Delay At Signal, Intercooler (Pressure) sec 0 1 3
LP Outlet Temp. Warning °C 100 210 220
LP Outlet Temp. Shutdown °C 100 220 220
Delay At Signal, LP Outlet Temp. sec 0 1 3
HP Inlet Temp. Warning °C 40 65 80
HP Inlet Temp. Shutdown °C 40 70 80
Delay At Signal, HP Inlet Temp. sec 0 1 3
HP Outlet Temp. Warning °C 100 210 220
HP Outlet Temp. Shutdown °C 100 220 220
Delay At Signal, HP Outlet Temp. sec 0 1 3
Oil Temperature Warning °C 40 65 69

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Oil Temperature Shutdown (1) °C 66 70 80

Motor Winding 1U1,1V1 & 1W1 Warning °C 0 145 155
Motor Winding 1U1,1V1 & 1W1 Shutdown °C 146 155 155
Delay At Signal, IC. Electr.Cond.Drain Warning sec 5 5 5
Delay At Signal, IC. Electr.Cond.Drain Shutdown sec 0 180 900
Delay At Signal, AC. Electr.Cond.Drain Warning sec 5 5 5
Delay At Signal, AC. Electr.Cond.Drain Shutdown sec 0 180 900
Delay At Start, Electr.Cond.Drain sec 0 15 60

Special Note : Settings deviating from std-settings are printed in '"Italic"

See for more technical data, section 8.9

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3 Installation
3.1 Dimension drawing

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3.2 Flow diagram

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3.3 Installation warnings

• Working with machinery controlled by a frequency converter requires special
safety precautions, which depend on the type of network (TN, TT or IT). Consult
Atlas Copco.
• ZR315 VSD compressor comply with group 1 class A limits for radiated
emission according to EN 55011 (1991). Beware of possible electromagnetic
interference in case stricter limitations are valid.
• Consult the “Safety precautions during installation” before starting the
installation.

3.4 Installation proposal

Compressor room example

Installation proposal

Description

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The compressor must only be moved or lifted as described in the section

“Operation introduction”.

1. Install the compressor on a level floor suitable for taking its weight. The recommended minimum
distance between the top of the body and the ceiling is 1200 mm (47 in).
2. Remove the plastic plug (if provided) from the compressor air outlet pipe and install an air outlet
valve. Close the valve and connect it to the air net.
3. The pressure drop over the air outlet pipe can be calculated as follows:

dp = (L x 450 x Qc1.85) / (d5 x p)

Symbol Explanation
d Inner diameter of the outlet pipe in mm
dp Pressure drop (recommended maximum = 0.1 bar)
L Length of outlet pipe in m
p Absolute pressure at the compressor outlet in bar(a)
Qc Free air delivery of the compressor in l/s

It is strongly recommended to make the connection of the compressor air outlet pipe on top of the
main air net pipe in order to minimise carry-over of possible condensate residue.

As a rule of thumb, the following formula can be used to calculate the recommended volume of the
air net:

V = (30 x C x p x Q) / dp

Symbol Explanation
C Correction factor
Pressure difference between unloading and loading pressures in bar
dp (recommended minimum = 0.6)
p Compressor inlet pressure in bar absolute
Q Free air delivery of compressor in l/s
V Recommended air net volume in l

Air consumption divided by

compressor free air delivery Correction factor C
0.9 0.10
0.8 0.15
0.7 0.20
0.5 0.25
0.3 0.20
0.2 0.15
0.1 0.10

4. The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling
air to the compressor is avoided. The maximum air velocity through the grids is 5 m/s (16.5 ft/s).

The required ventilation capacity (per compressor installed) to limit the compressor room
temperature can be calculated as follows:

Qv = 0.1 N/dT

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Symbol Explanation
dT Temperature increase in compressor room in ˚C
N Shaft input of compressor in kW
Qv Required ventilation capacity in m3/s

5. Lay out the drain piping from the condensate outlets towards the condensate collector. The drain
pipes must not dip into the water in the collector. It is recommended to provide a funnel to allow
visual inspection of the condensate flow.

6. See “Electric cable size” for the recommended size of the supply cables.
7. Check that the electrical connections meet local codes. The installation must be earthed and
protected against short circuits by fuses in all phases. An isolating switch must be installed near the
compressor.

8. Install a condensate drain valve in the lower part of the air net piping.

9. Remove the plastic plugs (if fitted) from the compressor water pipes (WI and WO) and connect the
pipes to the cooling water circuit. Fit a valve in the compressor water inlet pipe and outlet pipe.

3.5 Electric connections

General instruction for the electrical installation of VSD compressors
• Electrical equipment from Atlas Copco Compressor is designed in accordance with the safety
regulations described in IEC60204-1 and CENELEC EN60204.
• It is the responsibility of the customer to install the compressor unit according to the safety
regulations in order to protect people from electric shocks from direct or indirect contact.
• In drives with frequency converters, leakage currents occur along the RFI filter and the cable
capacities, especially during the motor start. Class A leakage detection protections would switch off
the machine. Therefore it is not recommended to use class A detection systems on frequency
converters.

Installation instructions for TN, TT, IT

In each network system (TN, TT or IT), the customer has to protect the installation using overcurrent
protection by means of fuses or automatic circuit breaker protection.
With respect to the power distribution system, additional installation instructions are given.

Network type TN (TN-S, TN-C and TN-C-S)

No additional protections need to be installed. If the customer wishes to or needs to install a leakage
detection device, it should be of type B and should comply with IEC755 Amendment 2 "General
requirements for residual current-operated protective devices". Atlas Copco advises customers to
install the following earth leakage detection device: BENDER RCMA 470LY with external current
transformer: http://www.bender.org/prod.html

Network type TT
In the case of TT-systems, safety regulations mostly stipulate the use of an earth leakage circuit
breaker (e.l.c.b). In combination with frequency converters, type B residual current-operated
protective devices should be used. Atlas Copco advises customers to install the following earth
leakage detection device: BENDER RCMA 470LY with external current transformer:
http://www.bender.org/prod.html

Power distribution systems (TN, TT, IT)

According to IEC 60950, there are three main types of power distribution systems: TN, TT and IT.
The electrical installation instructions depend on the type of network of the customer's power supply.

Network type TN (Terra Neutral):

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The TN power distribution system provides a direct earth to the exposed conductive parts of the
installation. The connection is made through the PEN-conductor. Within the TN power distribution
system, there are three sub-types: TN-S, TN-C and TN-C-S, identified according to neutral and
protective earth conductors. Nearly 85 % to 90 % of industrial networks are TN type.

Network type TN-S (Terra Neutral-Separate):

The TN-S power distribution system provides separate neutral and direct earth conductors.

A Power system earth

B Exposed conductive parts

Network type TN-C (Terra Neutral-Combined) :

In the TN-C power distribution system, the neutral and the protective earth functions are combined in
a single conductor.

A Power system earth

B Exposed conductive parts

Network type TN-C-S (Terra Neutral-Combined-Separate) :

In the TN-C-S power distribution system, the neutral and the protective earth functions are combined
to some degree in a single conductor, a direct earth to the exposed conductive parts of the
installation exists in part. The connection is achieved through the PEN conductor.

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A Power system earth

B Exposed conductive parts

Network type TT (Terra Terra):

The TT power distribution system has one point that is directly earthed. In addition, the exposed
conductive parts of the installation are connected to earth electrodes that are independent from the
power system's earth.

A Power system earth

B Exposed conductive parts

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3.6 Electrical diagram

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3.7 Electric cables

Mains and earth cable

Local regulations remain applicable if they are stricter than the values
proposed.
This size is valid for 90°C multicore cable

Voltage
440 V - 60 Hz 4x (3 x 95+ 50) mm2

3.8 Cooling water requirements

Recommendations
The cooling water quality must meet certain minimum requirements.

No general recommendation can encompass the effects of all combinations of the various
compounds, solids and gases typically found in cooling water in interaction with different materials.

This recommendation is a general guide line for acceptable coolant quality.

Type of system
First, it is important to consider whether you are dealing with a closed system or an open system. In
a closed system, the same cooling water circulates through a system without contact with air.

An open system is a pass-through system, or a circulating system with a cooling tower. In the latter
case, the composition of the water that enters the cooler must be considered, and not the
composition of the make-up water. Due to the evaporative effect in the cooling tower, much higher
concentrations of ions can be obtained in the circulating water than in the make-up water.

Ryznar stability index (RSI)

The Ryznar Stability Index (RSI) is a parameter for predicting whether water will tend to dissolve or
precipitate calcium carbonate. The adhesion of scaling deposits 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).

The saturation pH value is determined by the relationship between the calcium hardness, the total
alkalinity, the total solids concentration and the temperature.
The Ryznar Index is calculated as follows:

RSI = 2*pHs – pH

Symbol Explanation
pH Measured pH (at room temperature) of water sample
pHs pH at saturation

The pHs is calculated by using:

pHs = (9.3 + A + B) - (C + D)

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Symbol Explanation
A Depends on the total solids concentration (mg/l)
C Depends on the calcium hardness (ppm CaCO3)
D Depends on the HCO3 - concentration or M-alkalinity (mval/l)

The values of A, B, C and D can be found in the following table.

Total
dissolved Temperature Ca-hardness M-alkalinity
solids (mg/l) A (˚C) B (ppm CaCO3) C (mval/l) D
50 - 300 0.1 0-1 2.6 10 - 11 0.6 0.20 - 0.22 1.0
400-1000 0.2 2-6 2.5 12 - 13 0.7 0.24 - 0.26 1.1
7-9 2.4 14 - 17 0.8 0.28 - 0.34 1.2
10 - 13 2.3 18 - 22 0.9 0.36 - 0.44 1.3
14 - 17 2.2 23 - 27 1.0 0.46 - 0.54 1.4
18 - 21 2.1 28 - 34 1.1 0.56 - 0.70 1.5
22 - 27 2.0 35 - 43 1.2 0.72 - 0.88 1.6
28 - 31 1.9 44 - 55 1.3 0.90 - 1.10 1.7
32 - 37 1.8 56 - 69 1.4 1.12 - 1.38 1.8
38 - 44 1.7 70 - 87 1.5 1.40 - 1.76 1.9
45 - 50 1.6 88 - 110 1.6 1.78 - 2.20 2.0
51 - 56 1.5 111 - 138 1.7 2.22 - 2.78 2.1
57 - 63 1.4 138 - 174 1.8 2.80 - 3.54 2.2
64 - 71 1.3 175 - 220 1.9 3.54 - 4.40 2.3
72 - 80 1.2 230 - 270 2.0 4.6 - 5.4 2.4
280 - 340 2.1 5.6 - 7.0 2.5
350 - 430 2.2 7.2 - 8.8 2.6
440 - 550 2.3 9.0 - 11.0 2.7
560 - 690 2.4 11.2 - 13.8 2.8
700 - 870 2.5 14.0 - 17.6 2.9
880 - 1000 2.6 17.8 - 20.0 3.0

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Interpretation of the value obtained

RSI Water condition Action

Very high scale
RSI<3.9 formation Water cannot be used.
High boiler scale Regular inspection and descaling operation
4.0<RSI<5.5 formation necessary.
Slight boiler scale Water treatment not necessary.
5.6<RSI<6.2 formation Occasional inspection recommended.
Water treatment not necessary.
6.3<RSI<6.8 Neutral water Occasional inspection recommended.
Slight corrosion at Water treatment not necessary.
6.9<RSI<7.5 higher temperature Occasional inspection recommended.
Regular inspection necessary, use of corrosion
7.6<RSI<9.0 Strong corrosion inhibitor recommended.
Regular inspection necessary, use of corrosion
9.1<RSI<11 Very strong corrosion inhibitor required.
Very strong corrosion
in complete water
RSI>11 system Water should not be used.

The table indicates that distilled or demineralised water should never be used, as their RSI is > 11.

The RSI only indicates the equilibrium of scaling - descaling. A cooling water showing good RSI
conditions can still be unsuitable due to other factors.

From the table above, the RSI index should be between 5.6 and 7.5; otherwise, contact a specialist.

pH
The effect of pH is already calculated in the Ryznar index, but the pH itself has some additional
limitations : 6.8 < pH < 8.5

Total dissolved solids (TDS)

This is the sum of all the ions in the water. It can be derived from the dry residue after evaporation
(but not including suspended solids), or it can be estimated from the electrical conductivity.
In a closed system, the following limits apply: TDS < 3000 mg/l (< 3800 microS/cm)

Chlorides (Cl-)
Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited:
Closed cooling system : chlorides < 500 ppm
Open cooling system : chlorides < 150 ppm
However, if the water is scaling, lower limits should be used. (See The Ryznar stability index (RSI)).

Free chlorine (Cl2)

A level of 0.5 ppm should not be exceeded for long periods.
For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies.

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 - / SO4 2- should be > 1

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Ammonia
< 0.5 ppm

Copper
< 1 ppm

Iron and manganese

< 1 ppm

Organics
No algae
No oil

Suspended solids
Non-soluble particles, size < 1 mm.
< 10 ppm

3.9 Pictographs
8 Cooling water inlet
9 Cooling water outlet
10 Switch off the voltage and depressurize the
compressor before maintenance or repair
11 Before connecting the compressor
electrically, consult the Instruction book for
the motor rotation direction
12 Read Instruction book before starting the
compressor
13 Torques for steel (Fe) or brass (CuZn) bolts
14 Consult the Instruction book before greasing
15 Switch off the voltage before removing the
protecting cover inside the electric cabinet
16 Oil the gaskets, screw on the filters and
tighten by hand (approx. one half turn)
17 Consult the Instruction book before
maintenance or repair
18 Automatic condensate outlet, intercooler
19 Automatic condensate outlet, aftercooler
20 Warning: under tension

Safety icons

Danger for life

Warning

Important note

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4 Operating instructions
4.1 Operation introduction
Warning

The operator must apply all relevant “Safety precautions”.

Ambient conditions
Consult “Limits” for the limits with regard to the ambient conditions and altitude operation.

Moving/lifting
In order not to damage the frame, the compressor must be moved either by a lift truck or by using lifting
equipment as described below.

When moving the compressor with a lift truck, use the slots in the frame. Make sure that the forks protrude
from the other side of the frame. When moving the compressor with a lifting device, insert beams in the slots.
Make sure that the beams cannot slide and that they protrude from the frame equally. The chains must be
held parallel to the bodywork by chain spreaders in order not to damage the compressor. The lifting
equipment must be placed in such a way that the compressor is lifted perpendicularly. Lift gently and avoid
twisting.

4.2 Initial start-up

General preparations
Make sure the compressor is installed correctly.
See “Electric cables”, “Installation proposal” and “Dimension drawings”.
A sticker summarising the operating instructions is delivered with the literature set. Affix the sticker next to
the control panel.

Protection during transport

Figure 17 Motor transport spacers

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Figure 18 Gear casing transport support

Figure 19 Cooler block transport support

The compressor and motor are secured to the frame immobilising the vibration dampers during transport.
The transport protection devices are painted red and must be removed:

Step Action
On the motor side, remove bolts (1) and spacers (2). Fit the shorter bolts, which
are attached to the motor support in a plastic bag, to tighten the vibration
1 dampers securely to the motor support.
2 Remove support (1) on the gear casing side.
3 Remove supports (1) on the cooler block.

Preparation of cooling water system

Figure 20 Water drain plug, HP element

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Figure 21 Water drain plug, LP element

Figure 22 Water drain plugs, coolers

Figure 23 Water drain plugs, cooler block

Step Action
Fit the water drain plugs (DP2 up to DP6) that are attached to the water pipe of
one of the compressor elements (El and Eh) in a plastic bag. The plugs are
1 painted green and their positions are shown on the illustrations above.
Check that the cooling water drain valves (customer's installation) in the inlet
and outlet lines are closed. Open the water inlet valve and outlet valve
2 (customer's installation) and check for water flow.

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Electric cabinet

Step Action
Check that the electrical connections correspond to the local codes. The
installation must be earthed and protected by fuses in all phases. An isolating
1 switch must be fitted.
2 Check the connection of transformers (T1).
3 Check the setting of the circuit breaker (Q1).
See Figure 3 Electric cabinet

First start-up

Figure 24 Position of the oil level sight-glass

Step Action
1 Check that the gear casing is filled with oil.
2 Switch on the voltage.
Start the compressor and stop it immediately. Check for correct direction of
rotation while the motor is coasting to a stop. The correct rotation direction is
indicated by an arrow on the gear casing. Consult Atlas Copco if the rotation
3 direction is wrong.
Run the compressor for a few minutes and check that it operates normally. Fill in
4 the commissioning report.
Stop the compressor. If necessary, top up the gear casing with oil to the middle
5 of the sight-glass (SG).

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4.3 Before starting

Attention
The operator must apply all relevant safety precautions.
If the water system has been drained, close the drain valves and fit the drain
plugs.

Procedure

Figure 25 Position of oil level sight-glass

Step Action
Check the oil level, after stopping the level must be in the middle of sight-glass
(SG) or in the upper field of the green range. At longer standstill, the oil level
1 may increase. Top up, if necessary, with the correct type of oil.
Open the water inlet valve and outlet valve (customer's installation). Opening of
the water outlet valve can be overlooked if, after previous operation, the setting
2 of this valve has not been disturbed.

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4.4 Starting
Warning
When the compressor is stopped and the Status Window on top of the control
display indicates the information ‘Automatic operation/compressor loaded’ (see
Figure 26), the compressor may start automatically.
If the start/stop timer is active, the compressor may start automatically, even if it
was stopped manually.

Figure 26 Status Window

Procedure

Step Action
1 Open the air outlet valve (customer's installation).
2 Switch on the voltage
Press start button (see Figure 27). The status window on top of the control display indicates
3 that the regulator is operative (automatic operation/Compressor loaded)
Regulate the water flow with the compressor running loaded at maximum speed. For the
4 cooling water temperature and cooling water consumption, see section: “Compressor data”

Figure 27 Control panel

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Parts and functions

Reference Designation Function

Button to select “stand-alone” operation of the compressor,

1 Local
locally controlled.

2 Remote Button to select remote operation.

Button to start the compressor. The status window on top of the

3 Start control display will indicating that the regulator is operative
(Automatic operation/Compressor loaded).

Button to stop the compressor. Regardless if the selection is in

“Local” or “Remote”. Pressing this button will not stop the
compressor immediately, if the compressor is running in “loaded”
mode, it will be put in “unloaded” mode and the compressor stops
4 Stop
after a set time. When a shutdown circuit is active, the
compressor will stop immediately. The status window on top of
the control display will indicating that the regulator is not-
operative (Automatic operation/Compressor stopped).

Button to put the compressor in “loaded” mode when the working

pressure is lower then unloading pressure. The status window on
5 Normal top of the control display will indicate: ‘Automatic
Operation/loaded, Load in … sec or will load when pressure
drops loading pressure Standby’.

Button to manually unload the compressor. The status window on

6 Unload top of the control display will indicate: ‘Automatic
Operation/Manual unloaded’.

7 Reset To reset an active motor overload, shutdown or service

message or an emergency stop
Button, to activate that “setpoint 1” must be used. (see also
8 Main
section “Pressure setpoint”)

Button, to activate that “setpoint 2” must be used. (see also

9 Standby
section “Pressure setpoint”)

Button to force purging of electronic water drains. The status

11 Forced Drain window on top of the control display will indicate : Forced drain …
sec.

Display on top of the Control panel. Indicates messages

Status Window
concerning the compressor operations.

Display at the bottom of the Control panel. Indicates messages

Status Area concerning the compressor operating condition, a service need or
a fault.

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4.5 During operation

Warning
• Before starting any maintenance or repairs, stop the compressor, wait
until the compressor has stopped and open the isolating switch
(customer's installation) to switch off the voltage to the compressor.
• Repairs inside the start and speed regulation cabinet may only be
carried out by Atlas Copco.
• Wait at least 6 minutes before starting any electrical repairs as
hazardous high voltage remains on the condensers of the start and
speed regulation unit for 6 minutes after the voltage is switched off.
• Close the air outlet valve and open the manual condensate drain valves
to depressurise the air system.
• When the Status Window on top of the control display indicates that the
regulator is operative (automatic operation/Compressor loaded): the
speed will continuously vary to match the air delivery to the air
consumption, and the compressor will start and stop whenever
necessary.
• Keep all doors closed during operation.

Checking the display

Step Action
Daily check the Mainscreen / Status area window (see Figure 4 and Figure 8 )
for readings and messages. Normally, the main screen is shown, indicating the
1 compressor outlet pressure, the motor speed, the status of the compressor etc.
Always check the status area window and remedy the trouble if alarm is alight or
2 flashing,
4 Regularly check the Status area window

4.6 Stopping
Procedure

Step Action
1 Press stop button (see Figure 27) the compressor will stop
2 Close the air outlet valve.
To stop the compressor immediately in case of emergency, press emergency
3 stop button (S2) (see Figure 6)
4 Close the cooling water inlet valve.

Attention
If the compressor is installed in a room where freezing temperatures are
expected, drain the cooling system completely:
• By opening the main drain valves in the water inlet and outlet pipes
(customer's installation).
• By removing drain plugs (DP2 up to DP6). See “Initial start-up” for the
position of the plugs.

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4.7 Taking out of operation

Procedure
Step Action
1 Close the air outlet valve and stop the compressor.
2 Switch off the voltage and disconnect the compressor from the mains.
Shut off and depressurise the part of the air net which is connected to the outlet
3 valve. Disconnect the compressor air outlet pipe from the air net.
4 Drain oil and condensate circuits.
5 Disconnect the compressor condensate piping from the condensate drain net.
Drain the cooling water circuit and disconnect the cooling water pipes from the
6 compressor.

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5 Maintenance
5.1 Maintenance warnings
• Before starting any maintenance or repairs, stop the compressor.
• Depressurise the air system as follows:
Close the air outlet valve.
Press the test buttons on top of the electronic water drains.
• Open the isolating switch (customer's installation) to switch off the voltage
to the compressor.
• Repairs inside the start and speed regulation cabinet may only be carried
out by Atlas Copco.
• Wait at least 6 minutes before starting any electrical repairs as hazardous
high voltage remains on the condensers of the start and speed regulation
unit for 6 minutes after the voltage is switched off.
• Apply all relevant “Safety precautions”.

5.2 Preventive maintenance schedule

Regular service operations
To ensure safe operation and long service life, carry out following operations at the interval (period
or running hours) which comes first. The "longer interval" checks must also include the "shorter
interval" checks.
The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the
environmental and working conditions of the compressor.

Period Running hours Operation

Daily 8 Check readings on mainscreen.
Check that condensate is discharged during
Daily 8 loading.
Check oil level. Before starting, the level should be
Daily -- in the middle of the sight-glass.
3-monthly -- Clean compressor.
3-monthly -- Check for possible leaks.
3-monthly 500 Check coolers, clean if necessary.
Carry out the service actions according to the
When displayed -- displayed service plans.

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5.3 Motor greasing

Motor Greasing

General

Safety precautions
Stop the compressor and switch off the voltage.
The operator must apply all related safety precautions.

The data below are valid for an air intake temperature of maximum 40 °C
Consult your Atlas Copco Customer Centre for higher intake temperatures.
Reset the regreasing service warning after regreasing.
Also check the motor data plate.

DRIVE MOTOR
Make ABB
Type M3BP 315LK-4

DRIVE MOTOR GREASING

Type Klüberquiet BQH 72-102
Interval 4000 h
Quantity (per bearing) 80 g

Never mix greases of different brands of types

5.4 Storage after installation

Run the compressor, e.g. twice a week, until warm.
If the compressor is going to be stored without running from time to time, protective measures must
be taken. Consult Atlas Copco.

5.5 Service kits

Service kits
Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service
kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas
Copco parts while keeping the maintenance budget low. All service kits are mentioned in the
relevant Parts Lists. In the Spare parts list only standard Service kits are printed. Service kits of
special parts will not be supported

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5.6 Oil specifications

Oil type
Use Atlas Copco Roto-Z oil which has been specially developed for oil-free rotary compressors. This
oil has a long service life and ensures optimum lubrication.

Never mix oils of different brands or types.

Atlas Copco Roto-Z oil

Atlas Copco Roto-Z oil can be ordered in following quantities:

Quantity Ordering number

20 l can 2908 8501 01
209 l drum 2908 8500 00

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6 Adjustments and servicing procedures

6.1 Air filters
Location of the air filters

Figure 28 Air filter

Procedure
The filters must be serviced regularly; consult section “Preventive maintenance
schedule”.
Never install damaged or clogged filters.

Step Action
1 Stop the compressor and press the emergency stop button.
2 Switch off the voltage.
3 Remove nuts (1).
4 Loosen clamps (2).
5 Take out filter housing (3) with filter element (4).
6 Replace the dirty filter element with a new one.
7 Put the filter housing with the filter element back into place.
8 Tighten clamps (2) and nuts (1).
9 Switch on the voltage.
10 Unlock the emergency stop button and reset the air filter service warning.

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6.2 Oil and oil filter change

Oil system

Figure 29 Oil system components

Procedure
Step Action
1 Run the compressor until warm.
Stop the compressor.
2 Press the emergency stop button.
3 Switch off the voltage.
The filler plug and drain points are painted yellow.
Remove filler plug (FC). Drain the compressor sump by opening drain valve
(Dmo).
Drain the oil cooler by opening drain valve (Dmc).
4 Close the drain valves.
Remove the oil filters (OF). Clean the filter seats, oil the gaskets on the new
filters and screw the filters into place until the gaskets contact the seats. Then
5 tighten by hand.
Fill the compressor sump to the middle of the oil level sight-glass (SG).
6 See “Oil specifications” for the correct type of oil.
7 Reinstall the filler plug.
Switch on the voltage.
Unlock the emergency stop button and reset the oil and oil filter service
8 warnings.
9 Run the compressor for a few minutes.
10 Stop the compressor.
Check the oil level. After stopping, the level must be in the middle of sight-glass
(SG). After a longer standstill, the level may rise.
11 Top up, if necessary.

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6.3 Safety valves

Testing
The valves can be tested on a separate compressed air line. If a valve does not open at the pressure
specified in “Settings of safety valves”, consult Atlas Copco.

Never run the compressor without safety valves.

No adjustments are allowed.

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7 Problem solving
7.1 Faults and remedies
Warnings
• Before starting any maintenance or repairs, stop the compressor, wait
until the compressor has stopped and open the isolating switch
(customer's installation) to switch off the voltage to the compressor.
• Repairs inside the start and speed regulation cabinet may only be
carried out by Atlas Copco.
• Wait at least 6 minutes before starting any electrical repairs as
hazardous high voltage remains on the condensers of the start and
speed regulation unit for 6 minutes after the voltage is switched off.
• Close the air outlet valve.
• Press the test buttons on top of the Electronic Water Drains to
depressurise the air system.
• Apply all relevant “Safety precautions”.

Condition Fault Remedy

Compressor capacity or Air consumption exceeds Check pneumatic plant
working pressure lower capacity of compressor
than normal
Safety valves leaking Remove leaking valve and have it
inspected
Oil pressure too low Oil level too low Top up level to the middle of the oil level
sight-glass
Oil filter clogged Replace filter
Air temperature above Inlet temperature too high Improve ventilation in compressor room
normal due to bad room and prevent recirculation of cooling air
ventilation or recirculation
of cooling air
Air filter clogged Replace filter
Insufficient cooling water Check water temperature and increase
flow cooling water flow
Restriction in cooling Consult Atlas Copco
water system due to
formation of scale or dirt
deposits
Condensate is not Discharge flexible Check and correct as necessary
discharged from clogged
condensate traps during
operation

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8 Technical data
8.1 Readings on display
Common readings
Unit
Dp of air filter, approx. bar 0.015
Cooling water inlet temperature ˚C < 40
Cooling water outlet temperature ˚C < 50

8.2 Settings of safety valves

Unit
Low-pressure safety valve 3.7 bar(e)
High-pressure safety valve, 8.6 bar compressors 9.3 bar(e)

8.3 Circuit breakers and fuses

Circuit breaker Value
Control circuit (Q1) 2.5 A
- 440 V - 60 Hz 7.1
Circuit breakers

Main fuses
(customer's installation)
Voltage supply gL/gG
440 V - 60 Hz 2x (3x 315 A)
Main fuses

8.4 Reference conditions

Value
Absolute inlet pressure 1 bar(a)
Relative air humidity 0%
Air inlet temperature 20 ˚C
Cooling water inlet temperature 20 ˚C
Motor shaft speed 2430 rpm

8.5 Limitations
Maximum air inlet temperature 40 ˚C
Minimum ambient temperature 0 ˚C
Maximum cooling water temperature at inlet 40 ˚C
Maximum cooling water temperature at outlet 50 ˚C
Maximum cooling water inlet pressure 10 bar(e)
Maximum relative humidity of ambient air 95 %
Maximum altitude operation 1000 m

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8.6 Compressor data

Units 8.6 bar
Oil capacity l 60
Sound pressure level at reference speed
According to PNEUROP PN8NTC2.2 under free field
conditions at a distance of 1 metre dB(A) 69

8.7 Compressor specifications

8.7.1 General information
Compressed medium Air
Max. ambient temperature 40 °C
Max. working pressure 8.6 bar(g)
Pressure vessel approval ASME

8.7.2 Performance data

CONDITION 1 – DESIGN CONDITION MIN. SPEED
Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8.6 bar(g)
Air inlet temperature 28 °C
Air inlet relative humidity 75 %
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C
Volume flow rate 227 l/s Tol. ± 4 %
Normal capacity 730 Nm3/h Tol. ± 4 %
Package power input: 110 kW
Specific package power input: 485 J/l
Drive speed 1000 RPM
MRS Stage LP 4051 RPM
MRS Stage HP 6320 RPM
Total Cooling Water Flow 1.9 l/s
Pressure drop cooling water circuit 0.1 bar
Temp. LP Outlet 159 °C
Temp. HP Inlet 26 °C
Temp. HP Outlet 172 °C
Air discharge temperature 21 °C

CONDITION 2 – DESIGN TEMPERATURE MAX SPEED

Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8.6 bar(g)
Air inlet temperature 28 °C
Air inlet relative humidity 75 %
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C
Volume flow rate 743 l/s Tol. ± 4 %
Normal capacity 2386 Nm3/h Tol. ± 4 %
Package power input: 324 kW
Specific package power input: 437 J/l
Drive speed 2800 RPM
MRS Stage LP 11344 RPM
MRS Stage HP 17696 RPM
Total Cooling Water Flow 5.5 l/s
Pressure drop cooling water circuit 0.84 bar
Temp. LP Outlet 170 °C

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Temp. HP Inlet 26 °C
Temp. HP Outlet 183 °C
Air discharge temperature 26 °C

CONDITION 3 – MAXIMUM TEMPERATURE MIN SPEED

Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8.6 bar(g)
Air inlet temperature 15 °C
Air inlet relative humidity 75 %
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C
Volume flow rate 222 l/s Tol. ± 4 %
Normal capacity 686 Nm3/h Tol. ± 4 %
Package power input: 107 kW
Specific package power input: 484 J/l
Drive speed 1000 RPM
MRS Stage LP 4051 RPM
MRS Stage HP 6320 RPM
Total Cooling Water Flow 2 l/s
Pressure drop cooling water circuit 0.12 bar
Temp. LP Outlet 170 °C
Temp. HP Inlet 26 °C
Temp. HP Outlet 179 °C
Air discharge temperature 21 °C

CONDITION 4 – MAXIMUM TEMPERATURE MAX SPEED

Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8 bar(g)
Air inlet temperature 20 °C
Air inlet relative humidity 0%
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C
Volume flow rate 727 l/s Tol. ± 4 %
Normal capacity 2245 Nm3/h Tol. ± 4 %
Package power input: 317 kW
Specific package power input: 436 J/l
Drive speed 2800 RPM
MRS Stage LP 11344 RPM
MRS Stage HP 17696 RPM
Total Cooling Water Flow 6 l/s
Pressure drop cooling water circuit 1.01 bar
Temp. LP Outlet 182 °C
Temp. HP Inlet 26 °C
Temp. HP Outlet 190 °C
Air discharge temperature 26 °C

CONDITION 5 – MINIMUM TEMPERATURE MIN SPEED

Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8.6 bar(g)
Air inlet temperature 15 °C
Air inlet relative humidity 75 %
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C
Volume flow rate 229 l/s Tol. ± 4 %
Normal capacity 769 Nm3/h Tol. ± 4 %
Package power input: 112 kW
Specific package power input: 491 J/l

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Drive speed 1000 RPM

MRS Stage LP 4051 RPM
MRS Stage HP 6320 RPM
Total Cooling Water Flow 1.8 l/s
Pressure drop cooling water circuit 0.09 bar
Temp. LP Outlet 147 °C
Temp. HP Inlet 26 °C
Temp. HP Outlet 166 °C
Air discharge temperature 21 °C

CONDITION 6 – MINIMUM TEMPERATURE MAX SPEED

Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8.6 bar(g)
Air inlet temperature 15 °C
Air inlet relative humidity 75 %
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C
Volume flow rate 750 l/s Tol. ± 4 %
Normal capacity 2517 Nm3/h
Package power input: 331 kW
Specific package power input: 442 J/l
Drive speed 2800 RPM
MRS Stage LP 11344 RPM
MRS Stage HP 17696 RPM
Total Cooling Water Flow 5.1 l/s
Pressure drop cooling water circuit 0.72 bar
Temp. LP Outlet 157 °C
Temp. HP Inlet 26 °C
Temp. HP Outlet 176 °C
Air discharge temperature 26 °C

CONDITION 7 – TEST CONDITION

Ambient pressure 1 bar(a)
Air absolute inlet pressure 1 bar(a)
Air outlet pressure 8 bar(g)
Air inlet temperature 20 °C
Air inlet relative humidity 0%
Cooling water inlet temperature 20 °C
Cooling water temperature rise 15 °C

8.8 Special mechanical items

• Standard Elektronikon temperature and pressure sensors replaced by 4-20mA Rosemount with display:
- Type 3051 for pressure – Enclosure IP65
- Type 644 H for temperature
1. Vacuum transmitter after air inlet filter
- Range: - 80 to + 20 mbar
2. Rosemount pressure transmitter at HP stage inlet (I.C. pres.)
- Enclosure: IP 65
- Range: - 1 to 5 bar(g)
3. Rosemount pressure transmitter at discharge air
- Enclosure: IP 65
- Range: 0 to 10 Bar (g)
4. Rosemount pressure transmitter in oil circuit (after oil filter)
- Enclosure: IP 65
- Range: - 1 to 5 Bar (g)

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5. Rosemount temp. transmitter 4-20 mA at LP stage outlet

- Enclosure: IP 54
- Range: 0 to 300°C
6. Rosemount temp. transmitter 4-20 mA at HP stage inlet
- Enclosure: IP 54
- Range: 0-100°C
7. Rosemount temp. transmitter 4-20 mA at HP stage outlet
- Enclosure: IP 54
- Range: 0 to 300°C
8. Rosemount temp. transmitter 4-20 mA at air outlet
- Enclosure: IP 54
- Range: 0 to 100°
9. Rosemount temp. transmitter 4-20 mA in oil circuit
- Enclosure: IP 54
- Range: 0 to 100°
10. Rosemount temp. transmitter 4-20 mA at water circuit inlet
- Enclosure: IP 54
- Range: 0 to 100°
11. Rosemount temp. transmitter 4-20 mA at LP water circuit outlet
- Enclosure: IP 54
- Range: 0 to 100°
12. Rosemount temp. transmitter 4-20 mA at AC water outlet
- Enclosure: IP 54
- Range: 0 to 100°

MOTOR
The installed motor meets the following specifications:
• ABB type M3BP 315 LK-4
• Shaft power: 296 kW
• Service factor: 1.1
• Voltage (± 10.0 %): 400 V
• Frequency: 100 Hz
• Drive speed: 3000 rpm
• Max. cooling air temperature: 40 °C
• Connection of windings: DELTA
• Insulation class: F
• Enclosure: IP55
• Construction form: B5 + SUPPORT
• Full load efficiency: 94.7 %
• Nominal current: 595 Amp.
• Nominal torque: 942 Nm
• Weight: 1600 Kg
• Max. Altitude: 1000 masl

Note: CSA certified, NEMA name plate, VSD for ABB converter

Additional motor characteristics/information

• On data plate: KT 50°C; S.F. = 1.00 or KT 40°C, S.F. = 1.06
• 6 x PT100 in windings

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ELECTRICS
• Atlas Copco frequency converter, 460 V - 60 Hz
• PLC:
- Make: Siemens
- Type: Simatic S7
- Voltage: 220 V
- Frequency: 60 Hz
• Solenoid valve 220 V - 60 Hz
Auxiliary equipment / provisions:
• Adapted cubicle: installation of Siemens PLC etc.

8.9 Cubicle with PLC controlled regulator, Frequency Converter and

IL77 operating panel
8.9.1 General
Degree of protection: IP54
Installation: Indoor
Max. ambient temperature: 40 °C
Electrical area: Non hazardous
Electrical code: IEC 439
Power supply PLC: 220 V/60 Hz
Loading solenoid valve: 220 V/60 Hz
PLC: 24 VDC
Wiring: 220V circuits: red
circuit 24 VDC, wire L-: blue
other 24 VDC circuits: white
Interface: red
Earthing: green/yellow

8.9.2 Front panel apparatus

Hour meters: RUNNING TIME
LOADING TIME
Push button: EMERGENCY STOP

Display unit Siemens IL77 with following facilities:

• Push buttons: START
PROGRAMMED STOP
LAMP TEST
NORMAL / UNLOAD
RESET
LOCAL/REMOTE
LANGUAGE SELECTION ( Spanish / English )
• Display for reading:
All temperatures (°C)
All pressures (Bar)
Events such as:
- READY TO START
- AUTOMATIC OPERATION
- RUNNING LOADED
- RUNNING UNLOADED
- PROGRAMMED STOPPED
- EMERGENCY STOPPED
- SPEED
- FORCED DRAIN
• Warning messages for:
HIGH AIR FILTER PRESSURE DROP
TEMPERATURE LP OUT
TEMPERATURE HP IN

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TEMPERATURE HP OUT
OIL PRESSURE
OIL TEMPERATURE
SENSOR ERROR
MOTOR WINDING TEMPERATURE
• Shut down messages for:
TEMPERATURE LP OUT
TEMPERATURE HP IN
TEMPERATURE HP OUT
OIL PRESSURE
OIL TEMPERATURE
SENSOR ERROR
MOTOR WINDING TEMPERATURE
VSD FAILURE
• Reading of all warning and tripping levels

8.9.3 Start interlock / shutdown circuits / regulation / auxiliary circuits

Built-up with PLC Siemens S7 CPU318-2DP, Applicom card APP-ETH-PCU, CP343-1 for Ethernet and
Siemens operator Panel IL77.
Profibus link between CPU and ABB Frequency convertor.
GE-Ifix Development software for IL77

8.9.4 I/O circuits

• Analogue inputs:
- Temperature circuits:
PT100 's are installed locally inside the compressor canopy, and are fed by a common 24VDC
supply installed inside the electrical panel. The transmitter outputs ( 4-20mA ) are used as input in
the analogue input cards of the PLC.
Output of the PLC is used for display of the actual temperatures on the display unit IL77, warning-
and tripping levels.
Make of transmitters: Rosemount type 644H

- Temperature circuits motor:

3 x motor winding temperature PT100

- Summary of temperature circuits:

- LP outlet
- HP inlet
- HP outlet
- Compressed Air outlet
- Oil circuit
- Cooling water Aftercooler outlet
- Cooling water LP outlet
- Cooling water inlet

- Pressure circuits:
Pressure transmitters are installed in the instrument panel of the compressor and fed by a
common 24 VDC supply unit installed inside the electrical panel. The transmitter outputs (4-20
mA) are used as input in analogue input cards of the PLC. Outputs of the PLC are used for
display of actual pressures on display unit Siemens IL77, for load / unload the compressor and for
warning- and tripping levels.
Make of transmitters: Rosemount 3051

- Summary of pressure circuits:

- Inter cooler pressure
- Air discharge pressure
- Oil pressure
- Air filter vacuum

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• Digital inputs:
- Emergency stop push button

• Digital outputs
- Auxiliary relay for general warning
- Auxiliary relay for general shutdown
- Loading solenoid valve
- Auxiliary relay for motor run
- Auxiliary relay for Forced drain

8.9.5.Interfaces to Customer

• Communication processor for Ethernet (CP343-1)

• Digital I/O’s:
- One voltage free contact for "General warning”
Contact open when No warning or No control voltage
Contact closed = warning
- One voltage free contact for "Running"
Contact closed = running
- Facility for remote start/stop
Purchaser to provide 1 voltage free contact.
Contact closed = start
Contact open = stop
- Facility for remote programmed stop.
Purchaser to provide 1 normally closed voltage free pulsation break contact.
- One voltage free contact for “General shutdown”
Contact closed when no shutdown or no control voltage.
Contact open = shutdown.
- One voltage free contact for “Automatic Operation”.
Contact closed = automatic operation.

Remarks:

1. Interconnection cables between compressor and DCS are not in Atlas Copco scope of supply.

2. A removable undrilled gland plate is foreseen in the panel, accessible from the outside, for purchaser's
connections.

3. Communication processors are not parameterized. Data are gathered in one common data block,
accessible for Customer use.

4. Visualisation of IL77 realised with GE-Ifix

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9 Pressure equipment directives

PED instructions

ZR315 VSD is a pressure assembly of cat. I according to 97/23/EC.

The following pressure bearing parts are of category higher than I:

Pressure bearing part

Safety valve: Category IV
Design code: AD-Merkblätter, A2
IMD600: Category IV
Design pressure 11 bar(e), content 350 l
Design standard: ASME section VIII div. 1.

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