Atlas Copco Stationary Air Compressors Z718-ZT22-Z130-ZT37-ZT45-Z155-Z175-Z190 ZR45-ZR55-ZR75-ZRIO with Elektronikon regulator Instruction Book From following serial number onwards: AUF-O88 124 Important: 1 matter No. 20 rust be used together with the "User manual forthe Elektronikon’ regulator , printed ox, ‘© Copyright 2001, Atlas Copco Airpower ny, Antwerp, Belgium. ‘Any unauthorized use or copying ofthe contents o any part thereof i prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings, ‘© This instruction book meas the requirements fr instructions specified by the machinery directive (98/37/EC and is valid for CE as well as non-CE labelled machines, No, 2920 1345 01 swwvatlaseopea com Replaces No, 2920 1345 00 Registration code: APC Z $90 /38 984 2001-03, inc 0 0 00 ‘Atlas Copco— FittasCopeo 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 repait. 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, ete. in an operator's logbook available from Atlas Copco. Follow all applicable safety precautions, amongst others those mentioned in this book, Repairs must be eartied out by trained personnel from Atlas Copeo who can also be contacted for any further information Inall correspondence mention the type and the serial number, shown on the data plate. ‘The company reserves the right to make changes without prior notice, CONTENTS Page Page 1 Leading particulars 342 Motors 40 111" General description 3 42.1 Fanmotor bearings 40 112. Elektronikon* contol system % 422 Compressor motor greasing 40 12.1. Elekaronikcon™ regulator 8 43 Oilspecitiation 40 122. Control panel 5 43.1 Rolo hbricating il 40 123. Compressor conrol modes 10444 Storage afer instalation 40 12:4 Extemal compressor status indication... 104.5: Service kits 40 13.5. External communication nog “a u 1.3. Regulating system 15 & Servicing procedures a Airflow 13S Airfiter au 1.3.2, Condensate drain system 13 5.2 Oil and oil filter change aL 1.3.3 Oilsystem. . B $.3. Safety valves: at 1.3.4 Cooling system ty Coolers at 13.3. Regulating system ib § Fabien milan % HAs oes 16 7 Principat data & AL (Dineen drawings 7.1 Readings on display 4B 22 Tetalaton pmporale 217.2 Programmable setngs 43 23 Blericabes 2873 Sings ot ey aes 8 an) Se 2874 Motors settings of oeroad ay and aoe) Sateen Bs cirouit breaker - main fuses. 44 2 Goan rramrremuserents 2 7.4.1 Motor type - settings of motor overload 33 ERiapapts, a relay - main fuses for $0 Iz compressors 44 3. Operating instructions " 7.4.2. Motor ype slings of mar overload 31 Preperation for inti stat-ap 34 relay =main fuses fr 6) Hz compressors 32. Before starting 3 (yD starter) 45 33 suring * 74.3. Setting offi 3.3.1 Routine starting 33 50 Hz compressors 46 332. Starting aer emergency stopping or 7414. Setting of fan motor eiruit breaker for fade " 38 GO Hizcompressors a7 24:3; Mandl eamrdg 37.5. Compressor specifications 47 3. During operation 38 7S." Reference conditions ” 3.5. Checking the display ” 152 Limitations... ooo a7 3.6 Manual unfoading/loading . 38 7.5.3. Specitic data of 2718/37 - 50 Hz 47 S61 Maal usoeding Pa 754 Specie data of 211837 -60 liz... 48 362. Maal loadin 7 155. Specific data of ZT/ZR 45/55 - S02. 49 3.7. Stopping * 8 73.6 Specific data of ZTIZR 45/35 -60Hz .. 49 318 Taking out of operation oe 15.7 Specific data of ZTIZR 75/90 - 50 Hz .. 50 758. Specitie data of 2175/9060 liz ...... 50 4 Maintenance ° 159 Specie data of ZR7590- 60 Hz... 50 4.1 Preventive maintenance schedule forthe 7.6 Conversion list of SL units into British’ compressor 8 ‘American wits 31 2 a0 180Instruction book 1 LEADING PARTICULARS 1.1 General description ZTIB up to ZTSS, ZR4S and ZRSS are two-stage tooth compressors. 2175, ZT90, ZR75 and ZR9O are two-stage screw compressors. ‘The compressors are driven by an electric motor and deliver oil-free, pulsation-fiee air. ZT are air cooled, whereas ZR are water-cooled, ZTI8 up to 30 HAT (High Ambient Temperature) are provided witha larger intercooler, the cooling air of which is generated byan extra fan, “The compressors are available in following pressure variants: 1 Compressor data plate 2 Elektonikon® regulator 3° Electric cabinet 4 Airoutlet valve Type Frequency Maximum working pressure Ha bar(e) Zv18 HAT 86 2122 HAT 86 2130 HAT 86 Zui8 73 068.6 z722 75 0 8.6 2130 2037 75 06 8.6 ZVZR AS 750086 ZVER SS 750186 Z175990 50 8 Z17590 60 750186 2275/00 50 Bor 10 ZRII 6 75, 8.6 0r 10 S1217F 5 Automatic condensate drain outlet, aftercooler moisture rap 6 Manual condensate drain valve, aftercooler moisture trap Fig. 1.1 General view of 2137 2020 1545 01Instruction book Fig, 1.2 View of 2122 1 Aftercooter 11 High-pressure safety valve 21 Elektronikon® regulator 2 Iniercooler 12. Check valve 22. Airfiter 3. Fulhloadno-toad valve 13 High-pressure compressor element 23° Pulsation damper 4 Loading solenoid valve 14 Low-pressure compressor element 24 _Low-pressure safety valve 5 Oilfiller plug 15. Breather 25. Moisture trap. intercooler 6 Oillevel sight-glass 16 Fan motor 26 Vibration damper 7 Oil fiker 17 Cooling fan 27 Pre-aftercooler 8 Oildrain valve 18 Oilcooler 28 Regulating valve, water flow 9 Compressormotor 19 Door, aecess to coolers through oil cooler/intercooler 10. Moisture tap, aftercooler 20. Electric cabinet 29° Regulating valve, water flow through aftercooler Figs. 1.2 upto 1.8 General views 4 2000 1345 oFInstruction book Fig. 1 View of 2745 20 134501 3Instruction book Fig. 1.5 View of ZRSS Fig, 1.6 View of 2175 6 2000 1345 oFInstruction book Fig. 1.7 Front view of 2R90 Fig. 1.8 Rear view of ZR90— FittasCopeo Instruction book ‘The compressors are enclosed in a sound-insulated bodywork and inelude mainly = Air filter = Low-pressure compressor element = Intercooler = High-pressure compressor element = Aftercooker = Electric motor = Drive coupling = Elektronikon® control system = Safety valves 1.2 Elektronikon® control system 19) 12.1.1 Automatic control of compressor operation The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor. Anumber of programmable settings, e.g. the unloading and loading pressures, the minimum stop time and ‘the maximum number of motor starts are taken into account. ‘The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases. In case the expected unloading period is too shor, the compressor is kept running to prevent too-shor standstill periods. Warning A number of time-based automatic startstop commands may be programmed 1). Take into ‘account that a start command will be executed (if programmed and activated), even after ‘manually stopping the compressor 12.12. Protecting the compressor Shutdown ‘The compressor will be shut down if = the motor current exceeds the permissible maximum =the air outlet temperature of the low- or high-pressure compressor element exceeds the pre-set value = the air inlet temperature ofthe high-pressure compressor element exceeds the pre-set value = the oil pressure drops below the preset value Remedy the trouble and reset the message on display (41 1.9) before restarting, See "User manual for Elektronikon’ regulator’, section "Status data submenu”. Shut-down warning Before any’ shut-down level is reached, except for the overload, a message will appear on display (4-Fig, 1.9) and tor general alarm LED (3) will ight up, to warn the operator that the shut-down waming level is exceeded. The shut-down, ‘warning level isa programmable setting below the shut-down level ‘The message disappears as soon as the cause ofthe rouble is, remedied. 12.1.3 Monitoring components subject to service The regulator continuously monitors the oll, motor grease, oil filter and air filter. Each input is compared to programmed time intervals or pressure drops. Ifthese limits are exceeded, amessage will appear on display (4) to warn the operator to replace the indicated component, to change the oil orto grease the motor as the ease may be. 12.14 Automatic restart after voltage failure For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult Atlas Copco. Warning If activated ond provided the regulator was in the automatic operation mode and the compressor conirol mode (local, remote 1 or remote 2 - sce section 1.2.3) was not changed during the voltage failure, the compressor will ‘automatically restart ifthe supply voltage tothe module is restored within a programmed time period (this time period is called the power recovery time). The power recovery time can be set between 1 ‘and 254 seconds or to 0. Ifthe power recovery time is set ta 0, the compressor will abways restart after avoltage fatture, no matter hov Jong itrakes to restore the voltage 12.2 Control panel (Fig. 1.9) Indicators, keys and buttons 1 Automatic operation LED Indicates thatthe electronic regulator is automatically ‘controlling the compressor: the compressor is loaded, unloaded, stopped and restarted depending on the air consumption and the limitations programmed in the regulator. 2 Voltage on LED Indicates that the voltage is switched on 2970 1345 01Instruction book Fig, 1.9, Control panel icators, keys and buttons Indicators, keys and buttons General alarm LED [solight if shut-down warning condition exists. See section 1.2.1. Blinks if shut-down condition exists, if'e sensor used to protect the compressor is out of order of after an emergency stop. See section 1.2.1 4 Display Indicates messages concerning the compressor operating condition, service need or a fault. See "User manual for Elektronikon® regulator", sections ‘Slatus data submenu” and "Service submenu’ Function keys: Keys to control and program the compressor, See below 6 Scroll keys Keys to seroll throug the display 7 Tabulator key Key to goto the next field of the display 8 Start button Push button to start the compressor. LED (1) lights up indicating that the electronic regulator is operative (in automatic operation). ‘The LED goes out after unloading the compressor manual 9 Stop button Push button to stop the compressor. LED (1) goes cut. The compressor will run unloaded for 3 seconds before stopping S2_ Emergeney stop button Push button to stop the compressor immediately in case of emergency. After remedying the trouble, unlock the button by pulling it out $5 Control mode switeh Key switeh to select the compressor control modes. See section 1.23 Selecting a menu To facilitate controlling the compressor, menu-driven programs are implemented in the electronic regulator. Use the function keys (S) to select the menus in order to program and monitor the compressor. The "User manual for Elektronikon® regulator” deals elaborately with all regulator functions, Funetion kes ‘The functions of the keys vary deper the displayed ‘menu. The actual function is indicated just above the relevant key. The most common functions are listed below: 2020 1545 01— FittasCopeo Designat (4Fig. 19) Aad Cancel Delete Limits List Load Main Sereen Menu Modify ‘Show More Program Reset Return Select Unload Instruction book Function ‘To add compressor start/stop commands (@ay'hour) To cancel @ programmed setting when programming parameters ‘To delete compressor startstop commands ‘To show limits fora programmable setting To list programmed start/stop commands (day/hour) “To load the compressor manually “To return from a menu to the main display (Fig. 1.10) ‘Starting from the main display (Fig. 1.10), to initiate the main menu (Fig. 1-11) which sves access to submenus Starting from a submenu, to retum to the mainmenu (Fig. 1.11) ‘To modify programmable settings “To havea quick look atthe compressor status ‘To program modified settings “To reset a timer of message To return to a previously shown option or Toselect a submenu or toread more details ofa selection shown on the display To unload the compressor manually Compressor outlet 7.5 bar oil 2.1 bar Automatically Loaded Menu Show More Unload Fl RR BB Fig. 1.10, Example of the main display Select J FI FP FB Fig. 1.11, Example ofa main mena 12.3 Compressor control modes Key switch ( control modes: Fig. 1.9) allows the operator to select four Key y ‘Compressor control mode position 0 Compressor of u Local control mode (remote control mode is ‘made inactive). The compressor can only be controlled by the butions on the control panel The compressor can be started and stopped via function Timer (see section 1.2.1), if programmed and activate. R Remote control mode | (local control is made inactive). The compressor can ony be started and stopped by an ES100 sequence controller or by external switches, Compressor starvstop commands via function Timer (see section 12.1) are still possible, if programmed and activated. Emergency stop button (S2-Fig. 1.9) remains active 1B Remote control mode 2. The compressor can be controlled by an ES-ype controller or by computer. Consult Atlas Copco. Important = The control module will only react to anew control mode ithe new position ofthe control mode switch is maintained for 3 seconds. = Toavoid unauthorized switching over to another control mode, take out the key after selecting the requited mode. 12.4 Exte compressor status indication “Terminal strip (IXI-Figs, 1.13 and 1.14) is provided with auxiliary contacts for external indication of: Indication Relay strip 1X1 Automatic operation Kos M12, Warning, Ko7 134 Shutdown Ko8 1 Compressor Loaded KI Control mode REMOTE |= 2970 1345 01Instruction book Stop the compressor and switch off the voltage before connecting external equipment. Check the service diagram stuck inside the electric cubicle for the maximum load. Consult Atlas Copco. 1.2.5. External communication Itt is desired to connect the compressor to an Atlas Copco ES system (e.g. to an ESLOO sequence selector), an optional communication module (COMI) needs to be installed. Installation (Fig. 1.12) |. Fit the communication module (COMI) and fx it using plate G). 2. Connect the 24V power supply from terminals (6 and 7) of terminal strip (IX1) to connector (SX1) of communication module (COMI). Connect an earth cable between module (COM!) and the ‘module ofthe compressor regulator 4. Connect the cable delivered with the COM module from connector (5X3) of the COMI module to a free .X2 connector on a module ofthe compressor regulator 5. Consult Atlas Copco to check the installation and to have the communication software loaded a) pipe |--—— swe COMI Communication module 1 Guide MEI Elektronikon regulator 2 Slot SIOE Expansion modules2) 3 Plate 4 Cable Fig. 1.12 Installation of communication module (example) 2020 1545 01Instruction book ill Fu2 FAS K22. KB 1Xt 2s, TN ker Fea Fig, 1.13 Eleetrie cabinet, 2718/37 (typical example) kat FU2 Fuses F3/S_— Circuit breakers F21 Compressor motor overload relay KIL Auxiliary relay, loading K21—_Linecontactor K22 Star contaetor K23_Delta contactor Q25-— Fan motor circuit breaker (ZT18/37 and 2775/90 only) TH/T2 ‘Transformers 1X1 Terminal strip 1X3 Terminal stip, supply from main Figs, 1.13 and 1.14 Electric eabinet Fig. 1.14 Electrie cabinet, 2R/ZT 45/90 (typical example) 2970 1345 01Instruction book 1.3 Regulating system (Figs. 1.15 up to 1.17) 13.1 Airflow Air drawn through filter (1) is compressed in low-pressure compressor element (12) and discharged to intercooler (13). The cooled air is further compressed in high-pressure compressor element (15) and discharged through pulsation damper (16) to aftercooler (17). The caoled air is discharged through moisture trap (19) and outlet valve (21) towards the air net. Check valve (18) is provided upstream of the aftercooler (downstream of it on ZT18/37). 13.2 Condensate drain system ‘A moisture trap (19) is installed downstream of aftercooler (17) to prevent condensate from entering the air outlet pipe. 2175/90 and ZR are also provided with a moisture trap (28) downstream of intercooler (13) to prevent condensate from z718/37 DURING LOADING (8) DAIRINET() | Can ouner | Oates ~--* CONTROL AIR) —s iL Low pressure compressor element (15). Each trap is provided with afloat valve to automatically drain condensate and with a manual drain valve, 1.3.3 Oil system ZTISISS and ZR Oilis circulated by pump (24) from the sump ofthe gear easing through cooler (25) and filter (26) towards the bearings and timing gears 2075190 Oils circulated by pump (24) from the sump ofthe gear casing through cooler (25), the cooling jackets of compressor elements (12 and 15) and filter (26) towards the bearings and timing gears Valve (27) by-passes oil cooler (25) when starting the compressor from cold condition to ensure rapid warming of ‘the oil to normal working temperature, Fig. 1.15 ZT18/37 during loading 2020 1545 01— FittasCopeo — Instruction book DARiNET =a FLOW @) © WATER FLOW (7), ron row 6) ZRA5/55 ‘DURING UNLOADING @) 51210 Fig. 1.16 ZR4S/SS during unloading 134 Cooling system ‘The compressors are provided with an oil eooler (25 ntercooler (13) and aftercooler (17). In addition, ZT75 are equipped with a pre-aftercooler (32). ZT18/90 ave air-cooled. On ZT18/37 and 2175/90, the fan (23) is driven by electric motor (22). On ZT45/5S, the fan is, driven by the main shaft of the compressor. On ZT18/30 HAT two fans are provided, one for generating the cooling airof the intercooler, another for generating the cooling air of the oil cooker and aftercooler. ZRASISS ate water-cooled; the cooling system has wo eiruits: = one for oil cooler (25) and intercooler (13) = one for aftercooler (17) ZR75/90 ate water-cooled; the coolingsystem has wo circuits: + one for oil cooler, low-pressure compressor element and intercooler = one for high-pressure compressor element and aftercooler 13.5. Regulating system ‘The systems controlled by Elekironikon® regulator (9) which keeps the net pressure within programmable pressure Kimits by automatically loading and unloading the compressor depending on the aie consumption During unloading IF the air consumption is less than the air delivery of the compressor, the nel pressure increases. When the net pressure reaches the upper limit of the working pressure (unloading pressure), solenoid valve (8) s de-energized. The plunger of solenoid valve (8) moves downwards by spring force shutting otT the supply of control arto unloader (4) |. Control pressure is vented from chamber (7) of unloader (4) through solenoid valve (8) and chamber (6) towards the inlet of low-pressure compressor element (12). 2. As there is no longer any pressure difference between chambers (6 and 7), plunger (5) returns by spring force 4 2970 1345 01Instruction book Z175190 OAIRINLET(1) DURING LOADING (6) a ourier @ Sarr FLow @) . —-eCONTROLAIR YA) S01 FLOWS) op LO SB oe Fig. 1.17 2775/90 during loading 1 Ait filter 12 Low-pressure compressor element 23. Fan 2 Unloading valve 13. Intercooler 24 Oil pump 3 Full-loadino-load valve 14 Low-pressure safety valve 25. Oil cooler 4 Unloader 15. High-pressure compressor element 26 Oil filter 5 Plunger 16 Palsation damper 27 Oil cooler by-pass valve 6 Chamber 17 Aftercooler 28 Moisture trap, intercooler 7 Chamber 18 Cheek valve 29 Regulating valve, aftercooler 8 Loading solenoid valve 19 Moisture trap, aftercooler water circuit 9 Elekironikon® regulator 20 High-pressure safety valve 30 Regulating valve, intercooler 10 Diaphragm 21 Airoutletvalve ‘water circuit 11 Silencer 22 Fan motor 31 Silencer 32 Preaftercooler Figs. 1.15 up to 1.17 Regulating systems 2020 1545 01 1s— FittasCopeo — Instruction book keeping full-load/no-Ioad valve (3) closed and unloading valve (2) open. Compressed air between check valve (18). and valve (2) blown off through silencer (11), Check valve (18) closes. 4. As vacuum prevails in intercooler (13), diaphragm (10) switches tothe let Air delivery i stopped (0%), the compressor runs unloaded During loading When the net pressure decreases to the lower limit of the working pressure (loading pressure), solenoid valve (8) is, energized. The plunger of solenoid valve(8) moves upwards against spring force opening the supply port of contol air to unloader (4) 1. Atmospheric pressure is allowed through solenoid valve (8) fo chamber (7) of unloader (4). AS this pressure is, higher than the pressure in chamber (6), full-load/no-load valve (3) starts opening. 2. Intercooler pressure i building up causing diaphragm (10) to switch tothe right. Asthe pressure difference between (year chambers (7 and 6) increases, plunger (5) moves further ‘against spring force until full-foadno-load valve (3) fully ‘open and unloading valve (2) closed. Air delivery is resumed (100%), the compressor runs loaded. Footnotes chapter 1 1) This fancton is called the Timer function, See "User manual for Elektronikon* regulator", section "Timer submen” 2). Not installed on all compressor types. 2 INSTALLATION 2.1 Dimension drawings (Figs. 2.1 up to 2.7) on ” cn ne 9823 1710 0072 512070 Fig. 2.1 Dimension drawing, 271830 2970 1345 01Instruction book sara es ws RR 1158 (8) ‘512080 Fig, 2.2 Dimension drawing, 2718/30 HAT enone 7 senes tc sssutn ome 0 023.713 098 ke a FARGO RT MT mS By BY S1a0e0, ete) Fig. 2.3 Dimension drawing, 2737 2020 1545 01 0Instruction book abe Fee antes 1 7 ee) | F f onowents! 4" foo lo ak a © : : ssegoessoo7 [Ss 3 en a cr Bopasco7 e-waste —) Fig, 24 Dimension drawing, 2745/35 69, fee. i; anger oo 9829.0696 0055 So 9 a a a Fig, 2.5 Dimension drawing, 2R45/5S Is 2320 1345 01Instruction book 9823 0746 ons 12 Fig. 2.6 Dimension drawing, 2175/90 2020 1545 01 6Instruction book (Saect im a tra Eee can | iia frame 96230785 0014 312130. m Fig. 2.7 Dimension drawing, 2R7590 20 2320 1345 01Instruction book 2.2 Installation proposals (Figs. 2.8 up to 2.13) Ref, Description 1. Install the compressor on a level flor suitable for taking the weight of the eompressor. Recommended miniraum distance between the top of the bodywork and the ceiling: 1200 mm, 2 Remove the plastic plug from the air outlet pipe and fit, the air outlet valve (7-Fig. 3.2). Close the valve and connect it tothe air net. The pressure drop over the delivery pipe can be caleulated as follows: P= (Lx 450% Qe!) /(@ xP) AP = _ pressure drop (cecommended n 0.1 bar) = _ length of detivery pipe in m d inner diameter of the delivery pipe in mm Pp the absolute pressure atthe compressor ‘outlet in bar(a) Qe = freeair delivery of the compressor in lis It is recommended that the connection of the compressor ar delivery pipe is made on top ofthe main air net pipe to minimize carry-over of possible remainder of condensate Asa rule of thumb, following formula can be used to calculate the recommended volume of the air net: Vo = GOxCxpxQyaP V_ = recommended air net volume in 1 dP = _ pressure difference between unloading and lading pressures in bar (recommended ‘minimum = 0.5) P compressor inlet pressure in bar absolute Q = freeair delivery of compressor in Vs c correction factor, see below Air consumption divided by compressor air delivery c 09 0.10 08 os 07 020 os 028 03 020 02 os ol 0.10 Example: air consumption = 130 US compressor air delivery ~ 180 1's inlet pressure = | bar absolute unloading pressure = 7.5 ba(e) loading pressure ~ 6.8 bar(e) Recommended air net volume (sum of receiver volume and volume of pipe net)= 1540 1. Consult Atlas Copco if in any doubs. The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor or dryer (optional) isavoided. The air velocity tothe grids is limited to 5 ms. Ifeooting air ducts are installed as for proposal 2 (ALT 2), consult Atlas Copco for the maximum allowable pressure drop over the ducts, Common ducting for several compressors is not allowed. The required ventilation capacity (per compressor installed) o limit the compressor room temperature can be calculated as follows: For 2718/30 HAT Qv= 155 NUT For all other ZT compressors For compressors installed as indicated on (ALT 1) oF 3 (ALT3): Qv= 1.05 NUT For ZR Qv= 0.1 NT Qv = required ventilation capacity in m''s [N= shaft input of the compressor in kW AT ~ temperature rise over ambient in degrees Celsius Remove the plastic plugs from the condensate pipes (Fig. 3.2). Fitthe manual condensate drain valves (4 6}. Lay out the drain piping from valves (4/6) and automatic condensate outlets (3/3) towards the condensate collector. The drain pipes must not dip into the water of the collector. Itis recommended to provide a funnel to allow visual inspection of the condensate flow. Elektronikon control system with control panel See section 2.3 for the recommended cable size of the supply cables. Check that the electrical connections correspond to the local codes. The installation must >eearthed and protected against short circuits by fuses in all phases. An isolating switch must be installed near the compressor. Provide a condensate drain valve in the lowest part of the pipe between the compressor outlet valve and the air net. For ZR, remove the plastic plugs from the compressor water pipes (I and2-Fig. 32) and connect the pipes to the cooling water circuit. Provide a valve in the compressor water inlet pipe andl outlet pipe. See section 2.4 for the water requirements, 2020 1545 01 21Instruction book ® venritation PROPOSAL () Cal 1_t ra 2 aia Ltt it EL EL LA PLAID LEE hh EEE By @ SSRN VSS eee SSS AL CLITATTIT IIIS ITV IAT IAT TIT TE nna eae 21 Fig. 28 Installation proposal, 2718137 2 2970 1345 01Instruction book ‘1 Orewa noe, omens or ull ts eka (3) yo awl | 774 ae GALLE LLLLLLELLLL ELE L LLL LLL, b : C a | ¢ A Ay ii i Aad | i Ar J A 4 “ 7 ' E 4 “Ke 9823 1814000 1240 Fig. 2.9 Installation proposal, 2718/30 HAT 2020 1545 01 aInstruction book @® veNrivaTion PROPOSAL (1) 3 tp Pee | 7 ° z -2—lel] i = | SSS SSAA Fig. 2.10 Installation proposal, Z 24 2320 1345 01Instruction book ® vevtuation prorosat (1) nem ata 2) — fLLLLLILLLLELLLLLL LLL Edd LLLLLLLLALLLUL AA Eh dba Z / % Z g 4 | Z YZ Z ZB Z G g | SSS Soot MH SS DTPITITTTTTIIITTT TT OOITTITITTI TTI OTT I TT IOTITITTTTT ITIP Fig. 2.11 Installation proposal, ZR45/SS 2020 1545 01Instruction book @ venation prorosat (1 GLE Z Z Z Z ay UTITTPTTITITPTTITITPTTTOTOPTOOITI TIS TITETTITITTPTTTTOTTTT OEE Fig. 2.12 Installation proposal, 2775/90 2970 1345 01Instruction book — ® vewmuarion provosat ct) * off tree ato a é 3 ee a i L 4 LLL LL Lid LLL LLL Le fe Ly ] Z q a va SSH SEHHAMMMAM TIITITITITTII TPL TOT OTTO TOT ITT TOTTI TT TTTIL TIE Fig 2.13 Installation proposal, 2R75°90— FittasCopeo Instruction book 2.3 Electric cables 2.3.1 Size Remarl Local regulations remain applicable ifthey are sticter than the Values proposed below, Mains + earth cable for 50 Hz compressors For cable PVC 70 degrees Celsius, at ambient temperature 40 degrees Celsius according to EN60204, 230 ov 500 V 2018 HAT - 3x10 mm? + 10 mm? - 2018 3x25 mm? +16 mm? 3x10 mm? + 10 mm? 3x6 mm? +6 mn? 2122 HAT 3x16 mo + 16 mm? 2 2122 3x35 mm? + 16 mm? 3x10 mm? + 10 mm? 3x10 mm? + 10 mm? 130 HAT — 3x16 mm? + 16 mm? “= 2130 3x50 mm? +25 mm? 3x16 mm? + 16 mm? 3x10 mm? + 10 mm? 2037 3x70 mm? + 35 mm? 3x25 mm? + 16 mm? 3x16 mm? + 16 mm? ZUZRAS 3x70 mm? + 35 mu: 3x35 mm? + 16 mm? 3x25 mm? + 16 mm? ZUZR 55 3x95 mm? + 50 mm 3x50 mm? +25 mm? 3x25 mm? + 16 mm? 2175 3x150 mm? +95 mm? 3x95 mm? + 35 mm? 5 215 3x150 mm? +95 ma? 3x70 mm? + 35 mm? 219 3x240 mm? +120 mm? 3x95 mm? + 50 mm? ZR90 Sx185 mm? +95 mam 3x95 mm? + 50 mm* 3x70 mm 35 mm Mains + earth cable for 60 Hz compressors (except for Canada and USA) For cable PVC 70 degrees Celsius, at ambient temperature 40 degrees Celsius according to EN60204, 220230 V 380 440/400 V 2018 HAT 3x25 mm? + 16 mm? 3x10 mm? + 10 mm? 3x10 mm? + 10 mm? 2018 3x25 mm?+ 16 mm 3x10 mm? + 10 mm? 3x10 mm? +10 mm? 2122 HAT 3x50 mm? + 16 mun: 3x16 mm? + 16 mm? 3x16 mm? +10 mm? 2722 3x35 mm? + 16 mm? 3x10 mm? + 10 mm? 3x10 mm? + 10 mm? 2130 HAT 3x70 mm +35 mm’ 3x25 mm? + 16 mm? 3x16 mm? + 16 mm? 2730 3x70 mm +35 mm: 3x25 mm? + 16 mm? 3x16 mm? + 16 mm? 2037 3X70 mm? + 35 mm? 3x25 mm? + 16 mim? 3825 mm? $16 mm? ZUZR AS 3x95 mm? + 50 mm? 3x35 mm + 16 mm? 3x35 mm? + 16 mm? ZUZR SS 3x120 mm? + 70 mm? 3x50 mm? +25 mm? 3x35 mm? +16 mm? ZUR IS 3x185 mm? +95 mam? 3x95 mm? +50 mm? 3x70 mm? + 35 mm? ZUZR90 3x240 mum? + 120 mm? 3x120 mm +70 mm= 3x95 mm?+ 50:mam 28 2970 1345 01Instruction book M ‘earth cable for 60 Hz compressors (for C: ada and USA) For cable PVC 90 degrees Celsius at ambient temperature 40 degrees Celsius according to CE code Part I Tables 2, SA, 17 and rules 28-106, 28-108, 28-110. 440/460 V sT8V 2118 HAT zis 7722 WAT zI2 Z130 HAT z130 z137 ZVZRAS ZVZRSS ZVZR 1S 2190 ZR BxAWG6 + AWG6 3xAWG6 + AWG6 BxAWGM + AWGS 3xAWG6 | AWGS 3xAWGO0 + AWG 3xAWG30 + AWGI 3xAWG3/0 + AWGI SxAWGS + AWGS SxAWGS + AWGS SxAWGS + AWG SxAWG6 + AWG BxAWG4 + AWG 3xAWG3 + AWG3 BxAWGI + AWG BxAWGO0 + AWGE SxAWGO + AWGS 2.3.2 Connection The connections are shown on Figs. 2.14 up to 2.16. 2.4 Cooling water requirements Following requirements are given as a general rule to prevent cooling water problems. [fin any doubt, consult Atlas Copco. Recommended maxima - mg/l Recirculating system ‘Open system Chloride (Cl) < 600 150 Sulphate (S04)... 2.5 vetttesteeetereeesee 400 <250 Total solids <3000 «750 Suspended solids (2s SiO) sen sone 210 <10 Free chlorine (Cly) <4 <2 ‘Ammonia (NH4") Os <05 Copper 05 to <~. (1) is alight, the motor may start automatically. 3. Regulate the water flow with the compressor running ~ ‘If the start/stop timer is active (see section 1.2.1), the loaded. Consult scetion 7.1 for the cooling water compressor can start automatically, even if it was ‘temperature and sections 7.5.3 up to 7.5.9 for the cooling stopped manually. ‘water consumption and air outlet temperature. 2718/87 MOTOR SIDE (1) GEAR CASING SIDE (2) 70 maximus ZT/ZA 45155 GEAR CASING SIDE (2) Z1/2R 75/90 GEAR CASING SIDE (2) MOTOR SIDE (1) ie i> 4 sh "ys t 7 t ll | 75, all ‘ me 3h stilt | CTY 1 Bok 3 Bolt 2 Nut 4 Nut ig. 3.1 Vibration dampers 2020 1545 01 35— FittasCopeo — Instruction book 3.3.2 Starting after emergency stopping or shut- down Press the emergency stop button (S2-Fig. 1.9) (it not yet done so), switch off the voltage and then depressurize the compressor. After remedying the fault, unlock the emergency button by pulling it out and restart the compressor as described above, [the automatic restart function after voltage failures activated (Gee section 1.2.1) and the duration of repair is shorter than the programmed power recovery time, reset the display after remedying the fault: press the key <-Reset>>, the message “<> will appear, whereafier the compressor can be restarted. Press the keys <> and <

> (5) 2). To put the compressor back into ‘automatic operation, press the key <> (5) 2). Important = If the compressor is stopped, it See also section 12.1 ~ Keyswitch (S5-Fig. 9) allows the operator to select four control modes, see section 1.2.3. To avoid unauthorized, switching over to another control mode, take out the key after selecting the required mode. = The control module will only react to anew control mode ifthe new position ofthe control mode switch is maintained for 3 seconds. ay stat automaticaly. Automatic condensate drain outkt, intercooler moisture tap Manual condensate drain valve, intercooler moisture trap Automatic condensate drain outlet, aftercooler moisture wrap Manual condensate drain valve, aftercooler moisture trap Airoutlet valve Fig, 3.2 Air, water and condensate connections (ZR/ZT 45/90) 36 2970 1345 01Instruction book 51207F Low-pressure compressor element Regulating valve, water flow through aftercooler Regulating valve, water flow through ol cooler! intercooler 4 Moisture trap, aftercooler Fig. 33 Water regulating valves on ZR45/55 51228F ‘Air pipe to intercooler 51229F | High-pressure compressor element 2 Water drain plug Fig. 3.5 Water drain plug on high-pressure compressor clement of 2R75/90 3.5 Checking the display (4-Fig. 1.9) |. Rewularly check the display for readings and messages. Normally. the main display (Fig, 1.10) is shown, indicating the compressor outlet pressure, the status ofthe compressor and the functions ofthe keys below the display. 2. Always check the display and remedy the trouble ifalanm LED (3-Fig. 1.9) is alight or blinks. Consult section 1.2 and the "User manual for Elektronikon® regulator”, section "Status data submenu" ‘The display will show a service message if one of the monitored components is to be serviced; replace the ‘component, change the ol or grease the compressor motor as the ease may be. Reset the relevant timer. Consult the "User manual for Elekironikon® regulator", section "Service submenu" Warning Before carrying out any maintenance, repair or ‘adjustment, stop the compressor, press emergency stop bution (S2-Fig. 1.9), switch off the voltage ‘and depressurize the compressor. Notes = Whenever a waming, service request, sensor error or motor overload message is displayed, the free spaces on the 1 2 Low-pressure compressor element display between the function keys (5-Fig. 1.9) are filed 3) Water drain plug ‘with blinking indicators (**), = When more than one message needs to be displayed (eg Fig. 3.4 Water drain plug on low-pressure compressor both warning and service), the messages are continuously element of 27590, displayed for 3 seconds each. 2020 1545 01 37— FittasCopeo Instruction book 4. Regularly press the key <> (5: to call up the actual compressor condition: = the status of controlling the compressor (automatic or ‘manual, local or emote) = the status of the compressor start/stop timer (active or ot) 6) =the maximum working pressure the outlet pressure = the pressure drop over the ar filter (not on ZT 18/37) =the oil pressure =the intercooler pressure the outlet temperature (not on ZT18/37) = the temperatures ofthe compressor elements = the cooling water temperatures (not on ZT) = the status ofthe overload protection ofthe compressor ‘motor (normal or not) ~ the total running and loading hours 1995) 3.6 Manual unloading/loading (Fig. 1.9) ‘Normally, the compressor runs in automatic operation, i. the electronic regulator loads, unloads, stops and restarts the compressor automatically. LED (1) is then aight. [frequired, the compressor can be unloaded manually. In this cease, the compressor is switched out of automatic operation, i.e. the compressor remains running unloaded unless it is loaded again manually. 3.6.1 Manual unloading 2) Press the key > (5). LED (1) goes out. The tanually Unloaded>> appears on the display. 3.6.2 Manual loading 2) Press the key <>(5). LED (1)lights up. The command -Load> does not force the compressor in loaded condition, Dut it will switch the compressor to automatic operation again, ic. the compressor will be loaded ifthe air net pressure drops below the programmed level 3.7. Stopping (Fig. 1.9) 1. Close the air outlet valve (7-1 Press stop button (9). The compressor will run unloaded for 3 seconds, after which it will top, To stop the compressor immediately, press emergency stop buiton (S2). Alarm LED (3) starts blinking. After remedying the trouble, unlock the emergency stop button by pulling it out. 4. Open the drain valves (4 and 6-Fig. 3.2). 1) 5. OnZR, close the cooling water inlet valve. 6. Ifthe 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) and by removing following plugs For ZRAS/SS = underneath the oil cooler For ZR75/00 = undemeath the aftercooler, intercooler and oil cooler = Gig. 34 and 2-Fig.3.5)underneath the compressor elements (On ZT45/55, remove the condensate drain plug ftom the wtereooler and aftercooler, Reinstall them before restarting, 3.8 Taking out of operation AL the end of the service life of the compressor, proceed as follows Close the air outlet valve and stop the compressor. 2. Switch off the voltage and disconnect the compressor from the mains, 3. Shut off and depressurize the part ofthe air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net. 4, On ZR, drain the water circuit and disconnect the cooling water pipes from the compressor. 5. Drain the oil and condensate circuits. Disconneet the compressor condensate piping from the condensate drain net Footnotes chapter 3 1) Corlensate drains forthe intercooler moisture trp are only provided on ZR and 2175/90 2) Irthe <> or > finetion is not indicate on the bottom line of display (4), press key ™ (S) until the function <=Main Sereen> appears above hey (FI), thea press the key <

> 3) ZR and 217590 only 4) ZR only 5) Ifthe function “> is not indicated on the bottom line of display (4-Fig, 1.9), press key <> (5) until function <=Main Sereen>> appears above key (FI), then press the key <

>. 6) The compressor is sulomatically started and stopped if these startstop commands are programmed and activated; consult section 12.1 38 2970 1345 01Instruction book 4 MAINTENANCE Attention Before carrying out any maintenance or repair, stop the compressor, press the emergeney stop button and switeh off the voltage. Safeguard against unintentional "switch-on". Apply ll relevant safety precautions, including those mentioned inthis book. 4.1 Preventive maintenance schedule for the compressor 1) The schedule contains a summary ofthe maintenance instructions, Read therelated section before taking maintenance measures, In servicing, replace all removed gaskets, O-rings and washers, ‘The "longer interval” checks must also include the "shorter interval” checks. Period 2) Running Consult See notes Operation hours2) section below table - 1 Check oil level 8 asl = Check readings on display; on ZTI8/37, also cheek air filter service} indicator 8 - - (Check that condensates discharged from the moisture traps during loading] = 37 7 Drain the aftercooler and intercooler moisture traps after stopping Weekly 72 - Check programmed settings . i - = Drain condensate from air receiver, if installed . a = 4 Check for possible Ieaks Remove air filter and inspect : Clean compressor; inspect coolers e g 1 Yearly 8000 Replace filter of wear easing breather 4 30000 2 Cary outa LED/display test 2 = Replace oil filter 1 Replace air filter Have safety valves tested = - - Have efficiency of coolers tested = = a Have the compressor inspected by an Atlas Copco Service representative = = _ Have operation of sensors, electrical interlackings and components tested] by an electrician Dearly 16000 4.3/5.2 = IF Roto-Z is used, change oil 1 jn the level in the middle of the oil level sight-glass. 2. See "User manual for Elektronikon® regulator" 3. Preferably’to be carried out by an Atlas Copco Service representative 4, Any Teak should be attended to immediately 5, More frequently in very dusty surroundings. 2020 1545 01 39— FittasCopeo Instruction book 4.2 Motors 4.2.1 Fan motor bearings Z118(37 and 275/90 are provided with a fan driven by a electric motor, ZT18/30 HAT are provided with an extra fan ‘motor forthe intercooler. The bearings ofthis motor must be replaced after 25,000 operating hours. 4.2.2 Compressor motor greasing Use a lithium-soap-based grease according to DIN 51 825 K3N. Stop the compressor before greasing. Reset the regreasing service waming3) after regreasing, The data below are valid for an air intake temperature of maximum 40 degrees Celsius, Compressor Interval Quantity type (hours) ® 2018 HAT 3000 Is zis 3000 15 212 NAT 3000 zm 3000 2130 HAT 3000 2130 3000 2037 3000 ZUUZR 4S 2000 ZU/ZR $5 2000 ZU/ZR 75 2000 Z1/ZR90 2000 4.3. Oil specifications Attention Never mix different ols 4.3.1 Roto-Z lubricating oil It is strongly recommended to use Atlas Copeo Roto-Z oil which is specially developped for oil-free rotary compressors. This oil has a long service life and ensures optimum lubrication Atlas Copco Roto-Z oil ean be ordered in following quantities: Quantity, Ordering number Sean 2908 8503 00 20 ean 2908 8501 OL 209 drum 2908 8500 00 4.4 Storage after installation Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times. It the compressor is going to be stored without running from time totime, protective measures must be taken. Consult Atlas, Copeo. 4.5 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. Al service kits are mentioned inthe relevant Paris Lists Use following service kits for the oil filters and air filters: Compressor type Service kit ordering number Zr1837 2906 0545 00 (air filteroil filter) ZT1937 2906 0549 00 (yearly maintenance) ZI/ZRAS/3S. 2906 014 00 (yearly maintenance) ZU/ZR7590 2906 0182 00 (yearly maintenance) Footnotes chapter 4 1) Use only authorized pars, Any damage or malfunetion caused by the use of unauthorized pars is not covered by Warranty oF Product Liability 2) Whichever interval comes first. The local Atlas Copoo Sales Company may overrule the maintenance schedule, especially the service intervals, depending on the environmental and ‘working conditions of the compressor. 3). Sce"User manual for Blektroniken* regulator, section "Service submen" 40 2970 1345 01Instruction book 5 SERVICING PROCEDURES 5.1 Air filter 1 For ZT 18/37, the filter must be replaced yearly or when the red piston of the service indicator (I-Fig. 5.1) shows, completely For ZT/ZR 45,90, the filter must be replaced as soon as the service warning appears on display (4-Fig, 1.9) or yearly. ‘Stop the compressor, press the emergency stop button and: switch off the voltage. Remove the filter. Take care that no dirt drops into the inlet pipe. Install the new filter. Never install damaged or clogged filters. ‘Switch on the voltage and unlock the emergency stop button For ZT/ZR 45/90, reset the air filter service warning. 1) For ZT18/37, reset the service indicator (I-Fig. 3.1) by pushing the reset knob. 51222F 1 Vacuum indicator 2 Airfiker Fig. 5.1 Air fier on 2718/97 5.2 Oil and oil filter change (Figs. 1.2 up to 1.7) |. Run the compressor until warm. Stop the compressor, press the emergency stop button and switch off the voltage, 2. Remove filler plug (5). Drain the compressor sump by ‘opening drain valve (8). On ZR4S,00, also remove the drain plug of oil cooler (18). Close the valve and reinstall the plug after drainit 3. Remove the oil filter (7). Cleanthe filter seat, oil the gasket of the new filter and screw it into place until the gasket contacts the seat, Then tighten by hand, 4. Fill the compressor sump to the middle of the oil level sight-glass (6) with ol as specified in section 4.3. Reinstall the filler plug 5. Switeh on the voltage, unlock the emergency stop button and reset the oil and oil filter service warnings. 1) 6. Runthe compressor for a few minutes; check the oil level and top up ifnecessary to the middle of sightglass (6). 5.3 Safety valves Testing ‘The valves can be tested on a separate compressed ait line. If a valve does not open atthe pressure specified in section 7.3, consult Atlas Copco, Warning Never run the compressor withow safety valves No adjustments are allowed. 5.4 Coolers On ZT, keep the fins of the coolers clean. Remove any dust ‘rom both sides ofthe coolers with a fibre brush, Never usea wire brush or metal objects. Clean by ai jet. Consult Atlas Copco if it should be necessary to wash the coolers On ZR, consult Atlas Copco for cleaning. Footnote chapter § 1) See"User manu submenu for Elektronikon®regulatce” section "Service 2020 1545 01 4— FittasCopeo Instruction book 6 PROBLEM SOLVING Warning Before starting repairs, press stop button (9-Fig 1.9), wait wnt the compressor has stopped, press emergency stop button (S2-Fig. 1.9) and switch off the voltage. Take precautions to avoid an accidental restart Apply all relevant safety precautions, including thase mentioned in this book Faults and suggested remedies A service message appears on display (4-Fig. 1.9) Replace the indicated component, change the oil or grease the compressor motor as the ease may be. Consult the "User manual for Elektronikon® regulator” to reset the message (section "Service submenu”) 2. A shut-down warning message appears on display (4-Fig. 1.9) ig. 1.9) will ightup indicating that a shut-down level is almost reached. Consult the "User manual for Ekekaronikon® regulator" to look for the cause (section '). Remedy the trouble. The warning message disappears as soon as the cause of the trouble is, remedied 3. Compressor is shut-down LED (3-Fig. 9) will blink indicating that the con is stopped dueto a shut-down function. A messageappears on the display. Remedy the trouble, Consult the "User manual for Elektronikon* regulator” to reset the message (ection "Status data submenu") 4. Compressor capacity or working pressure lower than normal 1. Air consumption execeds capacity of compressor 8. Check pneumatie plant b. Safety valves) leaki b. Remove leaking valve and have it inspected ©. Unloading pressure incorrectly set ©. See"User manual for Elektronikon® regulator", "Modify settings submenu" ection Oil pressure too tow 8, Oil level too low Top up level tothe middle of the oil level sight-zlass b. Oil filter clogged b. Replace filter 6. Air temperature above a. Lalet temperature too high due to bad room ventilation or recirculation of cooling air 1. Improve ventilation of compressor room b. For ZR, insufficient cooling water flow or water inlet femperature to0 high b. Check and increase cooling water flow or decrease ‘water inlet temperature, if possible For ZR, restriction in cooling water syste Formation of seale or settling down of ditt Consult Atlas Copeo due to Push button 1 is pressed, compressor starts running, but does not load after delay time Pressure in airnet is above pre-set loading pressure a. Compressor will load when pressure in air net drops to pre-set loading pressure 2970 1345 01Instruction book 7 PRINCIPAL DATA 7.1 Readings on display 1) (Fig. 1.9) Maximum working pressure Outlet pressure aP air filter Intercooler pressure Oil pressure Air temperature element | out Air temperature element 2 out Air temperature element 2 in Air outlet temperature Cooling water inlet temperature Cooling water outlet temperature 7.2. Programmable settings See sections 7.3 up to 7.5.9 Depends on compressor type Below 0.050 bar 3) During unloading 2) Z01837 0.6 bar ZV/ZRASISS OA bar ZV/ZR 7590 -0.610.65 bar During loading 2) Approx. 24 bate) Approx. 1.8 barte) 2) Approx. 165 degrees Celsius 2) ‘Approx. 170 degrees Celsius 2) ZT: Approx. 45 degrees Celsius 2) ZR: Approx. 35 degrees Celsius 2) Approx. 30 degrees Celsius 2)3) Below 35 degrees Celsius 4) Below 50 degrees Celsius 4) ‘A number of regulation settings (e.g. loading and unloading pressures), protection settings (e.g. shut-down level for the temperatures ofthe compressor elements) and service s 1 (e.g oil service life) are programmable. The "User manual for Elektronikon® regulator" deals elaborately with this matter (section "Modify settings submenu"). 7.3 Settings of safety valves Safety valves (pening pressure in bax(e) Low-pressure safety valve(s) High-pressure safety valve 37 Compressors with max. working pressure(e) up to 7.5 bar Compressors with max. working pressure(e) up to 8.6 bar Compressors with max. working pressure(e) above 8.6 bar 88 93 W 2020 1545 01— FittasCopeo Instruction book 7.4 Motor type - settings of overload relay and circuit breaker - main fuses 74.1. Motor type - settings of motor overload relay - main fuses for 60 Hz compressors. Compressor Motor Supply Maximum setting of “Maximum fase ratings ‘ype ype voltage overload relay F21 aL/eG Type? 6) Ww) “ “w 2018 HAT ILAS 183.2 400 28 3x50 2018 ILAS 166-2 230 38 3x10 2018 ILAS 166-2 400 25 3x30 2018 ILAS 166-2 500 18 3x50 2722 HAT ILAS 206-2 400 335 3x80 2122 ILAS 183.2 230 4B 3x10 Z722 ILAS | 400 25 3x80 2122 ILAS 183-2 500) 20 3x50 2130 HAT ILAS 207-2 400 a2 3x10 2130 LAS 206-2 230 58 3x12 2730 ILAS 206-2 400 33 3x80 2030 ILAS 206.2 500 27 3x80 2037 ILAS 207-2 230 R 3x60 2037 ILAS 207-2 400 2 3x10 2137 ILAS 2072 500 33 3x80 Compressor Motor Supply “Maximum setting Maximum fuse ratings gL/gG ype ype voliage of overload relay Type 2 6) ‘Type | §) w) Fal (A) vy a ZUZR AS 1LA6 223-2 230 84 3x160 - ZU/ZR AS 1LA6 223-2 400 49 3x10 ZUZRAS ILA 223.2 500) 39 3x80 ZUZR SS 1LA6 228-2 230 105 3x224 ZUZR 35 IAG 228-2 400 61 3x25 ZUZR 3S 1LA6 228-2 500 48 3x00 ~ ZUZR IS 1LA6 258-2 230 3 2x x20) 3x35 2UZR IS ILA 258-2 400 83 3x20 - ZUZR IS 1LA6 258-2 500 67 3x60 se ZT/ZR 90 ILA6 250-2 230 169 2x Gx2D4) 3x400 ZUZR 1LA6 250-2 400 96 3x20 ZUZR90 1LA6 250-2 500) n 3x160 - 44 2970 1345 01Instruction book 7.4.2. Motor type - settings of motor overload relay - main fuses for 60 Hz compr Compressor Motor Supply Maximum setting Maximmum fase rat ‘ype ype voltage of overload relay CSAHRC UL Class KS ™ FRICSAMUL(A) A) (a) ZTISHAT ILAS 183-2 220-230 34 3x80 3x70 2118 HAT ILAS 183-2 380 31 3x60 3x60 zis HAT ILAS 183+ 440-460 27 3x60 3x60 zri8 ILAS 166-2 220-230 a7 3x80 3x70 Zs 380 27 3x60 3x60 ZTI8 4440-460 23 3x60 3x60 zig ILAS 166.2 575 18 3x60 3x60 2122 HAT ILAS 206-2 220-230 ot 3x25 3x150 2122 HAT ILAS 2062 380 40 3x80 3x70 7122 HAT 1LA3 206-2 440-460 35 3x80 3x70 z122 ILAS 183-2 220-230 s4 3x80 3x70 Z122 380 31 3x60 3x60 Z122 440-460 27 3x60 3x60 z122 ILAS 183-2 375 20 3x60 3x60 130 HAT ILAS 207-2 220-230 7 3x200 3x75 2130 HAT ILAS 207.2 30 3x80 3x70 7130 HAT 1LA3 207.2 43 3x80 3x70 2730 ILAS 206-2 0 3x125 3x150 7130 ILAS 206. 40 3x0 3x70 2130 IAS 206: 35 3x80 3x70 Z130 ILAS 206-2 7 3x80 3x70 Z037 ILAS 207-2 37 3x20 3x75, 2137 1LAS 207.2 30 3x80 3x70 2137 1LAS 2072 43 3x80 3x70 7137 ILAS 207.2 33 3x80 3x70 2020 1545 01 45— FittasCopeo Instruction book Compressor Motor Supply Maximum Maximum fuse ratings ype ‘ype voltage setting of eleG — gligG = CSAHRC UL Class KS a) overloadrelay Type 2 6) Type! §) (A) rN) FOIA) a “a ZUZRAS IAG 23-2 220.230 ” 3x20 7 7 ZUZRAS1LAG 223-2380 37 3x25 ~ = ZUZRAS 1LA6223-2 440-460 48 ~ 3x80 3x70 ZUZR4S LAB 515 38 - 3x80 3x70 ZUIZRSS 1LA628-2 220.230 121 3224 - - ZV/ZR SS LAG 228-2 380 0 3x25 = = ZUZRSS ILA6 228-2 440-460 60 a RRS 3x12 ZUZRSS ILA62282 575 a7 = = 3x80 3x70 ZUZR7S 1LA6258-2 220.230 165 2x (3x20) 3x355 - ZUZR73 LAG 258-2380 93 3x20 - - ZUZR75 LAG 258-2 440-460 83 = 3x150 3x50. ZUZR7S LAG 258-2575 64 = 3x25 3125 ZT/ZR9 —ILA6250-2 220-230 201 2x G2) ISS “ ZT/ZR90 LAB 250-2 380 Ms 3x20 - - ZUZR90 LAG 250-2 440-460 100 3200 3x17) ZT/ZR9 —1LA6 250-2 S75 7 3xI7S5 3175 74.3. Setting of fan motor circuit breaker for 50 Hz compressors Compressor type Supply voltage (V) Maximum setting of circuit breaker Q25 (A) Maximum setting of circuit breaker Q26 (A) Z18/30 HAT 201837 201837 201837 217590 2175/90 2175/90 380-15 200-240 380-415 500 200-240 380-415 500 26 45 26 175 1 10 47 46 2970 1345 01Instruction book 744 Setting of fan motor circuit breaker for 60 Hz compressors Compressor type ‘Supply voltage (V) Maximum setting of Maximum setting of| circuit breaker Q25(A) _cireuit breaker Q26(A) 271830 HAT 220-230 39 93 ZT18°30 HAT 380-460 28 225 771830 HAT 575 28 1.96 zr 1837 48 - zris37 380-160 28 ZT1837 375 215 z Z17590 220-230 10s “ 2175/90 380-460 39 - 2175/00 575 4a - 7.5 Compressor specifications 7.8.1. Reference conditions Absolute inet pressure... escseeeeeeeeeeeeeeeeeeese Banta) 1 Relative air humidity... oe tee 0 Air inet temperature coictiteteestecese Celsius 20 Nominal effeetive working pressur bar(e) see seetions 7.5.3 up 10 7.5.9 Cooling water inlet temperature (ZR only) Celsius 20 7.8.2, Limitations Maximum air inlet temperature - 271830 HAT. SaReEETSNANNEE . Celsius $0. sOthint ascinsressrte pesnsteviencacecs Cokie 40 Minimum ambient temperature... ....eceeceeeeceseeses Celsius 0 “Maximum effective working pressure barfe) see sections 7.5.3 up 10 75.9 “Maximum cooling water temperature: Atinlet Celsius 35 At outlet Celsius $0 ‘Maximum cooling water inlet pressure bar(e) 7 75.3 Specific data of 2718/37 - 50 Hz 1) 2718/30 HAT 2018 Z12 z130 Maximum working pressure barte) 86 86 86 Nominal working pressure bate) 8 8 8 Air temperature at outlet valve Celsius 26 7 28 Motor shait speed min 2940 2945 2945 Power input at maximum working pressure 9) kW 228 265 353 Oil capacity Il 21 21 au Sound pressure level 8) .. ce . Bia) 79 0 9 2020 1545 01 a— FittasCopeo — Instruction book Others ZUI8 2122213902037 ZTIB 2022 ZN3O.— 2137 Maximum working pressure.. bare) 75 75 7S 78 86 86 86 86 Nominal working pressure... bar(e) 7 7 4 7 8 8 8 8 Air temperature at outlet, VONC .cccsccssvevssesese Cobins 26-27-2830 630 Motorshaftspeed.......... r/min 2930 2940--2945-=«2945 «2930-2940 --2945 2945 Power input at maximum ‘working pressure 9) kW 21854 MAS MAL Oil capacity V 21 21 21 21 21 21 21 21 ‘Sound pressure level 8) ..... dB(A) 70 R 8 mM 2 45 76 75.4 Specific data of 2718/37 -60 Hz 1) 201830 HAT Z0i8 2122 2030 ‘Maximum working pressure bare) 86 86 86 ‘Nominal working pressure bare) 8 8 8 Air temperature at outlet valve Celsius 26 27 28 Motor shail speed esetaevs min 3540 3545 3545 over input at maximum working pressure 9). kW 26 298 393 Cileapacity.....-. ee. 1 2 2 21 ‘Sound pressure level 8) aA) 79 1” 9 Others gris Z122 21302137, ZT18_—Z122,— «21302137 Maximum working pressure. bare) 7.5 75 «7S 75 8G BG BH 8G Nominal working pressure ... bar(e) 7 7 7 7 8 8 8 8 Air temperature at outlet VaNC .eccsecsesecseesese Cebus 26 9 27 2830, 2687830 Motorshaftspeed.......... nmin 3530 3540.—«3S45.—«3845—3530 384035453548 Power input at maximum ‘working pressure 9) kW 04227877 ALD. Oil capacity V 2 21 21 2 21 21 21 21 ‘Sound pressure level 8) ..... dB(A) 70 n 15 %6 7 2 7 16 48 2970 1345 01Instruction book 7.5.5 Specific data of ZT/ZR 45/55 - 50 Hz 1) ZUAS | ZTSSZTASZTSS—ZRAS—-ZRSS_—ZRAS—_ZRSS Maximum working pressure. bar(e) 7.5 7S 86 = -8H_sTS TS BGG ‘Nominal working pressure ... bare) 7 7 8 8 1 7 8 8 Air temperature at outlet Valve ose ceceese Celsius 3030 3030 30 3230 2 Motorshat speed.......... rimin 2960 2965-2960 29652960 ©2965-2960 2965. Power input at meximum working pressure 9) kW 494612482 HMO SRB AAO Oil capacity 1 34 34 FI 34 34 Moa 34 Sound pressure level 8) aB(A) 75 76 5 1 78 75 16 Cooling water consumption at temperature rise of 15 Celsius Us = = 7 - 068 0.80 0.66 0.82 75.6 Specific data of ZT/ZR 45/55 - 60 Hz 1) USA version zs ZT45 ZTSSZRASZRSS—ZRASZRSS Maximum working pressure. bar(e) 7.5 7S BBHRHOCTS TS BHR Nominal working pressure ... bar(e) 7 7 8 8 1 7 8 8 Air temperature at outlet valve Celsius 3030 30300 32302 Motor shat speed vimin 360 3570 -—3860-««-3570-—«3860 «357038603570 Shaft input at maximum, working pressure 9). KW ABS GID ABA ART OD ARGO. Oil capacity... eee cece U 34 34 4 34 34 34 3a 34 Sound pressure level 8) aB(A) 75 16 75 6 75 75 16 Cooling water consumption at temperature rise of 15 Celsius Us = = 7 = O71 089071089 Others 20S 2TSS—2T4S—ZTSS—-ZRAS_—ZRSS_—ZRAS—ZRSS Maximum workingpressure.. bar(e) 7.5 7S 86 BHTS: SHR ‘Nominal working pressure ... bare) 7 i 8 8 1 7 8 8 Air emperature at outlet valve Celsius 3030 30 300 2 30 Motor shalt speed vimin 3545 355535453585 3843. BSS 38453555 Powser input at maximum ‘working pressure 9) kW S14 G48 SIA 6G SLO GSTS HT Oil capacity ' 34 34 4 34 34 MW 34 Sound pressure level 8) dB(A) 75 76 75 16 78 % 78 16 Cooling water consumption at temperature rise of 15 Celsius... Us « ~ - - 071 0890.71 0.89 2020 1545 01 49— FittasCopeo Instruction book 75.7 Specific data of Z1/ZR 75/90- 50 Hz 1) ZT75 2190 ZR7S.—ZROO_—ZR7S—_ZROO Maximum working pressure bate) 8 8 8 8 10 0 Nominal working pressure bar(e) 7.5 78 18 «SSS Air temperature at outlet valve Celsius 28 308 32030 Motor shaft speed : min 2970 2970 2970-2970 2970-2970 Power input at maximum working. pressure 9) KW 841 100626977 D9. Oil capacity 1 B45 MSS SS 29S ‘Sound pressure level 8) dB(A) 75 16 5 16 75 %6 Cooling water consumption at temperature rise of 15 Celsius Wo = = Wooo 4 75.8 Specific data of 2T75/90 - 60 Hz 1) 2075 2190 2075 2790 Maximum working pressure « arte) 18 15 86 86 Nominal working pressure . bare) 7 7 8 8 Air temperature at outlet valve Celsius 28 32 28 34 Motor shatt speed fin 3565 3565 5565 3565 Power input at maximum working pressure 9) kw 92.6 105.6 906 106 Oil capacity 1 34S MS 345 345 ‘Sound pressure level 8) dBA) 15 16 15 16 75.9 Specific data of ZR75/90- 60 Hz 1) ZRIS—-ZROO—ZR7S—ZROO.—ZR7S—_ZROO Maximum working pressure arte) 7.5 7S 86 8610 10 ‘Nominal working pressure bare) 7 7 8 8 9s 98 Air temperature at outlet valve Celsius 30 2 0 2 30 oR Motor shaft speed min 3565 3565-3565 «356535653565 Power input at maximum working pressure 9) kW 906107, 889107903109 Oil capacity 1 2S 2S 2S WS WS 29S Sound pressure level 8) BA) 75 16 8 16 15 %6 Cooling water consumption at temperature rise of 15 Celsius We 12 Is 12 SS so 2970 1345 01Instruction book 7.6 Conversion list of SI units into British/American units bar 4.504 psi 1 y= 0035 02 kg =2.205 tb 1 kmh = 0,621 mie 1 kW = 1341 hp (UK and US) 11= 0.264 US gal 11= 0.220 Imp gal (UK) 11= 0.035 cu.tt Im=32818 1mm =0.039 in 1 m3/min = 35.315 efin 1 mbar = 0.401 in we 1N=0.25 Tht Nm = 0.738 Ibe ‘x degrees Celsius = (32 + 1.8.x) degrees fahrenheit 7) Footnotes chapter 7 1D) Atrsference conditions. See sxtion 7.5.1 2), The readings are typical values which may differ depending on the compressor type 3) Not shown on ZTI8/7. # NotonZt 5) Disturhance of contactor andor overload relay may occur (i damaged, the component must be replaced). 6) No damage will occur the overload rely 1) Atemperature ditferene of | degree Celsius ~ a temperature difference of 1.8 degrees fahrenheit 18) According to PNEUROP / CAGI test code under fee Field conditions at I m distance with a tolerance of = SAB, 9) Values may differ up to 0.5% depending on the supply vokage 2020 1545 01 st