‘ S Instruction Book for Stationary Rotary Screw Compressors ZR3-ZR4-ZR5-ZR6 Pack Def unit corset # Me 4h aie he JahanCompressor| | SAFETY PRECAUTIONS FOR STATIONARY COMPRESSOR UNITS In aaiican % no:matsalaly rules wiveh should be ob strvee with sistonary ar commesenr, te. folowing niet dreciona and besauions re of specs impo" bipeee te smoloy safe work precto=s and to Tne onnor se reponse for ty me compressors mainte in gate operatne.condion Compressor ‘ort and actoasonge gral be felgced unausble Yor fale operavon, Inaalaten,eperation, mamtonance ene repar aha! ony be petted by autnorza, Waihegcompatan pers Ceca roungs presses. tomporattes, wne-sotunas fis) shat be auraby marked 34d maintanes any statemen: in ths Bo0K especially wit eagard to ety does nt comaly with foeaogiiaton, the steer OF the two shal aay. Tn orecaunons are general nd ove several comores cor None and saupment. Meroe some. sates ma tot aaply fo bw unt aascnged tha book (See also the Ane Gopee Commressor instalation Narva’ ‘Azar fom ganiral engimeznng eracuce confom. with the rogulanons 0 toca! autionty he folowng srctves 1 Any blanking Hanger. plugs oF c8Pe ae wall as even: fea! doaizcan: age anal De femaveg before canna 'ng uo the Dione Diawnuton pose ang someckons Shall be of sotaet aie ond Wisi far the working 2. Pace te sombrentor wnere the umbiont a HE a6 00! an clean go poesibie Mi recesyaty mia! see fon duct Gave sna beter 22 rime the eny of Trowtire wot te mist ai 5. The aspwsted oir enall oe fos om fammable fumes or apour ep vers, Pt cane 0 re wey mat an aoeqiate few of tooling gro ayaiadle fn Sat the cuba owe rot ral 9 the le. fear an wou sign seeing DANGER: THIS COMPRESSOR 15 REMOTELY CONTROLLED AND MAY START WnHOUT WARNING. [Aso furthor soepuatd porsone ewishing on amoley Conalied. comprescors sal! tke sdnquteprechu lone wo enoute ir thore en ene checking of wate tng on te compresaar To the and #sutebly worded rouse shale eigad to te mer eGuomett 6 ln muttpie unt compressor eyatem= marial valve ‘hal bn cai to alate each somreseer. Gnsce “avs anal nor 8 roled upon for lating pressure 7 Dp not remove of tnnar stn the softy deve ‘pear Vsuladong Fed! or the corprassor Every ptesbute vessel or aunlary Mtaied ours "Re unt contin aw above atmosphane. press Fall be prtecied hy w prescurerelwng gevnee oF Govioee as roqucod xu B Ppmwark of other part wih an extynal surface temperate ie excess of DO ('TSE) and wich may bo eoeidantaly touches by peaonnel ie nama oper Shon ofall be guarded or navited. Oer hgh 8 IF the unt Foundation snot level or ean by subject to Vangblninsinater, consuit tae Capea Open 1 iF ar noces are ueea, they shell be of covest ze 4nd sible Tor te working prasture Cone veo fovoe oe and soe si nose one hinge and =r Fechone Won bowng through nase eneute at the op0n ong te helo seourely A tae en wil Wp tnd couse mpuy Never Gi comproseed ot ahs ‘oreo than using Tor eating sows equipment Ma Eo wth extras caiion and use eye protection Do not aise eomeressor ar 1 pretting. unlese Ieswn fe be propery sunted for ue use 2 Do not aperate tho corors860" in surroundings whore inere is porsbiy oF thing wp fammasie o fone 2 De aot operas the compressa a prapires below 0 Inveneess of iterating as indicteg on the Princip bate shoot 4. Al canopy doors shall Se anst uring eneraton 5 Paople saying 7 compresscrracma were the suns ‘exceeds 0 8B(A) eral use 2a" pro Paricaly check mat fo puntos are m piace and acne 4 noses anslr pings aren Bood eondten. secure fre not ant ng stra are ny loans a tastners ave tant fall ect! esas 270 secure and on good order + pressure (ela! davens ore Pot cbsiructed By art Maintenence Maintenance and repair work shal! only be extred out by tdsauately tamed persone 1 reauras under ipervaion oF someone. quate for che ob. 1 se ony se ore tale for maintananee and reper Use oniy genuine sare pant ‘all only be undertaken when tia comereasor i ‘Stopped! a he maine a stone aff Ene a ‘pent cannot bp marae advent, 4 Belore renewing ary mreasunzed comzonont fee vay isolate he unt fem all sources of aes ne vshave the ontre syrem For pressure De nat use Fammasie soivents for cesring par. Observe seruouiows clearness during maintenance tnd who petting. reeare. Keeg drt twty, be Seven the prt and ewened Spang wh F 1 De not weld or parfoim any sther operation ive fhg heat near the of system’ OF tne mute co ere purged, 0 ay stewn cleaning, before ear tng ov su3h oparations, ny way mod any pressure wee 1 Make cure tat ms yout, looze parts cr rags are ltt tor on the compressor, te atime mover oF he Ceving gear Before olsaring th unt for use aftr mantenance oF ‘ree end te-zetings. are correct end that the Ccomol ane ahst-down eaviees Mncton Sura 10. Every six monte examine the discharge pipe and charge pulse damper for carvan devote |All respon for any damage or inury resin ‘eam neglecting these precautions, oF By none te handing, operating, nmtanance 8 rena, sven 1 fot exprenaly monsoned rn he. DOOR oll Be Gacinmed by Alas Capes,SAltlas Copco 8 283/6-50 Instruction Book for Stationary Rotary Screw Compressors ZR3-ZR4-ZR5-ZR6 Pack zA3 2R3 2R3 zRa zAa 2R4 na Applies to units ARP ARP ARP. ARP ARP ARP: ARP ARP ARP ARP ARP. ARP. ARP. from following serial numbers onwards 490.212 481 765 a2 234 38 495 042 497 378 498 125 499 12 483539 494 260 485 018 486 196 487 128 499013 ATLAS COPCO AIRPOWER n.v. — B-2610 WILRUK — BELGIUM ‘AIRPOWER — Printed Matter No. 70615THIS INSTRUCTION BOOK daseribes now the subject rotary screw compressors shauld be operated to ensure optimum working economy and sence hfe Reas thie book potore putting te compressor into operation. Thie Is a pre Feauiste #F the machine Is to recewve praper maintenance from to beginning ‘The maintenance schedule contains a summary of the measures for keeping the compressor in god repair Tha maintenanes procedures are simpig but must be carted out regulary Always nave the book available and foliow the insyuchons carefully at the periodic overnauls, and major inspectons. Record the running me, maintenance work offected, oi replenishments. temperatures. repairs, oyernauls, etc. in an pporator's logbook, Compressor repair operations should be performed by spe- cally trained personnel, available at Aas Copco service outlets Wf nny farmer information Deyond that contained in this book 1s desired. please get in touch with Atas Copco Ir all correspondence concerning this compressor and esaecialy when ordering spare parts always mention the unit sens’ qumper, stencilled on the data plate fixed 10 the compressor The company reserves the right to make changes without prior notice. When operating thie compressor unit, the aperator is expected to emoloy ‘safe working practices and tu observe any related legai safety requirements. It shall be the owner's responsibility to assure that the compressor Ip main tained in a safe operating condition, Compresaor parts and accessories shall be replaced.f unsuitable for safe operation, Operation, maintenance and repair shall only be performed by authorized, trained, competent personnel Critica) ratings, e.g. pressures, temperatures, time-settings, etc... shall bbe durably maintained. 1 bar = 100 kPa = 1.02 kg/cm’ = 14.5 psi Contents Page 1 LEADING PARTICULARS 3 33 Preveotve maintenance schedule for the 1 General description 3 compressor * 1.2 Compressor air flow 6 33.1 Notes on maintenance schedule 1.3 Coaiing water eystem 7 23.2 Readings on gauges 114 Lubricating system 7 34 Lubrication 18 Unloading system - 9 38 Storage 15 Electrical system and safety devices 39 eee anne yeneaia 4, ADIUSTMENTS AND SERVICING 61 Operation and trouble’ shooung 13 a 2, OPERATING INSTRUCTIONS 13 4.1 Setting of the air pressure switch . 21 Pregaration for initial starcup 3 42 Avr intake filter 22 Operating grecauons 18 42.1 Flecommendations 23 Each ume before starting 16 422 Servicing 22 Starting 16 423 Cleaning the eartrdge(s) 2.5 Compression staring ie 43 Ol fier : 28 During operation 7 44 Unloader assembly, safoly valves and 27 Stopping 7 swtchas 3 175, PROBLEM SOLVING 7 32 Balsty precautions 6, PRINCIPAL DATA Page 18 13 19 20 20 20 2 at 2 a 2 a 2 261 Temng gore 2 for beernge 3 End plate * i 5 Socting aeke! 10 On euver pon. 5 Mate rovor 11 Brain hole, bearing Sealing packages air leak 12 Balancing piston Ft 1. Leading particulars 4.1 General description ZR Pack machines ore stationary Gwo-of c00es, sieetric motor driven rotary screw c which daliver completely oil-free ar. water smpressars, Compressor unit The compressor unit has one iow pressure and one high pressure compressor element, each individually bolted ta the housing of a common steo-up gear. The power from the motor és ransmitied to tre step-up goar shaft through a fiexible coupling ensuring vibraton-ree running and power transmission, Zhe compressor a furnished with a data plate on which ‘era stencilled the type, serial number and maximum permissible working pressure, The electric motor 18 also prowded with a data plate sway view of 3 Z compressor wlement Drive arrangements ‘The comareasor/motor unit is mounted an e base frame im ane of two motor drive arrangements, ie, Arr. E and Arr. i, In At. E the motor is directly flanged to the com pressor step-up gear casing by means of an adapter housing. The power is ansmitted through a rupber bolt type coupling and the unit 1s supported on vibration dampers at three points on the base frame, In Arr. 1 ‘motor and compressor are separately mounted on fa sub-frame, supported on the base frame on vibration damgers, The coupling 1 of the flexible multiisk stee! type. Compressor elements The compressor elements are designed for working pr sures(e) of up to 105 (182 psi). The maximum working pressure(e) of M version units 16 limited to 85 bar (123 psi). Standard Arr. E units are equipped with an ei trie motor rated for a maximum working pressur BS bar (128 pel)of ZA E compressora. ash AS: asi 82, BR, BE) — process Ain —— cooune warer ow =~ CONDENSATE DRAINS coNTROL AIR Fig 4. Flow diagram of ZAG (tnat of ZR5, -4 -§ unite w sighay differant) Compressoe unit ‘A intake itor Ae Outiet silencer, HP comprector element die eae shencer Air outlet sensor, ( comaresser element essing Sitereveie Bleed coater Imorevoler Flexo drive coupling Check vaive: ° Brain plug, pulsation damper Expansion eomponcators HP compressor elament LP compressor element Eisciric regulator Step-up gear casing Working pressure gauge Iinercooter pressure auge ‘ompressed air outlet 822 526 828, svt 8v2 i Ua. w Ye ‘Ay temperature shut ‘down safety switch Bices-of pressure ‘ghutsdow safety swntoh Bir oraesure awitch Ingercaoler ie! valve(s) HP safety vatve(s) ‘sr iiet tote. va've Unloader evinder hese aero HP Unloading valve Leading solenoid vaive Lubricaing systom V1 By-pass valve, oi! pump EV? by-pass valve. oi fiter oe Os Ont Drain cock compressor Ds Goo. Gi! pressure gauge Pot fitor oS OF. Oil pump OT Oi! Sumo. step-up gsar easing Fi. Flow restrictor Unigader eireut temperate gauge Airintake fer serie indiator Fir let vite asin Prime mover: : Molture vp, | aftercooler Masture rap, intercooler Futsaton eames, Biena:of preveurs swith Figs. 2, 8 and 4 ona aatey owtch enone Bena 925. Dini Drain vaive, intercooler ‘erecolor DA, Drain racener, via, Me Ritercosiar cooking water cutot tamperaiure sor cooling water outlet temperature gauge ‘Paarmometer {on Zi oni) ‘Taermometer, intercooler tooling water creuit {on 286 ony) Regulating cock atereoolar cootin eater tow Regulating. cock comprester cooing Feguiating cock Imtercoaler cooling wwater Row (on 2R6 ony) wi Numbered toms on Figs Beads 2 3 Cooling water inlet pipe to blesg-off cocter Blowof! inlet pip 10 ised of cooler Unloador piston cover Air intake aperture 8. Balancing piston cover UP ‘compressor emer! Comoressed at outer be, HE ar ‘outlet lence ‘2 shorcoole: Eoaing weter net pee Date plate Bh inlet pe to ot fraument pene! Bind panot MD ty dyer conra and incletor pare rrountod hace, W inetd Geontol and indistor Panel, perspe fron plate fenoved We Sabi ery vox leuiaar cabinet Combrossor cabinet Pipe 19 working. resure enge Sent rpe to and trom Mlorescer dram recover Compressed ir owe oe Sensing element, com preseeg si outst fompesuire gauge Coning water met spe storcoier Drain ctl pipe, Iretesien moire tap Bind Hanger conection for hot ar pe to MD an ayer Gonoral views of 2Fe E compresiar (canopy partly stipped) ond Flow diagramEach compressor element comprises two screw-type pre~ Cision machined meshing rotors, mounted on ball ancl roller bearings. There is no surface contact between the rotars and their casing The male rotors driven by the step-up gear and the female rotors are synchronized through @ set of timing gears which maintain the slight clearance between the male and female rotor lobes. The male rotors have four lobes, the female rotors six flutes. The male rotors consequently revolve at 1 Vp limes the speed of the female rotors. The absence of metal-to-metal contact between the rotore and also be: tween the rotor crests and the compressor casings eliminetes the possibilty of wear of mese parts and power loss through friction In order te provant air and oil leakages along the rotor shafts, sealing rings held in special retainers are fitted fon the shafts. Waved spring rings maintain an axial pressure on the sealing rings, but they are otherwise free for radial self-adwustment, The sealing packages located next to the compression space prevent air leakage and those located next to the rotor bearings prevent the lubricating oll from entering the compressor space, To provide an absolute safeguard against the penetration ‘of ol! into the compression space, drains are provided for evacuating any oil that might gather between the ll and air sealing packages. Lubricating system ii ie used for lubricaung the rotor bearings, ung gears, driving and step-up gears, The or! system includes 2 gear-type oll pump, @ water-cooled oll cooler and a fullslow ol filter, Cooling system Water is used throughout for cooling. The compressor elements have cooling jackets for that purpose. An aftercooler maintains the temperature of the discharge far within specified limits, The moisture content of the discharge air is reduced in the water separator incor- porated in te aftercooler The tubes and end plates of all the coolers are made of stainless steel. The cooling water system includes regulating cocks and thermometers for controlling the outler water temperature, Safety devices (On ZR3 Pack ums, a roliet valve orotects the intercooler and @ safely vaive the aftercooler and HP side of the compressor ZR4 unvts have two relief valves. ZRS units have one and ZR6 units have two safety valves for the protection of the aftercooler and HP side of the com- pressor, the ntercosier is protected by two relief valves. ‘A check valve in te HP air outlet silencer (ZR3, -4) or outlet pipe system (ZRS. -6) prevents blow-nack of compressed air from the main air system dunag the 6 compressor off-load parlode ar when the motor stope unexpectedly, while the compressor is connected te an air main with other compressors. Pressure and thermal switches safeguard the com: pressor in the event of te high alr temperature, oll pressure or bleed-off pressure failure Canopy The electric motor, compressor, coolers, oll filter, ete are all enclosed in @ modern sectional pressed steel sounc-insulated canopy, witn doors providing easy ac- cass to the comgressor for normal maintenance. The front pane! of tre canopy comprises a bipartite cubicle The canopy also incorporates an alr intake silencer with air intake filter element(s). Electric equipment The operation of the unit is governed by an eclectic regulator, comprising @ blocking relay t prevent an automate re-start If and when the compressor has been stopped through te action of any of the safety switches, [Al| tke componente of the regulator are housed together with the motor starsng equiament in the “regulator eab- met” of tho cubicle, the door of which carries the ‘centro! and indicator panel The safety switches are panelsmaunted in the “com: pressor cabinet” of the cubicle, which also serves to hhouse the electrical control unit of the MD air dryer, if Installed, The doar of this cabinet carries all the pressure land temperature gauges, and may also comprien tne, contro! and indicator pane! of the air dryer Service exchange elements Atlas Conco service outlets have avaliable LP and HP compressor elements, ready-to-fit and tested-to-factory standards, for immediate replacement on machines due for overhaul The elements are easy to remove and 10 Install on the compressor step-up gear casing. Down- time 18 reduced to 2 minimum while the need far mayor repairs im the field ie eliminated. Compressor siemonts are NOT to be dismantiod fr sinpped ey customers, After an element has been taken off the compressor it should bo re turned to Atlas Copeo for reconditioning, this in ‘order to benefit the customer with a "service ex change system" 1.2 Compressor air flow (Fig. 4) Aur drawn through the filter element(s) (AF), air intake silencer (ASi) and inlet throttle casing (IM) into LP comaressor element (El) is compressed, then cischargad to intereoaler (Ci) where the air temperature 1s brought down to within @ specified range. The cooled air then enters HP compressor element (Eh) \ where st 1s further compressed and discharged through outlet siiencer (ASh} and HP check valve (CV) te after cooler (Ca.4» During full rated capacity operauan of the comoressor fay inlet throttle valve (TV) \s fully open and HP un- Toading valve (UY) closed. The valves are simultaneot closed and opened respectwely by loading solenoid valve (¥28) through the spring-loaded diaphragm sealed riston of the unioading system, when the working pres Bure rises above the pre-set maximum pressure. Under this condition, the air pressure of the HP eler te released to the atmosphere vis unloading valve (UV), bieed-of? eoolen’s) (Cb) and the air iniet casing (iM), resulting n alosing of check valve (CV). The throttle valve fs designed s0 as to leave a slight a passage in the closed posinan, Thus, a limited quantity of air continues to ne drawn into the compresnor in order to maintain the pressure rabo over the HP element at & reasonable vaive ‘An air-operated balancing piston (BP) 18 fied behind the maie rotor cear thrust bearing af each compressor sloment These pistons decrease the load on the front male rotor thrust beanngs during loaded operation During the load periods the LP balancing piston is ac- tated by air at intercooler pressure (see "Unioading system") and the HP balancing piston by air at HP. Outist pressure (see Fig. 4), while during the off-load periods both pistons are in communication with the atmosohere: A compressed air outlet temperature gauge (Gth), an Intercooler pressure gauge (Gpi), a working pressure gauge (Goh). intercooler ralief valves (SV1} (one on 289) and a HP safety valve (SV2) (two on ZRG) are comprised in the cireut, as well ag a high alr temper- ature smiicn (S22) and a bleed-off pressure switch S24), the function of which are described uncer "16 Elecinical system and safery devices 1.3 Cooling water system (Fig. 4) 2R6 The cooling water system is divided into three eircults one for the cil cooler {Co} and comaressor elements (El and Zn), one for the intercooler (Ci) and the two bleed-off coolers (Cb), and one for the aftercoaier (Ce), The cooling water leaving the oil cooler first flows through the cooling jacket of the LP compressor elo- ment and then through that of the HP element. All circuits are provided with a regulating cock (Vic, Vfi and Via). Tne two firstmentioned circuits have a thermem- eter (Twe and Twi) fitted in the outlet piping. 29, +4, -5 The cooling water system of these units is different from that shown on the flow diagram, as it consists only of two circuits; one for the compressor and one for the aftercooler. way to the compressor elements the cooling “e-water first passes regulating cock (Vic) and olf cooler {Co}, and then, successively, the intercooler (Ci), bleed off cooler (Cb), caving jacket of tha LP compressor ‘lement (El) and from there to the cooling jacket of the HP compressor element (Eh), from where It is drained “The aftercoolers of ZAS anc ZRG units have wo and three cooling elements respectively. The cocling water for tre aftercooler (Ca) 1s branched off uostream of the compressor cooling water regulating cock(s} and is rainec directly The intercooler and each aftereosier element 1s provided ‘with a morsture tap (MT ang MTa). each connected to a condensate aran receiver (DR) and DRa) with an automatic float valve for draining condensate during aeration of the unit, and © manually operated drain valve (Dts and Oma} for sraiming the recewvers after the Unit has bean stopped. The compressor and afterceoler cooling water circuits comprise @ temperature gauge (Gtc and Gta), the sens- Ing elements of which are fitted in the drain pipes. For Fepuiating the water flow through the attercooler, a cock (Vfa) 1s fitted in the drain ripe, “The cooling jacket of the compressor elements consists of two interconnected compartments, the Jower parts. of Which are connected external!y by @ pipa for draining urposes. Other arain points are also provided. & drain cock snouid be fitted by the user in the lower part of the main coeling water inlet pipe for draining most of the water from the cooling system. When the unit is stopped and freezing temperatures are expected, the ecoling system must be drained completely. The cooling water shall be free from sold impurities, The content of calcium compcunds or similar scale forming substances should preferably not exceed 100- 120 mg calcium oxide (CaO) per iire. The use of “hard” water. that is water with a relatively high calcium compound, should be avoided 28 it will bring about se- cimentation and the formation of scale in the whole cooling eystem. 1.4 Lubricating system (Fig. 4) Oil from the all sump (OT), located in the bottom of the step-up gear casing (GC), 18 pumped through the lubricating system by a gear-type 2 pump (OP) mounted fon the front of the step-up gear casing, The pump is gear-dnven from the compressor main drive shi The cit é pumped through the water-cooled oll cooler (Co} and from thore it passes through the full-flow (twin) cit Filter (OF) before entering the LP and HP compressor olement oil pipes and ducts to lubricate the front and rear rotor bearings, step-up and timing gears. From the diferant compartments the oil then flows back to the oll cuma A by-pass valve (BV!) in the oll pump housing opens ‘and allows oil to by-pass back 19 the sump whenevar the maximum permissible pressure Is exceeded on the Gelivary side of tha pump. The step-up gear casing Is vented f the atmosphere through a breather. A by-pags valve (BV2) in the header of the olf Filter (2RB and ZM4) or in each of the oi! filter elements (ZRS ‘and ZA6), opents) when the pressure drop over the 7@aqv01 YOsssuANoo aaavorwn HOss3u4Noo }—seafilter 1 above normal due to clogging of the filter element(s). The il will then de pumped unfiltered to the lubricating ponts. Regular filter maintenance is there- fore imperaave, as unfitered oll may eventually lead to bearing failure. ‘An off pressure gauge (Gpo}, as well as 2 low oil pressure safety switch (S25) and @ loading solencic valve (¥28) are incorporated in the system. ‘Apart from lubrication, the oll under pressure is also used to open the air inlet throttle valve when the solenoid valve ig energized by the electric regulator (ER). A Festrictor washer (Rf) is fitted in the all return pipe of the solenois vaive. Thus, when the valve Is activated, sufficient oi! pressure will prevail in the system upstream of the restrictor for operating the unloading mechanism. 1.5 Unloading system (Fig. 5) Basically the unloading system is an on-off system, operated by an air pressure switch wnich senses the pressure variations in the air discharge system The function of the system is to control the air output of the compressor in relation to the air consumption of the equipment connected to the air net and to maintain the pressure in the alr net within 2 selected range, ie. between the pre-set upper and lower limits of the working pressure. ‘The air delivery control ie effected by closing the com- pressor air inlet whereby air delivery is completely stopaed (0% air output). At the same time, the com- pressor is unloaded by the opening of the air discharge outlet to the air iniet unstieam of the throttle valve. Compression is resumed to the full rated capacity (100 % air output) at the end of the unloading period. Unloading/loading The pneumatic side of the air pressure switch (S26) Is connected to the air discharge pipe, the electrical side to the electric regulator If the air consumption is Jess than the full rated capacity of the compressor, the pressure in the air net will Cb. Bieed-off cooler DPS. Drain plug, puistion UP. Untoader piston UV" HP cunloading. valve damper ‘Y26 Loading solenoid velve ER, Electne regulator 5 Fiterea AIR IN IM. Air inlet throtie casing. To LP compressor PD. Pulsation dempee element RE. Oi flow restrictor ©. From HP air cute S24. Bleec-olf provsure silencer ‘efaty ewiten| fe To Balancing platon 526, Air pressure. awit "TV. fue inlet tittle valve UA Unloader assembly When the aressure in the air net has reached the pre-set Upper jimit of the working (maximum) pressure, the air pressure switch ($26) will be operated by air at working pressure , the electric contact of the switch opens with the result that loading solenoid vaive (¥28) is de-ener. ‘ized through the electric regulator, This will cause the unloader assembly (UA) to operate, i.e. the throttle vaive (TV) to close and the HP unioading valve (UV) t open, The air delivery is now completely stopped, the compressor runs unloaded (9% air output) It the pressure in the alr net decreases to the pre-set lower Jimit of the working (loading) pressure, the con- tact of the alr pressure switch closes so. that the solenoid valve ig snergized again. Unioasing is stopped, the throttle vahe opens, the HP unloading valve closes land the air delivery resumed to the full rated capacity ‘of the compressor (100% output} The unloading and loading pressures are the opening ane closing operating pressures of the alr pressure ‘teh The unloader assembly comprises a shuttle valve (8) fone side of which ie actuated by of prassure admitted to chamber (11) from the comaressor lubricating circuit The other side le actuated by spring pressure. The loaded and unloaded operation cycle of the com. pressor is a6 follows Loaded operation The pressure in the air net is less than the pre-set maximum pressure and the contact of alr pressure switch ($26) Is closed. Under this condition 1. Loading solenoid valve (28) ts energized ; olf under pressure is present in chamber (11). 2 Starting plunger (10) and shuttle valve (8) have moved against the spring force of plunger (5). Port {@) ts closed and port (7) open 3, Switching valve (3) admits air at interovoler pressure ( to the balancing piston of the LP compressor eie- ment and to chamber (2) of unloader piston (UP) via chamber (6). The atmospheric pressure inlet port of the switching valve is closed. F Connected to inereaolsr 4, Chamber, atmospheric 4g Airat working pressure, pressure Binet from lube ail circu —&, Unloader plunger 1, Outlet to sume 6, Shuttle valve chamber 1 Chamber, piston spring springloadaa side sige 7, Imereaoier pressure port 2, Chamber, piston 5 Shuttle. valve pressure side 9. Vacuurn pore 3. Diaphragm type 0. Starting plunger . pwiching vale 11. Chamber, ll from Tavieating circuit Fig. & Unioader aacomby4 Armosonenic pressure 1g present in chamber (1) o! joader piston (UP) The pressure difference newsen chambers (1) and (2) Keeps throttle valve (TV fully ‘oben and MP unloading valve (UV) closes The compressor delivers ite maximum rated ouRput Unioatled operation Tae pressure m the alr net (g) nas reacned the pre-20 maximum pressure The contact of the air pressure t Solenord vaive (¥28) 1S de-energized and tne oil pressure consequently released from chamber (11) Plunger (10) and shutte valve (8) are moved by soring force , intercooler pressure alr iniet port (7) 18 closed, Part (8) 18 open 3, The intercooler oressure 18 released from champe (2) and repiaces hy atmospnenic pressure This causes springrloaded unloacer piston (UP} to close throrte vaive (TV) and to open HP unloading vaive (UV) fully The comaressed air present between the HP compresgor element and the unloading valve 1s blown off through pleeceaff cooler (Cp). the check valve upstream of tne aftercooler closes and prevents blow. back of romnressed air from the net 4, As 9008 es the shrattie valve has closed, @ vacuum prevails in unioader piston chambers (1) ane (2}. ang In the intercooler (8 as well. This causes switching valve (3) 19 operate so that atmosphanc pressure read of air at intercooler pressure is agmitted 10 the balancing piston of the LP compressor elemente) This condition will prevail until the pressure in the air net has decreased to the pre-set loading pressure of the air pressure suitor, ‘The compressor can at all times be manually unioaded by means of toggle switen fitted on the contra! panel also preciuded from auiomatic loading after starting: up through the same switch 1.6 Electrical system and safety devices Arrangoment E compressor units are completely equip- ed ane wires, and require anly connection to tha maine supply line. The electrical system comprises the follow: Ing main components Electric motor with terminal box Mater starting equipment Transformer for eontrol voltage Electric regulator Satety devices Motor starting equipment The starting equipment and basic electrical service diagram of the motor are not dealt with in this Book, a5 they depend on the type of motor installed. The basic elecvical service diagram 1s, however, supplied with the to 822 s24 922, HP ar niet tompers- S26. Air pregeure awn ture safety switen Y28. Loading solenore 824, Bloos-off pressure ye safety owen fompersture sethng 825 Oi pregaure safe nab Fig. 6. Comoressor panel of ZFS, -4, -S unite Electric regulator and safety devices The electric regulator and safety devices are housed In a cubicle consisting of two cabinets, named regulator land compressor cabinets. The regulator cabinet also houses the voltage transformer and motor starting equip: ment Compressor cabinet Safety devices in the form of pressure and thermat switches are connected to various points of the com- pressor They serve to automatically stop the electric motor and thus prevent damage resulting from a dan gerous operating condition, All te switches are mounted ‘and grouped together with the air prossure witeh and leading solenoid valve on a panet inside the compressor ‘cabinet, the door of which also carries the instrument panel The switches ave connected to the clectne circult of the regulator via a terminal strip. The contro} pane! of the regulator has individual fault indicator lamps. If en fbnarmal or dangerous aperating conditian arises during vunning, the operative switch will break the circuit to the regulator, thus causing the motor to stop and the fault Indicator lamp of the switch concerned 20 light up. The lighting of the lamp assists in tracing the cause of the All the switches with their characteristics are listed in the table,Safety switches in compressor cabinet Contact Setting valve et, | Designation | Connected to | Tripping cause | Unit at rest | Unit eunning : ———| Breaks at | Makes at el ‘open | cu ‘Oper | Closed. 825 | 01 pressure | Ourer ping of ol] Oil preseure too | + . $22 | HP ar inet] Intercooler aw out] Iniercooler av . . temperatura | let manrote uti tempers ture" 200 ah - ‘824 | Biesd-o® | Pulsation samper, | Blead-of ores : . pressure wich ie ms tun | sure t00 high Connected 10 bleed | wien camprecso tf piping own. | 6 unioades Stream at HE une ‘823 | OF tempera. | Ou cooler outler| Ov tomperature . eo | aoe fore fon ZA6 | pipng too hig i6F units only) \ Altenlion : The switches are adjusted at the factory, De not sel the temperature switches to oper their contact at_& highay tomperature If the unit has ahut down through the action of @ safely switen, the foult shoule first be waced and remedied before 9 new starting attempt 1s mode Regulator cabinet Basically the compressor control equipment, which is housed in this cabinet, is an on-off reguiatar with builtin delay circuits for timing the required interval before the compressor is loaded when started up (loading delay) and before the electric metor is stopped after the com- pressor has been unloaded {idling del The regulator adapts the operation of the comoressor, i.e, loading, unloading, stopping and restarting according to the variations in the compressed air demand, and serves to protect the compressor and motor from over: loads. When the current is switched off at the end of the working shift or after @ power failure, it also takes care of automatically unloading the compressor The regulator consists of a relay panel, and a contrat and indicator panel attached te the door of the cabinet, The wires between the panels are grouped in a plastic sheath, Relay panel (Fig. 7) 1e pane! comprises two time relays, 13 relays, two voltage transformers, four fuses and 9 terminal strip. The function of tre time relay for delayed Ioading (KB) is to temporarily break the circuit to the loading solenoid valve (Y28 - Fig. 6) and to override the oil pressure safety switch during automatic starting, The relay should make the zircult to the solenoid valve eaprox. 20 seo: fonds after the RESET/STAAT button on the control panel has been pressed. By this time the motor should have reached its normal operaung speed and the oll pressure switch should have closed. This switch i¢ normiaily open when the motor is stopped and the oil pressure zero, it closes when the ol! pressure 1s normal ‘A toggle switch (83 - Fig. 11) for manually breaking the erreut to the solenoid Is provided ee CEES i) ow 1 (from the top downwards) 10-= KSt = K32 - KBB - Xa ow 2 (rom the top dowawards) Ki Ke = KS = Ka Ke = Kr = Ka KIT ki = xt keat = Ke See legond of Fig. & for denomination of comy + Components of starting equipment F21 Thermal overload relay Delta contactor me cen, tanidelte sthgy 2022104) we) SuNSSaWs 10 cH a ‘uy s2e0}p4, 1 Nouwuado auvNoLAY zt wea ses, ‘55, ves es GVOTHIAD HOLOW SH ‘de 2s soweapput ne) eimereayial Li swoysuen yg 0804 Zt ued soseasduey —yo-perid bjs) Umop-IMYS STING IY aH MEN Satan ‘vAOog Yew ‘49638 s0.0u! Jo wonduinsuED JoHKOL 1x dans uo fo “posn sy si 209 YBewo098IpThe ume relay for delayed motar stooping {K10) las the frequency of motor starts during aperatian by de: termining the period dung which the compressor runs, Linloaded withaus wnterruption I. 18 normally faciory-set for a compressor idling period of anprox. 20 minutes. The setting may Be changed, as required, but is imited by the maxmum permissible number of motor starts ner hour (consult mator data) Controt and indicator panel (Fig. 11) The panel comprises the following switches, lamps and indicators Nanking Deseriotion and tunetion RUNNING TIME Hourmater iagieoung t0ta! cunning me Py ft comprassor mater UNCOADINGAMAL Toggle switch fax manually unloadiny 89) the compressor > TOADING TIME Hourmeter rabcaung: tot lnaded run. 2) hing te of comoressor une RESETISTART Dutton to stan compressor and sn eae: operative regulator shulesown. re Toy. ang) smultaneousty stort uns or ater a foutt has ocpurred STOF 82) Push button to stop compresion ay VOurAGE ON Tnaicator lamp Tor signaling that vo (ane) CF fe ne been switches on ane supplied fe starting age control gguipmiert. AUTOMATE Indicator lamp for signaling thal regu OPERATION lator is ready for stating the motor (green) (42) Fema aight aller starting and during forma! operation Wii go out I's safety device tnos due to a” aénormel pers ting. condion ic PRESSURE Ged) (3) Fou aot ame Tae ub wi i pressure slay ch taste to oe oregon Woon AIR TEMPerature Fauk maicator lama lights up when ME HP INLET {rec} (H4) ir inlet temperature safety wer Sets" eto temperature of av leaves einieagiar bang:ton high. The reG4 tor tape. the. motor = a WMOTOR OVERLOAD GA indicator amp: ughie UENHODn (oe) (48), Overload relay trgs, wich ha “ashen the molar current exceeds 2ermic bible macmuneThe regulator sto>e the moter BLeeo.OFF Faull indicator lamp hghte up jwien PRESSURE (red) _bleed-off pressure safety switch heads (55) ido 100 hugh pressure at the monfont he comoreeser’ ie unloaded. Tho Iator stops the motor " Boe Foult inteator lamp hghis ub whea.ol temperature safety switch reacts to {00 ‘On ZRB unit only GIL TemPerature (98) (482) high an ‘ol temperate. The requftor On ZAS, -4, -§ unite: Lamp is cannected to requlaiér Be blank used for axdtonal cafaty device “AEH ‘Hany (ea), Blanc eT Balety device, regulator Ente full mdcator lamp for acdphal fame te ane * In the standard version, the ingut terminals provided thr the Biditonal controls ave bridged; thus, tne spare fault ndi+ Estar lamps. always tight up wher the voltego is. switches 2 (lama tee) though ty are nt actually vowed th No lamps are installed behund the thrse windows (K = Fig. 11), they are avaitable for eventual extra controls, provided that adaptation 1s made 1.6.1 Operation and trouble shooting A separate ASB (Service Bulletin) dealing with tne operation and trouble shooting of the electric regulator ts available on request 2. Operating instructions 2.1 Preparation for initial start-up On af Acr € uni. ascertan that the wooden wedges ace removed from between the motor and com pressor coupling flanges 2 Make sure that all the bage with silcage! placed in the mosture {199 of the intercooie: have been removed The bags are aceesaible after removal of the adhesive tape closing off the marvfold tiange bottom anfice {finstal-te morsture trap flange ané connect the pipe fo! tg drain receiver to the flange after removal of the Silicagel bags. 3, On an Arr { unt supplied extactory with @ motor Mcheck the motor alignment as it may have been istucbed during wansportation or ietaliation 4 Check the drain piping. The lines should pitch slight'y sowawards, away from the compressor The open Sends must never dip inte the water of the sewer, °F Make sure that the water supply is connected and * open to give proper flow, @ Fil the compressor sump to the MAX. mark on the J. dipstick with ol as species in section ‘34 Lupri cation”. Do not overfl 7. Check the electrical connections, which should be in accordance with local codes, The electrical source ‘must have the seme voltage and frequency as in- Hicated on the motor data plate. Have the electrical sonnections to the power source made by a qualified electrician ‘The installavon must be earthed and protected against short circuits by cartridge fuses of the inert type in + all three phases. A circuit breaker should be Installed In the immediate vicinity of the unit > Check for correct direction of rotation as indicated by the arrow on the motor housing, On Arr. E units, the coupling can be observed trough the access open ings in the motor to compressor adapter housing Stop the compressor immediately after the slightest Indication of rotation. If the rotation direction is wrong, reverse two of the input line connections. 8 Chack that the connection at the primary sid2 of the transformer for control voltage correspands to the supply voltage, Connect the voltage selecting wire(s) to the correct terminals, |23 pine HP fen, COMpreBsor met cock eomoreator oF side 2ZR6 compressor9 Remove the bridge between terminals 15 and 16 on regulator stp Xt, if #1 desired that the electric motor will not be cut out automatically approx. 20 minutes after te compressor kas been unica 2.2 Operating precautions Distribution pipework and eventual a hoses muisi be of comesi sie and suitubia for the working not use frayed, camaged or dotenoreted hnoses Use only the correct type and size of hose end firungs and connections When biovang through @ hase, ensure that the open fend 18 held securely A injury Do no! play with camaressed ar Never apoly 8 to your skin or direct it at another person Naver use Daa Zr 4 Daa Automate ain cuties Di Draw mooie DA Dean nate drain outlet, © On 2h wetorcooter inlet pire Draw valve, ofercadler dain Gn ahs Bie Grpin valve. ytercooler rn * Accessible 3 5. In case af remote control, aravide the A to clean dirt from your clothes. When using it for cleaning down eawupment do so with extreme caution and use the required protechan Do not use compresees air tor nreathing, unless it 18 known to be properly purified for a Do not operate the compressor in surroundings where risk of taking in flammebie or toxic fumas Do not operate the camressor at pressures in excess of is rating as indicated on the Principal Data he doore shall be chur curing operation, People stay Ing in compressor rooms where the souns pressure level excoeds 90 d3(A) shall use ear protectors with an obvous warning reading © DANGER. THIS COMPRESSOR IS REMOTELY CONTROLLED AND MAY START UNEXPECTEDLY land the remote contrat pane! with a sutably worded notice for the aperacar to fret make sure that the compressor 1s clear far oneration before starting, ie thar a Gne iS cheskang oF working an the anv easing water inlet ope Fig 10 Condensate rainsi t 2.3 Each time before starting Check the ol level Top up, necessary. to the MAX. mark on the dipstick (DS = Fig 9) with the correct type of lubricating ait 2 Check that the condensate drain valves (Dmi and rma - Fig 10) of the intercooler an eceivers are closed. aitercogier drain 3 Oheck that the cooling water dr installation) in the main inlet fine is closed Check that toggle switch ($3 - Fig 11) 16 pla the UNLOADed position 5 Open the main cooling water inlet valve 6 Open the water flow regulating cocks (WFe and Via 9} of the compressor and aftercooler cwrcuits. On ZAG, also open the cock (Vii - Fig. 9) of the miter ‘oles and bieed-off covier This step can be dispensed with if, after previous operation of the unit, the above-mentioned cocks have not beer closed afer stopping 24 Starting (Fig. 11) 1, Switch on the voltage at the main circuit breaker and check that tle VOLTAGE ON lamp Hi. lgnts| up All red fault indicator lame H3, Ha, H5, HOt 132 and H33 also light up (lamp teat), except AUTO. Matic OPERATION lamp HZ Pross AESETIS that AUTOMATIC OP: VATION lamp ag that all the red lamas HS. H4, 45, H31, H32 and 13 are out wat_hourmeter AUNNING TIME Pt ie counting the total motor running time. 2. the lubricating oil pressure (Gpo - Fig, 12), Intereooier pressure (Gol 12), Instructions regarding the number of starte a. With regard to the temperature rise im the rotor windings of the motor, the number of nermal starts should be limited to maximum four starts per hour An interval of 15 mines between each start should be observed. 8. In order to limit the frequency of motor stans during the automatic operation eyele of the unit, the time relay for delayed motor stopping (K10 - Fig. 7) should never be set for a compressor idling period shorta than 15 minutes, A seting of a shorter period is only permissibie i connection with an operstional test, Do not adjust the setting when the voltage Is switched on. e. W the motor is prevented from starting by ary me. chanical cause, only ane exira start in the course of tracing the cause of the trouble can be made in one Pi $3 P2 s1 se Hi vouTaGe ON 0° lame faut Mise" OPER. lame 9 OIL PAESSURE faut RUNNING TMi indicator ame Houmeier, compressor ie High HP Al JADING Tie TEMPERATURG /START pust STOP push button ule cat0= lamp UNLOAD edNORNHAL Spare taut tame compressor operation Spare foul amp on toggte 5 ZR. OIL TEMP. X Duty windows rote fauk indicator om Fig 17 Control ond ineieator panet 25 Compression starting 1 Qven the compressed alr outiet valve 2. Move 10 83 to NORMAL to open t air niet throttle valve and load the compressar Check that hourmeter LOAD! ME P2 records the npressor loading time As soon as the pre-set working pressure is reached fand registers on gauge (Gon - Fig. 12), the air pres sure switch will unload the compressor. Hourmeter LOADING TIME P2 then stops counting 3, With the compressor running loaded, regulate the cooling water flow through the main compressor This is only necessary when fa the unit te started-up for the first time b. the water flow regulating cos! closed after stopping (5) should rave boon «the setting of the cock(s) shavid have been acc dentally disturbes ar slight resetting is required For optimim operation, \©. for efficient cooling tn the intercooler and te avoid excessive cooling in the bleed-off cooter(s), the coeling water outlet temper. ature or the difference between the inlet and outlet water temperatures should be as shown in section 382 Readings on gauges On ZAS, -4, -8 units, the water outlet temperature is controlled by cock (Vic - Fig. 9), ZAG units havetwo cocks (Vic and Vii Fig 9) installed «m the main cireuit, The cooling water outlet temperature 6 indi tated on gauge (Gte - Fig. 12). and on ZR6 units also fon thermometers (Two and Twi - Fig. 9). Turning the hhand wheel of the cock{s) clockwise will increase the water outlet temperature On ZAG units, adjust tne twa cocks until the same temperatures register on the gauge ang the two ther- mometers 4 Under load congition, adjust the cooling water flow through the aftercooler by means af cock (Vfa - Fig 9) to obiain the most suitable water and compressed fir outlet temperatures (Gta and Gth - Fig. 12) 2.6 During operation Consult section "3.3 Preventive Maintenance Schedule’ under "Daily 2.7 Stopping 1 Move toggle ewiteh $3 to UNLOADed 2, Press STOP button $2, at which AUTOMATIC OPERATION lamo H2 ges out and the compressor stops The VOLTAGE ON lamp Ht, as well as the fault Indicator lamps 43, Hé, HS, H31, H32 and H33 will remain alight as iong as the voltage has not been ewitoned off at the man circuit breaker 3. Close the main cooling water inlet valve, and the compressed alr outlet val 4 Open the drain valves of the intercooler and cooler drain receivers, Close the valve of the fatter after the condensate has been drained 5. When freezing temperatures are expected. drain the cooling system compictely by opening the main drain cock {customer's installation) and by removing the drain plugs from the intercooler and LP compressor element water inlet pipe, the vent piug on top of the Intercooler inlet fiange and the two copper pipes that Interconaect the cooling jacket compartments of the LP and HP compressor alements 3. Maintenance 3.4 Electric motor Refer to the motor manufactures’s Instruction leaflet and data piate for full particulars of motor maintenance, The absolute nacessity of using the correct type and quantity of grease for lubricating the baarings, and t greasing and motor air path cleaning intervals are Specinlly stressed. If operating in @ rather hazardous en- wronment. clean the air path at shorter intervals. 3.2 Safety precautions Maintenance end repair work shall only be carried out by adequately tvaines personne! In addition to the many normal common sense safety rules, which should be obsorvec with this type of fmacninery. the following additional safety precautions fare specially stressed, 1 Use only the correct tools for maintenance and repair works. 2. All maintenance work, other than routine sitention, shall only be undertaken when the compressor is stopped. Ensure that the unit cannot be started is advertentiy. og. by taking out the main fuses and placing @ warning tag on the fuse holders gad control pane! Before removing any pressurized component, effec: twvaly igalate the unit from all sources of pressure, land relieve the entire system from pressure. Do not, rely on check vaives to isolate pressure systems, 4 Do not use fammabie solvents or carbon tetra: chioriae for cleaning parts. Take safety precautions against toxie vapours of cleaning liquids such as chiorinated hydrocarbon, 5. Observe scrupulous cleanliness during maintenance and when performing repairs. Keep dirt away by cov- ering the parts and exposed openings with a clean cloth, peper or tape. 6. Do not weid or in any way modify any prossure vessel. Do not weld or perform any other aparetion involving heat near the oil system. 7, Make sure that no tools, loose parts or rags are left in of on the compressor or its drive parte 8, Before clearing the unit for use after maintenance or overhaul, check that operating pressures and tem= peratures are comect and that the control and shut- down devices work correctly All respensibiity for any damage or injury resulting from nneplecting these precautions, ar by non-observance of jrdinary caution end due care required in handling, operating. maintenanee or repair, even iF not expressly, mentioned in this book, will be disclaimed by Atlas Cope.3.3 Preventive mai compressor Tho schedule contains a summary of the maintenan instructions. Turn up tenance schedule for the section dealing with the cam ponent or part concerned and read it through carefully before taking any maintenance measures. Whichever irene eration Notun | Seaton Check unlosdng and lading pressures Gph heck intercooler presure Gp Check oil pressure Gpo see Check aftercooler water outler temperature Gte a DALY | cmc compressor male ote ensesive Gc fig 12 rt | chuck camressee ar tet temperate Git tours | Check at inibke fier sevice indestor Gv Check oil level before stating we | sat Dram condensste fom intercooler and altercooler drain receives after stoping 27 Choc hat connote 6 dashed rom nace anatase: dain rece cheng ona ; wa | aos Dian condensste tom pulsation damper of Beetoft pressure safety swtzh ws | oan weexiy | Ciean down uni sr every | Drain condense fom, a recover, i insole 0 hours Chee roo els neta ass and ube, Ton lang co ‘cone race damaged goskels ©” Mace me | aan Every @ | Romove alr inake flor elements): clean by ar jt end mapact 422 MONTHS: Clean breather of step-up gear casing: M5, 331 have biting oll rabeed. Fy arabes cane ota ol ar clanento) MB | gat $ Dismonto nd clear fost valves of dan receivers Replace a sniske fitor stamens) aa Replace roting d8ph-00m of unlooder piston wo | aa Damas nd leaect parte of unlonder cyinder Road assonbly vo Femave and Inspect rutber chaphragn of compressor cipment balancing pistons] MO Remove and inspect chnck valve vo ee Test safety valves: Mg 44 Tet safety witches wo | aa hack cooling efcency of wiorooior and altecooler Prossure test al the cooler) ¥T/MO Meanure pressure ratio oF eompreseer lemon van Hove gratin of wc ieoking, motor tava tesa by o qui (On ave, chuck motor alignment ws On Aor mepect rubber bushes of coupling M033.1 Notes on maintenance schedule M1 Alwaye maintain the level near the upper mark and never allow * 10 drop to the lower mark an the aipstie On ZA3, -4 unite, the breather assembly must be removed from the otf filler pipe when lubricating oil 18 te be added, and each time the oi! 8 changed Never add oi! through the breather. M2, Take immediate remedial action if the automat drain of the intercooler does not discharge conden: a sate. a5 this may cause damage to the HP com. pressor element, IF te unit cannot be stopped, slightly open the manial rain of the inter’ drain receiver to prevent the condensate from en: tering the HP element M3. A drain plug 1s provided on the damper The most inwerval between draining operations may be determined by exaerience, a8 the amount of indensate mainly depends on the operating con- ditions Fig. 12. Inawument panei gauges 33.2 Readings on gauges I I ] et Marking Indies Fading | 8 | ns | ph Compressed air (net) pres Modulates during loading, depend: | | medic ownateat of fag. on a eonaimpian “AR un: | | Iogeng ‘between "man, and” min. | | resol vauen oer Fresco pevaling belveon LP ond |e. Dung unending, veoun bo AB Sonprocear elements 30" ane tes bar (SIS ont coresponcing | Seeninas Sete) G25 aae During landing: between 2:27 j° ere: @O30 pei at norma | wonng ressur Geo | OW PRESSURE BI pressure Tv an Woe ator a | Average 23 bare) (99 pagh Should | Ble! oC be alowed to crop Below 1 Sere) Go "sao) Gia “TEuPeratre, stwrcaoier | Aftecooior cooing water outer [1&a00 (@TS0A) “* above thar of temperature Icomang cvelng water durng oad : ina . Gte ‘Compressor cooling water outiet |15-30°C (27-54°F) ** sbove that of vemporaare Incoming cooing wate, during teat | ie e 16 | om Compressed ar temperature Innes | Novoally 10156 CAPA) above S Siatay str “ahtrroclen cooing. water inet temperate Sr a actu prevaling botwoen ‘Wiien pointer reads 48 mbar (1 | snd UE Compronsor element fr tha | wo} comes sp to roa tne. or Purse ef dating wen titer | Fold Suing” “osdg, servic ea | Barend) 1 are) cogana rep) Nyr ant" eacans jodging the condition of the machine by the inlercaaiar praseure, remember that st mainly varies in dect proportion fe baromavie pressure and fo a lesser extent with the working pressure, ambient temperature and cooling water inlet Never set the cooling water flow regulating cacks for 6 water outlet temperature sxceedng SC (122) without authors ation of an Jilas Cazco eerview reprocentatve 19Ma. Especially check the LP and HP balancing piston pipes. Repair even the slightest leak. Replace dam- aged or pinched pipes. An inoperative balancing piston means overloading of the male rotor thrust bearings, which may cause serious damage. MS. Remove the breather, dismantic and wash the two stee! mesh pads in diesel fuel oll or some simitar cleaning solvent. Wash the sinter bronze filter disk in tnichiorethylene. Dry the parts with compressed assemble and reinstall the breather M6. Have sample of oll analysed in specialized labora tory to determine if i 18 oxidized or deteriorated beyand the rejection limits, Based upon the of sample analysis the optimum ell change interval can be established, IF the oll ts not analysed, it should be changed yearly Change the ol! as follows drain the compressor sume and ol! coaler A drain cock is provided on the sump and a drain plug on the cooler, Close the cock and reinstall the plug after raining. Re- placo the oll Alter element(s) Refill the sump to the upper mark on the dipstick: witn fresh oil of the correct type, Remove the vent plug on top of the ol! cooler and fil it with the same type and brand of oil, Reinstall the olug Stact the unit and run it for a few minutes; check the oll level again, Top up, if necessary M7. The difference in temperature between the incoming water and the outgoing air of the intercooler and aftercooler should never exceed 25°C (45°F) during loading. Use a sensitive thermometer of the sur face contact type (electric) to measure the temper atures at the various paints. Have the entire cooling system cleaned if the cooling efficiency is insufli- lent MB. Special gauges are to be used and a record of the measured values should be kept over the years of operation of the unit, Based on this record the sondition of the compressor elements can be judged Ma. These operations should preferably be carried out by an Atlas Copco service represontative, 34 Lubrication The use of a high quality TURBINE OIL. contsining rust and oxidation inhibitors, and having good water separa tion properties is recommended. The viscosity grade should be ISO VG 65. in conformity with the specitieae tions of ISO 3448 (International Organization for Stand ardization). In order to cover a wide temperature range the viscosity index should be minimum 35. The following grades of the most commonly available brands of TURBINE OILS have bee. found suitable. Equivalent grades of other reputable makes can of course also be used, Once a brand has been adopted, keep to it. Never mix different brands or gradee of oil 20 Make Grade Moke Grade eee0 | Toresso 88 Kosmo! TL 68 ae | Energoi THE se Perfecto T 68 Golf| Hormony 68 | OC Turbine oi 6 hat | Turbo ot T 68 Turbolt 68 Total | Preslia 68 Bokola 68 Mooi | DTEheay mediun | Texaco | Regal oi! R&O 3: Hydraulic alls with @ vscosity grade conform to ISO VG. 68 may also be used. If in any doubt, consult Atlas Copee. The rejection Himits are ae follows = Water contents: max. 0.1 % = Total acidity number: max, 1 TAN = Non-soluble contents + max. 0.08 % 35 Storage ‘An ASB (Service Bulletin) dealing with storage before ‘nstaliaticn, es well as with storage after operation is available on request 4, Adjustments and servicing procedures 4.4 Setting of the air pressure switch The adjustment of the unloading of the compressor is effected by means of the air pressure switch (S26 - Fig, 13) installed in the compressor cabinet. The pressure switch controls 1, The maximum operating pressure(e) in the range of 11-85 bar (16-123 psi) on Arr, E and M versions, and 114-105 bar (16-152 psi) on Arr. 1 unite, b. The pressure difference between the pre-set maxi- mum pressure and that at which compression is resumed (loading pressur Before any adjustment is made, always ascertain that the pressure witch breaks the circult to the ioading sole noid valve (¥28 - Fig. 13) when the pressure in the compressed air discharge system has reached the pre- set maximum pressure, and that the control oil from the unloader assembly is drained ss otherwise the compressor will not unload (see Fig. 5). Also ascertain that the loading solenoid valve is energized at decreas-\ Ing pressure in the air discharge system and that control oll is admitted to the unloader assembly,