Instruction book

Atlas Copco Stationary Air Compressors ZH6000 - ZH10000 - Two-stage With PLC Controller

Instruction book

Copyright 2003, Atlas Copco Airpower n.v., Antwerp, Belgium. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. This instruction book meets the requirements for instructions specified by the machinery directive 98/37/EC and is valid for CE as well as non-CE labelled machines.

Note: The PED instructions for this machine are included at the end of the book.

Registration code: APC ZH>4000 2-stage / 38 / 991

2003-02 No. 2920 1485 00

This instruction book describes how to handle and operate the subject machine(s) to ensure safe operation, optimum working economy and long service life. Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from the beginning. The maintenance schedule comprises measures for keeping the compressor in good repair. Keep the book available for the operator(s) and make sure that the compressor is operated and that maintenance is carried out according to the instructions. Follow all applicable safety precautions, amongst others those mentioned in this book. Repairs must be carried out by trained personnel from Atlas Copco who can also be contacted for any further information. In all correspondence mention the type and the serial number, shown on the data plate. The company reserves the right to make changes without prior notice.

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CONTENTS

Page

1 LEADING PARTICULARS.........................................................................................................................................4 1.1 General description .............................................................................................................................................4 1.2 Air flow.................................................................................................................................................................8 1.3 Condensate drain system ...................................................................................................................................8 1.4 Oil system ...........................................................................................................................................................8 1.5 Cooling system (Fig. 1.3) ..................................................................................................................................14 1.6 Electrical system ...............................................................................................................................................14 1.7 Programmable Logic Controller - PLC..............................................................................................................15 1.7.1 Controlling the capacity of the compressor ................................................................................................15 1.7.2 Protecting the compressor .........................................................................................................................16 1.7.3 Monitoring components - service warning..................................................................................................18 1.7.4 Checking the start conditions .....................................................................................................................18 1.7.5 Controlling the lubricating oil system..........................................................................................................18 1.7.6 Start commands during minimum stop time...............................................................................................18 1.7.7 Automatic restart after voltage failure.........................................................................................................19 1.7.8 External compressor status indication .......................................................................................................19 1.7.9 BUS connection system .............................................................................................................................19 1.8 Control panel (Fig. 1.9) .....................................................................................................................................20 1.8.1 Display (1-Fig. 1.9) .....................................................................................................................................20 1.8.2 Control buttons/keys/pictographs/lamp (Fig. 1.9) ......................................................................................21 1.8.3 Pictographs below display (Fig. 1.10) ........................................................................................................22 1.8.4 Buttons below display (Fig. 1.10) ...............................................................................................................23 1.9 Menu-driven control programs ..........................................................................................................................25 1.9.1 Main screen ................................................................................................................................................25 1.9.2 Calling up the Main menu and other menus ..............................................................................................25 1.9.3 Returning to the Main menu and Main screen ...........................................................................................26 1.9.4 Screen saver ..............................................................................................................................................26 1.9.5 Main screen menu ......................................................................................................................................27 1.9.6 Configuration menu ....................................................................................................................................31 1.9.7 Settings menu.............................................................................................................................................32 1.9.8 Service menu..............................................................................................................................................38 1.9.9 Timer menu ................................................................................................................................................42 1.9.10 Saved data menu .....................................................................................................................................45 2 INSTALLATION .......................................................................................................................................................47 2.1 Dimension drawings (Figs. 2.1 and 2.2) ...........................................................................................................47 2.2 Installation proposal (Fig. 2.3)...........................................................................................................................49 2.3 Mounting of outlet piping ...................................................................................................................................52 2.3.1 Rubber compensator types ........................................................................................................................53 2.3.2 Alignment tolerances (Fig. 2.5) ..................................................................................................................54 2.4 Cooling water requirements ..............................................................................................................................54 2.4.1 Type of the system .....................................................................................................................................54 2.4.2 Cooling water parameters ..........................................................................................................................54 2.5 Pictographs .......................................................................................................................................................58 3 OPERATING INSTRUCTIONS ...............................................................................................................................59 3.1 Preparation for initial start-up............................................................................................................................59 3.2 Compressor control modes...............................................................................................................................60 3.3 Before starting...................................................................................................................................................61 3.4 Starting ..............................................................................................................................................................62 3.4.1 Routine starting ..........................................................................................................................................62 3.4.2 Starting after emergency stopping or shut-down .......................................................................................63 3.4.3 Number of motor starts...............................................................................................................................63 3.5 During operation................................................................................................................................................64 3.5.1 Checking the display ..................................................................................................................................65 3.6 Manual control of compressor operation ..........................................................................................................65 3.7 Stopping ............................................................................................................................................................66 3.8 Taking out of operation .....................................................................................................................................67 4 MAINTENANCE.......................................................................................................................................................68 4.1 Preventive maintenance schedule for the compressor 1) ...............................................................................68

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4.2 Motor greasing ..................................................................................................................................................69 4.3 Lubricant specifications.....................................................................................................................................69 4.4 Storage after installation ...................................................................................................................................70 4.5 Service kits........................................................................................................................................................70 5 SERVICING PROCEDURES ..................................................................................................................................71 5.1 Air filters (Fig. 5.1).............................................................................................................................................71 5.2 Oil and oil filter change (Figs. 5.2 and 5.3) ......................................................................................................71 5.3 Demister (Fig. 5.5) ............................................................................................................................................73 5.4 PLC battery change (Fig. 5.6)...........................................................................................................................74 6 PROBLEM SOLVING ..............................................................................................................................................75 7 PRINCIPAL DATA ...................................................................................................................................................77 7.1 Readings on display (1-Fig. 1.9) 1)..................................................................................................................77 7.2 Programmable settings .....................................................................................................................................77 7.3 Circuit breakers - motor types...........................................................................................................................77 7.3.1 Circuit breakers ..........................................................................................................................................77 7.3.2 Motor types.................................................................................................................................................78 7.4 Compressor specifications................................................................................................................................78 7.4.1 Design conditions .......................................................................................................................................78 7.4.2 Limitations ..................................................................................................................................................78 7.4.3 Sound pressure level 3) .............................................................................................................................79 7.4.4 Specific data of 3.5 bar - 50 Hz compressors 2) .......................................................................................79 7.4.5 Specific data of 3.9 bar - 50 Hz compressors 2) .......................................................................................79 7.4.6 Specific data of 4.2 bar - 50 Hz compressors 2) .......................................................................................79 7.4.7 Specific data of 4.6 bar - 50 Hz compressors 2) .......................................................................................80 7.4.8 Specific data of 50 psi - 60 Hz compressors 2) ........................................................................................80 7.4.9 Specific data of 55 psi - 60 Hz compressors 2) ........................................................................................80 7.4.10 Specific data of 60 psi - 60 Hz compressors 2) ......................................................................................81 7.4.11 Specific data of 65 psi - 60 Hz compressors 2) ......................................................................................81 7.5 Conversion list of SI units into British/American units.......................................................................................81 8 PROGRAMMABLE SETTINGS ...............................................................................................................................83 8.1 Regulation settings - See section 1.9.7.1 .........................................................................................................83 8.2 Protection settings - See section 1.9.8.2 ..........................................................................................................83 8.3 Service settings - See section 1.9.7.3...............................................................................................................84 8.4 Settings for other parameters - See section 1.9.8.4 .........................................................................................84 9 Options.....................................................................................................................................................................85

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1 LEADING PARTICULARS
1.1 General description
ZH6000 and ZH10000 two-stage are water-cooled centrifugal compressors which deliver oil-free, pulsation-free air. The compressors are driven by an electric motor. The compressors are available either fully enclosed in a sound-insulated bodywork or on a base frame without bodywork. ZH10000 are 50 Hz compressors designed for following nominal working pressures: 3.5, 3.9, 4.2 and 4.6 bar(e). ZH6000 are 60 Hz compressors designed for following nominal working pressures: 50, 55, 60 and 65 psig. Six capacities are available for following pressure variants: 3.5, 3.9 bar(e) and 50, 55 psig. The variants with five capacities are: 4.2, 4.6 bar(e) and 60, 65 psig. Example of compressor designation ZH10000-1-3.5 stands for: Compressor type ZH10000 - 50 Hz Capacity size 1 Nominal working pressure 3.5 bar(e) Main components (Figs. 1.1, 1.2 and 1.3) Air filters Compressor core Blow-off valve Drive coupling Oil reservoir Auxiliary oil pump Electrical system (see section 1.6) The compressor core comprises: Inlet guide vanes Gearbox First compressor element Intercooler Second compressor element Aftercooler Check valve Oil cooler Main oil pump

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1 2 3 4 5 6 7 8 9 10 11 12 13 14

Drive motor Actuator, blow-off valve Blow-off valve Coupling Check valve Air filters Compressed air outlet Cooling water outlet Auxiliary oil pump Cooling water inlet Condensate drains Condensate trap, aftercooler Aftercooler Oil reservoir

Fig. 1.1 Front view

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Air filters Inlet guide vanes Actuator, inlet guide vanes First compressor element Second compressor element Drive motor Demister, oil reservoir Oil filter (dual oil filters are optional) Oil reservoir Condensate trap, intercooler Intercooler Thermostatic by-pass valve Oil cooler Auxiliary oil pump Cooling water inlet pipe Cooling water outlet pipe

Fig. 1.2 Rear view

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Fig. 1.3 Core

Gear casing Oil pump Positioner, inlet guide vanes Inlet guide vanes First compressor element Water regulating valve, aftercooler circuit Thermostatic by-pass valve Water regulating valve, intercooler circuit Intercooler Aftercooler Oil cooler Auxiliary oil pump Motor, auxiliary oil pump Condensate trap, aftercooler Cooling water inlet Cooling water outlet Compressed air outlet Blow-off valve

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1.2 Air flow

Air drawn through filters (1-Fig. 1.2) and inlet guide vanes (2-Fig. 1.2) is compressed in first compressor element (4-Fig. 1.2) and discharged to intercooler (11-Fig. 1.2). The cooled air is further compressed in second compressor element (5-Fig. 1.2) and blown through aftercooler (10-Fig. 1.3) and check valve (5-Fig. 1.1) towards the air net.

1.3 Condensate drain system

Two moisture traps are installed, one downstream of the intercooler (11-Fig. 1.2) to prevent condensate from entering the second compressor element and one downstream of the aftercooler (13-Fig. 1.1) to prevent condensate from entering the air outlet pipe. Each trap is provided with a float valve to automatically drain condensate and a manual drain valve.

1 2 3 4 5 6 7

Oil filler cap Oil strainer Oil level sight-glass Oil drain valve Oil heater Oil reservoir Inspection cover, oil reservoir

Fig. 1.4 Oil reservoir

1.4 Oil system

The system mainly includes: Oil reservoir (6-Fig. 1.4) Strainer (2-Fig. 1.4) Oil heater (5-Fig. 1.4) Oil demister (7-Fig. 1.2) Main oil pump (2-Fig. 1.3), driven by the main shaft Auxiliary oil pump (12-Fig. 1.3), driven by electric motor (13) Oil cooler (13-Fig. 1.2) Oil filter(s) (8-Fig. 1.2) Thermostatic valve (7-Fig. 1.3)

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During normal operation, oil is sucked up by the main oil pump from the reservoir through the strainer and is supplied to all bearings and gears. The operation of the auxiliary oil pump is automatically controlled by the Programmable Logic Controller (PLC - see section 1.7.5) to ensure sufficient oil pressure during start-up and shutdown, and also in case the oil supply pressure should become too low. The heater will warm up the oil in the reservoir to the required minimum temperature. The heater is automatically controlled by the PLC (see section 1.7.5). The thermostatic valve mixes heated oil from the reservoir and cooled oil from the oil cooler to maintain the temperature of the oil to the lubricating points as constant as possible. At starting, the temperature of the oil in the gearbox and the oil pressure are checked by the PLC. If the permissive start conditions are not fulfilled, the compressor will not start (see section 3.3). Oil fumes from the oil reservoir are sucked in by the oil demister and filtered inside the demister. Oil droplets are drained back to the oil reservoir.

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100 101 102 103a 103e 104 105 106 108 109a 109b 110 111 112 113 114a 114b 120 121 122 123a 123b 125 126 127 128 129 130 131 140 141 142 143 145 146 147a 147b 148 149 150 152a 152b 153 154 155 156 157 158 159 160 161 172 173 174 175 176

Air filters Air inlet silencer Joint Inlet guide vanes Actuator, inlet guide vanes Flexible coupling First compressor element Flexible coupling Intercooler Condensate trap, intercooler Electronic condensate drain (optional) Flexible coupling Second compressor element Flexible coupling Aftercooler Condensate trap, aftercooler Electronic condensate drain (optional) Check valve Compensator Flexible coupling Blow-off valve Actuator, blow-off valve Silencer Condensate drain receiver Manual condensate drain valve Non-return valve Condensate drain receiver Manual condensate drain valve Non-return valve Oil reservoir Oil strainer Main oil pump Drive coupling, main oil pump Oil cooler Thermostatic by-pass valve Oil filter Dual oil filter (optional) Auxiliary oil pump Motor, auxiliary oil pump Non-return valve Oil demister Fan motor, oil demister Pressure control valve Oil reservoir heater Oil drain valve Non-return valve Flexible coupling Restriction Manual operated valve Drive motor Drive coupling Compensator Compensator Cooling water flow reverse valve (optional) Water shut-off valve (optional) Water regulating valve, intercooler circuit

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177 180 180a

Water regulating valve, aftercooler circuit Programmable Logic Controller User interface

Transducers/Sensors/Timers/Positioners/Solenoid valve KSH02 KSH41 KSH48 KSH49 KSH93 LSHL17 LSHL28 LSL42 LSLL42 PDT02 PDT19 PDT20 PDT46 PT22 PT29 PT49 R96 TT18 TT29 TT43 TT44 TT51 TT60 TT95a TT96a TT97a TT98 TT99 VP10 VP20 Y2 Y3 Y51 Air filter lifetime Oil demister lifetime Oil filter lifetime Oil lifetime Drive motor regreasing time Condensate drain level, intercooler (automatic drain is optional) Condensate drain level, aftercooler (automatic drain is optional) Oil level Oil level Air filter pressure drop DP element 2 nozzle pressure DP element 2 pressure Oil filter pressure drop Outlet pressure, second compressor element Delivery air pressure Gearbox oil pressure Anti-condensation heater (optional) Air inlet temperature, second compressor element Aftercooler outlet temperature Oil reservoir temperature Gearbox oil supply temperature Cooling water inlet temperature Drive motor inlet temperature Motor winding temperature U1-U2 (T1-T4) (optional) Motor winding temperature V1-V2 (T2-T5) (optional) Motor winding temperature W1-W2 (T3-T6) (optional) Motor bearing temperature, drive end (optional) Motor bearing temperature, non-drive end (optional) Vibration, first compressor element Vibration, second compressor element Positioner, inlet guide vanes Positioner, blow-off valve Solenoid valve, cooling water shut-off (optional)

Fig. 1.5 Instrument and piping diagram

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) Ventilation line Drain Air Oil Water Signal air Signal electrical Only with dual oil filter (optional) From transducers, transmitters, sensors Motor winding temperature protection (optional) Motor bearing temperature protection (optional) Only with electronic drain (optional) Only with anti-condensation heaters (optional) Atlas Copco installation Customers installation Water shut-off valve (optional) Cooling water flow reversing valve (optional) For compressors without starter, current transformer XA-SA to be supplied by customer Sleeve bearings only

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A B C D E F G H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Air inlet Air Air outlet Oil Water inlet Water Water outlet Condensate Air filters Air inlet silencer Inlet guide vanes First compressor element Intercooler Second compressor element Oil filter Pressure control valve Aftercooler Check valve Blow-off valve Silencer Oil demister Oil reservoir Oil reservoir heater Oil strainer Main oil pump Auxiliary oil pump Non-return valve Oil cooler Thermostatic by-pass valve

Fig. 1.6 Air-oil-water flows

1.5 Cooling system (Fig. 1.3)

A piping system is provided to supply the intercooler (9), aftercooler (10) and oil cooler (11) with cooling water. Following flow regulating valves are provided: downstream of the intercooler (8) downstream of the aftercooler (6)

1.6 Electrical system

The system mainly includes: Electric cubicle (Fig. 1.11) with Programmable Logic Controller Compressor control panel (Fig. 1.9) Pressure, temperature, vibration and oil level sensors (Fig. 1.5) Drive motor (6-Fig. 1.2) Motor for auxiliary oil pump (13-Fig. 1.3) Motor for fan of oil demister (1-Fig. 5.5) Oil heater (5-Fig. 1.4) Positioner, inlet guide vanes (3-Fig. 1.2) Positioner, blow-off valve (2-Fig. 1.1)

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1.7 Programmable Logic Controller - PLC

In general, the Programmable Logic Controller - PLC - has following functions: Controlling the capacity of the compressor Protecting the compressor Monitoring components subject to service Checking the start conditions Controlling the lubricating oil system 1.7.1 Controlling the capacity of the compressor The system includes: PLC (Fig. 1.11) Inlet guide vanes (4-Fig. 1.3) Blow-off valve (3-Fig. 1.1) The PLC continuously regulates the capacity of the compressor from maximum air capacity to a minimum capacity by controlling the position of the inlet guide vanes and blow-off valve. The compressors are standard provided with the constant pressure control system. As an option, the compressors may be provided with the AUTO-DUAL control system. Constant pressure control system (standard) The constant pressure control system is designed to continuously control the air output while keeping the net pressure fluctuations to a minimum. The PLC will continuously regulate: the position of the inlet guide vanes (from 100 % open to a minimum open position) the position of the blow-off valve (from 100 % closed to a minimum closed position) The air delivery will be matched to the air consumption while the net pressure is maintained as close as possible to the programmed pressure setpoint. The PLC takes into account a number of programmable settings such as the minimum stop time and maximum number of motor starts. In case the net pressure should rise to a programmed pressure, the compressor will be switched to completely unloaded running. The compressor may be stopped after running completely unloaded for a programmed time period. When the net pressure drops below a programmed pressure, the compressor will again run loaded, continuously regulating the air output as described above. See also section 1.9.7.1. AUTO-DUAL control system (option) The system is designed for applications with a large compressed air volume where the fluctuations in air demand are generally within the throttle range capability of the compressor, combined with occasional requirements for lower air flows. The PLC will regulate the position of the inlet guide vanes (IGV) to match the air delivery to the air consumption while maintaining the net pressure as close as possible to the programmed value (called Regulation setpoint). If the air consumption decreases causing the net pressure to exceed the programmed unloading pressure, the inlet guide vanes (IGV) will close to their minimum open position while simultaneously the blow-off valve (BOV) will be opened completely; the compressor runs unloaded. If the net pressure drops below the programmed loading pressure, the inlet guide vanes (IGV) will be completely opened while simultaneously the blow-off valve (BOV) will be fully closed. The PLC will again regulate the position of the inlet guide vanes (IGV) as described above.

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The PLC takes into account a number of programmable settings such as the unloading pressure, loading pressure, minimum stop time and maximum number of motor starts. The compressor is stopped when possible (depending on the setting of the maximum number of motor starts) to reduce the power consumption. The compressor is restarted automatically when the net pressure drops below the programmed loading pressure.

1.7.2 Protecting the compressor Several temperature, pressure, vibration and oil level sensors are provided on the compressor. They are connected in the control circuit of the PLC. If an abnormal operating condition arises, a pictograph (Fig. 1.7) on the compressor control panel will blink to warn the operator. In case of a malfunction, the compressor is shut down and a pictograph (Fig. 1.8) on the control panel will blink to warn the operator. 1.7.2.1 Shut-down warning The shut-down warning level is a programmable setting below the shut-down level. If the PLC detects a vibration, temperature, pressure or oil level exceeding the programmed shut-down warning level, warning pictograph (Fig. 1.7) will blink to warn the operator before the shut-down level is reached. In case of a shut-down warning: The warning pictograph (Fig. 1.7) is blinking. Press button (F2-Fig. 1.9) after which the reason for this warning will appear on display (1-Fig. 1.9), e.g.: OIL SUPPLY TEMPERATURE NEW WARNING Press reset button (5-Fig. 1.9) to acknowledge this warning: the warning pictograph will light steadily and the message NEW WARNING will change into WARNING.

It remains possible to scroll through other screens after pressing Main menu button (F8-Fig. 1.9) to check the gearbox oil temperature as well as other actually measured values, and afterwards to return to the Main screen (Fig. 1.12). See also section 1.9.3. Check and remedy. The warning message disappears as soon as the warning condition disappears. Remark If more messages need to be shown on the display, the messages will be displayed one after the other for a few seconds.

Fig. 1.7 Pictograph, shut-down warning Warning Before starting any maintenance or repair, stop the compressor, switch off the voltage and depressurize the compressor. Apply all relevant safety precautions, including those mentioned in this book.

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1.7.2.2 Shut-down If the PLC detects a vibration, temperature, pressure or oil level exceeding the programmed shut-down level, the compressor will be stopped and the shut-down pictograph (Fig. 1.8) will blink. The compressor will also be shut down in case of: An overload or undervoltage at the drive motor Surging of the compressor (see section 1.7.2.3) Failure of some important sensors In case of a shut-down: The shut-down pictograph (Fig. 1.8) is blinking. The message COMPRESSOR IS NOT READY TO START appears. Press button (F2-Fig. 1.9) after which the reason for this shut-down will appear on display (1-Fig. 1.9), e.g.: GEARBOX OIL TEMPERATURE NEW SHUTDOWN Press reset button (5-Fig. 1.9) to acknowledge this shut-down: the shut-down pictograph will light steadily and the message NEW SHUTDOWN will change into SHUTDOWN.

It remains possible to scroll through other screens after pressing Main menu button (F8-Fig. 1.9) to check the gearbox oil temperature as well as other values measured at the moment of shut-down, and afterwards to return to the Main screen (Fig. 1.12). See also section 1.9.3. Switch off the voltage and remedy. After remedying and disappearing of the shut-down condition, switch on the voltage and press reset button (5-Fig. 1.9). When the OK pictograph (5-Fig. 1.10) lights up green or starts blinking, the compressor can be restarted (message COMPRESSOR IS READY TO START). If not, press OK button (F5-Fig. 1.9) or button (F2-Fig. 1.9) to check which condition is not fulfilled to permit a restart. See also section 6.

Remark If more messages need to be shown on the display, the messages will be displayed one after the other for a few seconds.

Fig. 1.8 Pictograph, shut-down

1.7.2.3 Surge control Surge is recognized by rapid, rhythmic fluctuations of the discharge pressure. In case of prolonged unstable running, this operating condition may cause damage to the compressor. To prevent surging, the PLC has a surge anticipation system. The limit between stable and unstable operation is referred to as "surge line". To prevent the compressor from entering the unstable operating range, a safety margin to this surge line must be kept. This is called the control line and is set up during commissioning.

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1.7.3 Monitoring components - service warning The PLC continuously monitors critical components subject to service: - motor grease - oil - oil filter - oil demister - cooler approach temperatures (is the temperature difference over the cooler between the cooling water inlet and the compressed air outlet) - PLC battery - air filters Each input is compared to the programmed limits. Exceeding these limits causes a message on the control display to warn the operator. In case of a service warning: Pictograph (11-Fig. 1.10) is blinking. Stop the compressor, switch off the voltage and replace the indicated component or take the necessary service action. Switch on the voltage and reset the actual lifetime of the component. See section 1.9.7.3. Press reset button (5-Fig. 1.9) and start the compressor.

1.7.4 Checking the start conditions At starting the programmed permissive start conditions (such as the minimum temperature of the oil in the gearbox and minimum oil pressure) are checked. If these conditions are not fulfilled, the compressor will not start. See section 3.3.

1.7.5 Controlling the lubricating oil system The PLC automatically controls the lubricating oil system, i.e.: Energize the oil heater (5-Fig. 1.4) Start and stop the auxiliary oil pump (12-Fig. 1.3)

When the compressor is not running and with key switch (9-Fig. 1.9) in position local (11) or remote (12), the oil in the oil reservoir will be kept at the correct temperature by switching on and off the oil heater and the auxiliary oil pump will periodically circulate the oil.

1.7.6 Start commands during minimum stop time Minimum stop time After stopping, the motor is prevented from restarting within a programmed time period which is set ex-factory at 240 seconds. A start command during this period is ignored.

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1.7.7 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, the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period (between 0 seconds and 60 minutes), increased by the initiating time of the CPU (which takes about 35 seconds). The minimum stop time is taken into account. Automatic restarting after voltage failure is not allowed for medium-voltage motors. 1.7.8 External compressor status indication Auxiliary contacts are provided for external compressor status indication:

Indication Automatic operation Warning Shut-down Compressor running Permissive start OK

Relay K6 K7 K8 K1 K9

Terminals on strip 1X4 51-52 53-54 55-56 59-60 61-62

Max. load 8 A / 230 V AC 8 A / 230 V AC 8 A / 230 V AC 8 A / 230 V AC 8 A / 230 V AC

Indication Control mode OFF Control mode LOCAL Control mode REMOTE

Switch S5 S5 S5

Terminals on strip 1X4 43-44 45-46 47-48

Max. load 2.5 A / 230 V AC 2.5 A / 230 V AC 2.5 A / 230 V AC

Stop the compressor and switch off the voltage before connecting external equipment. Consult Atlas Copco.

1.7.9 BUS connection system As an option, a BUS connection system can be provided to enable the controller to communicate with a plant monitoring system (through MODBUS or PROFIBUS connections). Consult Atlas Copco.

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1.8 Control panel (Fig. 1.9)

A control panel is provided allowing the operator to communicate with the PLC. The control panel includes: Start button (15) and stop button (17) Emergency stop button (13) Display (1) indicating the compressor operating condition, a service need or a fault Illuminating pictographs (22) indicating the status of the compressor and explaining the functions of the corresponding buttons (F1 to F10) below the display. Voltage on lamp (7) Reset button (5) to reset a warning/shut-down/emergency stop condition Key switch (9) to select the required compressor control mode Keypad (3) and keys to enter or modify parameters (2, 4, 19, 20 and 21)

Fig. 1.9 Control panel

1.8.1 Display (1-Fig. 1.9) The alphanumeric display indicates: the compressor operating condition pressure, temperature and vibration levels a service need a fault

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1.8.2 Control buttons/keys/pictographs/lamp (Fig. 1.9) 2 3 4 5 6 7 8 9 Backspace key Keypad Return key Reset button Pictograph Lamp, voltage on Pictograph Control mode switch To clear the last input during changing of parameters or to leave the text input line. To enter or modify parameters. To call up menus and to enter or modify parameters. To reset an active shut-down warning, shut-down, motor overload condition, a service message or emergency stop condition. Reset Lights up if the voltage is switched on. Voltage on To select the compressor control modes: -compressor off -local control -remote control See section 3.2 Compressor off: the PLC will not react to any start/stop command; the oil will not be heated and not circulated. Local control (remote control mode is made inactive): the compressor can only be controlled by the buttons on the control panel; the oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). Remote control (local control is made inactive): the compressor will only react to start/stop and manual load/unload commands by external switches, emergency stop button (13) remains active; the oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). Maintained-action push button to stop the compressor immediately in case of emergency. After remedying the trouble, unlock the button by pulling it out (some compressors may have a button with arrow which must be turned anti-clockwise to unlock). Emergency stop To start the compressor Start To stop the compressor in a normal stop sequence (programmed stop): the compressor will run unloaded for about 15 seconds and then stop; the auxiliary oil pump will remain running for about 10 minutes to cool down the compressor. The oil will be kept on operating temperature as long as switch (9) is in the local (11) or remote (12) position. Stop To switch to another rectangular text box on a screen. To scroll within a rectangular text box on a screen. To switch to another rectangular text box on a screen. See section 1.8.3.

10 11

Pictograph Pictograph

12

Pictograph

13

Emergency stop button Pictograph Start button Pictograph Stop button

14 15 16 17

18 19 20 21 22

Pictograph Arrow key Scroll keys Arrow key Pictographs

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1.8.3 Pictographs below display (Fig. 1.10) 1 2 3 3 3 3 4 5 Oil heater Shut-down Automatic operation Automatic operation Automatic operation Automatic operation Unloaded operation OK Lights up green when the oil heater is energized. The heater is automatically controlled by the PLC. Blinks red in case one or more parameters exceed the shutdown level or after emergency stopping; after acknowledging by pressing button (F2), the pictograph lights up steadily. Lights up steadily green indicating that the compressor is running in automatic operation mode (see section 1.7.1) Blinks green indicating that the compressor may be started and stopped automatically by programmed time-based commands (see section 1.9.9) Blinks green indicating that the compressor may be started automatically after power failure (see section 1.7.7) Blinks green indicating that the compressor is stopped after a period of unloaded running but will be started if the pressure drops below a programmed value (see section 1.9.7.1) Lights up green if the compressor is running in manual unloaded condition (see section 3.6). Lights up green if the compressor is not running but all start conditions to have a permissive start are fulfilled (see section 3.3). If the pictograph is not green illuminated, the permissive start conditions are not fulfilled; press button (F5) to check the reason. See section 6. Blinks green if the auxiliary oil pump is not running before starting: when pressing start button (15-Fig. 1.9), first the auxiliary oil pump will start and then the compressor will start. Lights up green when the auxiliary oil pump is running. Lights up green if it is allowed to adjust the position of the inlet guide vanes (only by Atlas Copco). Indicates the function of button (F8). See section 1.8.4. Indicates the function of button (F9). See section 1.8.4. Lights up green if the compressor is controlled by the (optional) sequencer (consult Atlas Copco). Blinks yellow in case one or more parameters exceed the shutdown warning level or service warning level; after acknowledging by pressing button (F2), the pictograph lights up steadily (see sections 1.7.2/1.7.3).

OK

6 7 8 9 10 11

Auxiliary oil pump Inlet guide vanes Main menu Next screen Sequencer Warning

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1.8.4 Buttons below display (Fig. 1.10) F2 F2 F3 F4 Information in case of a warning Information in case of a shutdown Automatic operation Manual unload To check which parameter is causing the warning. After scrolling through other screens, this button allows to return to the information on the warning screen. To return to the information on the shut-down screen after scrolling through other screens. To set the compressor in automatic operation mode: the compressor is automatically controlled by the PLC (see section 1.7.1). To unload the compressor manually. The compressor is switched out of automatic operation (no capacity regulation by the PLC). The compressor will remain running unloaded unless it is put in automatic operation again by pressing button (F3). Press this button before starting to check which start condition is not fulfilled. See section 3.3. To manually set the inlet guide vanes (this function is only accessible to Atlas Copco personnel). To return to the main menu (Fig. 1.13) of the compressor control programs (see section 1.9). To scroll down to the next screen. To have the compressor controlled by the (optional) sequencer (if desired, consult Atlas Copco).

F5 F7 F8 F9 F10

OK Manual control of inlet guide vanes Main menu Next screen Sequencer

Note: The functions of buttons (F1 up to F10) may vary depending on the chosen menu; see section 1.9.

1 2 3 4 5 6 7 8 9 10 11

Oil heater Shut-down condition Automatic operation Unloaded operation Start conditions fulfilled Auxiliary oil pump Manual control of inlet guide vanes Main menu Next screen Sequencer Warning condition

Fig. 1.10 Pictographs and buttons, control panel

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B61 CPU F3/4/5/10 K6 K7 K8 K9 K13 K25 K27 K29 L1/2/3 Q1 Q25 Q27 Q29 T1 U2 VT10/20 Z1 1X2 1 2 3 4 5

Current transmitter, drive motor current Central processing unit Circuit breakers Auxiliary relay, automatic operation Auxiliary relay, general warning Auxiliary relay, general shut-down Auxiliary relay, permissive start OK Auxiliary relay, motor starter control Contactor, auxiliary oil pump motor M25 Contactor, oil demister fan motor M27 Contactor, oil heater R29 Terminals, 3-phase low voltage supply Circuit breaker, control circuit Circuit breaker, auxiliary oil pump motor M25 Circuit breaker, oil demister fan motor M27 Circuit breaker, oil heater R29 Main transformer Power supply, 5V DC Vibration transmitters, compressor elements Line filter, AC power Terminal strip Fuse Power supply Key, RUN/REM/PROG Input/output cards Terminal strips

Fig. 1.11 Electric cubicle, without starter (typical example)

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1.9 Menu-driven control programs

In order to facilitate programming and controlling of the compressor, menu-driven control programs have been implemented in the PLC. A simplified menu flow is shown in Figs. 1.15 and 1.16. Function of control programs Program Main menu Main screen Configuration Settings Section 1.9.2/1.9.3 1.9.5 1.9.6 1.9.7 1.9.7 1.9.7 Service 1.9.8 1.9.8 1.9.8 Timer Saved data 1.9.9 1.9.10 Function Shows the six available control programs. Is the gateway to have access to these programs. Calling up the actually measured data and the compressor status Programming the date, time, display language and units of measurement. Regulation: modifying the regulation settings (e.g. pressure setpoint) and calling up information about the compressor starts and stops Protection: calling up the protection settings (e.g. shutdown and shut-down warning settings) Service: modifying service warning settings and resetting the actual lifetime of a component after servicing Modifying settings (e.g. shut-down warning and shut-down settings). Password needed. Surge history. Password needed. Modifying parameters (e.g. permissive start level for the oil temperature). Password needed. Programming time-based commands to start and stop the compressor automatically. Calling up shut-down and emergency stop data saved by the PLC.

1.9.1 Main screen When the voltage is switched on, a screen is shown indicating a test protocol. After about 30 seconds, the Main screen (Fig. 1.12) is shown indicating the compressor status. If the buttons on the control panel are not used for about 4 minutes, the display will automatically return to the Main screen.

1.9.2 Calling up the Main menu and other menus After pressing button (F8), the Main menu (Fig. 1.13) is shown. The Main menu shows the six available control programs (called menus). The Main menu is the gateway to have access to these menus. To select another menu: use scroll keys (22) to move symbol > to the left of the desired menu and then press return key (13).

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1.9.3 Returning to the Main menu and Main screen To return from whatever menu to the Main menu (Fig. 1.13), press button (F8) until the Main menu is shown. Press scroll keys (22) until symbol > is situated on the left of item MAIN SCREEN. Press return key (13) to switch to the Main screen (Fig. 1.12).

1.9.4 Screen saver If the control panel buttons are not used for about 10 minutes, the screen saver will be activated: the Atlas Copco logo will slowly move over the screen. Press button (F8) or button (F5) to return to the Main screen (Fig. 1.12).

Fig. 1.12 Main screen (typical example)

Fig. 1.13 Main menu

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1.9.5 Main screen menu Function The Main screen is used to call up the actually measured data as well as the compressor status. Calling up this menu 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item MAIN SCREEN. Press return key (13) to select this menu. Following menu appears (typical example): 3.37 bar 4.20 bar 2.22 bar 3.38 bar BOV % CLOSED 100 TIMER NOT ACTIVE

COMP OUTLET PRESSURE PRESSURE SETPOINT OIL PRESSURE ELEMENT 2 OUTLET IGV % OPEN 100 COMPRESSOR IS LOADED LOCAL CONTROL

This menu shows: the compressor outlet pressure the compressor setpoint (see section 1.7.1) the gearbox oil pressure the outlet pressure at compressor element 2 the position of inlet guide vanes IGV (4-Fig. 1.3): the open position of the vanes is expressed in percentage the position of the blow-off valve: the closed position of the valve is expressed in percentage whether the compressor is controlled locally (start/stop and manual load/unload commands only possible by means of the buttons of the control panel) or controlled remotely (start/stop and manual load/unload commands only possible by means of external switches) the status of the Timer (if activated, the programmed time-based start and stop commands will be executed; see section 1.9.9) 3 Fig. 1.14 shows all data which can be called up in the Main screen. Use button (F9) for scrolling down in the menu. All values shown are typical examples.

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COMP OUTLET PRESSURE PRESSURE SETPOINT OIL PRESSURE ELEMENT 2 OUTLET IGV % OPEN 100 COMPRESSOR IS LOADED LOCAL CONTROL AIR FILTER DP OIL FILTER DP OIL/CONDENSATE LEVEL OIL RESERVOIR TEMP GEARBOX OIL TEMPERATURE ELEMENT 2 INLET TEMP COMPRESSOR OUTLET TEMP COOLING H20 INLET TEMP COOLER 1 APPROACH AFTERCOOLER APPROACH DRIVE MOTOR INLET AIR DRIVE MOTOR CURRENT ELEMENT 1 VIBRATION ELEMENT 2 VIBRATION MOTOR OVERLOAD OIL PUMP OVERLOAD EQUIPMENT OVERLOAD HOURS RUNNING 3013

3.37 bar 4.20 bar 2.22 bar 3.38 bar BOV % CLOSED 100 TIMER NOT ACTIVE -0.02 bar 0.15 bar OK 58 C 50 C 37 C 35 C 28 C 8 C 7 C 19 C 55 A 7.50 micron 11.50 micron NORMAL NORMAL NORMAL LOADED 2774 REGULATOR 3013

Fig. 1.14 Main screen (all values shown are typical examples)

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Fig. 1.15 Simplified menu flow, main screen configuration settings

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Fig. 1.16 Simplified menu flow, service timer saved data

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1.9.6 Configuration menu Function The Configuration menu is used to program the date, time, display language and units of measurement. Calling up this menu 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item CONFIGURATION. Press return key (13) to select this menu.

Fig. 1.17 Pictograph 3 Following menu appears (typical example): ENGLISH bar micron C 14/03/1999 HOUR MINUTE << << << << >> >> >> >> 14:32:11 14 32

LANGUAGE IN USE PRESSURE UNITS VIBRATION UNITS TEMPERATURE UNITS SUNDAY YEAR MONTH DAY

1999 3 14

Fig. 1.18 Configuration menu Important If pictograph (Fig. 1.17) is lit up red, the date and time values are not accessible. Press button (F10): pictograph (Fig. 1.17) will light up green, indicating that the date and time may be changed.

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To change the date and time 4 5 6 To change the year: use arrow keys (21 or 23) until a vertical line is situated on the left of the YEAR text box. Press return key (13), type a new value by means of keys (14) and press return key (13). If required, use backspace key (12) to clear the last input or to leave the text input line. Use the method described in step 4 to change the value for the month, day, hours and minutes. The indication of the day will automatically change after modifying the date. Press button (F10); the colour of the related pictograph will become red, indicating that the values are no longer accessible.

To change the display language 7 8 Use arrow keys (21 or 23) until a vertical line is situated on the left of the << >> box. Use scroll keys (22) to move symbol > to the left of line LANGUAGE IN USE and press return key (13).

To change the units 9 10 Use arrow keys (21 or 23) until a vertical line is situated on the left of the << >> box. Use scroll keys (22) to move symbol > to the line of the unit to be changed and press return key (13).

1.9.7 Settings menu This menu has three submenus.

1.9.7.1 Regulation Submenu Function The Regulation submenu is used: to modify regulation settings (e.g. pressure setpoint) to call up information about the compressor starts and stops. See Fig. 1.19. 1 Press main menu button (F8). The Main menu is shown:

MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA

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Press scroll keys (22) until symbol > is situated on the left of item SETTINGS. Press return key (13) to select this menu. Following menu appears:

REGULATION PROTECTION SERVICE 3 Press scroll keys (22) until symbol > is situated on the left of item REGULATION. Press return key (13) to select this menu. Following menu appears (typical example): 4.20 bar 4.60 bar 0.60 bar 0.60 bar 3 3 06:00:0 0 17:15:0 0 1 1 >+ + + -

PRESSURE SETPOINT MAX PRESSURE SETPOINT LOADING PRESSURE SETPOINT UNLOAD PRESS SETP STARTS ALLOWED/HOUR STARTS ALLOWED/DAY STARTED ON STOPPED ON STARTS THIS HOUR STARTS THIS DAY Fig. 1.19 Regulation submenu

05/03/99 05/03/99

This menu shows: The pressure setpoint The maximum pressure setpoint The loading pressure setpoint The unloading pressure setpoint The allowed starts/hour and starts/day The date and time the compressor was started/stopped The number of starts/hour and starts/day To change the pressure setpoint The PLC will maintain the net pressure as close as possible to the programmed pressure setpoint (see section 1.7.1). To increase the pressure setpoint: 4 Use scroll keys (22) until symbol > is situated on the left of symbol + on the PRESSURE SETPOINT line and press return key (13) until the desired value is reached.

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To decrease the pressure setpoint: 5 Use scroll keys (22) until symbol > is situated on the left of symbol - on the second line and press return key (13) until the desired value is reached.

To change the unloading pressure setpoint The unloading pressure setpoint is the pressure increase with regard to the pressure setpoint at which the compressor is automatically switched to completely unloaded operation: Example: Pressure setpoint Unloading pressure setpoint Automatic complete unload at 6 4.20 bar 0.60 bar 4.80 bar

Use scroll keys (22) to move symbol > to symbol + (on the third line, to increase the setting) or to symbol (on the fourth line, to decrease the setting ) and press return key (13) until the desired value is reached.

To change the loading pressure setpoint The loading pressure setpoint is the pressure decrease with regard to the pressure setpoint at which the compressor is automatically switched back to loaded operation (with continuous regulation of the inlet guide vanes and blow-off valve): Example: Pressure setpoint Loading pressure setpoint Automatic switch to load at 7 4.20 bar 0.20 bar 4.00 bar

Use scroll keys (22) to move symbol > to symbols + or - (on the fifth or sixth line) and press return key (13) until the desired value is reached.

Important The PLC includes the function Stop after unloaded delay. This function is not activated ex-factory; if required, it can be activated by Atlas Copco. If activated, the compressor will be stopped in case it runs automatic completely unloaded for an uninterrupted period of 15 minutes (programmable). Pictograph (3) for automatic operation will blink indicating that the compressor will automatically restart when the net pressure decreases to the loading pressure setpoint.

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1.9.7.2 Protection Submenu Function The Protection submenu is used to call up protection settings (e.g. shut-down and shut-down warning settings). See Fig. 1.20. 1 Press main menu button (F8). The Main menu is shown:

MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item SETTINGS. Press return key (13) to select this menu. Following menu appears:

REGULATION PROTECTION SERVICE 3 Press scroll keys (22) until symbol > is situated on the left of item PROTECTION. Press return key (13) to select this menu. Following menu appears (typical example): SHUTDOWN 1.00 bar

OIL PRESSURE WARNING 1.60 bar

This menu shows the shut-down warning settings and shut-down settings for the mentioned parameter.

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Figure 1.20 shows all data which can be called up in the Protection submenu. Use button (F9) for scrolling down in the menu. All values shown are typical examples

OIL PRESSURE WARNING 1.60 bar ELEMENT 1 VIBRATION WARNING 24.00 micron ELEMENT 2 VIBRATION WARNING 24.00 micron GEARBOX OIL TEMPERATURE WARNING 57.00 C ELEMENT 2 INLET TEMPERATURE WARNING 52.00 C

SHUTDOWN 1.00 bar

SHUTDOWN 27.00 micron

SHUTDOWN 27.00 micron

SHUTDOWN 63.00 C

SHUTDOWN 66.00 C

Fig. 1.20 Protection submenu (all values shown are typical examples)

1.9.7.3 Service Submenu Function The Service submenu is used to call up and modify service warning settings and to reset the actual lifetime of a component after servicing. See Fig. 1.21. 1 Press main menu button (F8). The Main menu is shown:

MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA

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Press scroll keys (22) until symbol > is situated on the left of item SETTINGS. Press return key (13) to select this menu. Following menu appears:

REGULATION PROTECTION SERVICE 3 Press scroll keys (22) until symbol > is situated on the left of item SERVICE. Press return key (13) to select this menu. Following menu appears (typical example):

OIL FILTER DP WARNING 1.00 bar This menu shows the programmed service warning pressure for the oil filter 4 Figure 1.21 shows all data which can be called up and reset in the Service submenu. Use button (F9) for scrolling down in the menu. All values shown are typical examples.

To modify the service warning value 5 Use scroll keys (F9 and F10) until the parameter to be changed appears. 6 Use the - button (F1) to decrease or the + button (F2) to increase the service warning value. To reset the actual lifetime of a component after servicing 7 Replace the related component. 8 Use scroll keys (F9 and F10) until the actual lifetime of the related parameter appears. 9 Press reset key (F3).

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OIL FILTER DP WARNING 1.00 bar AIR FILTER DP WARNING -0.05 bar COOLER 1 APPROACH WARNING 20.00 C AFTERCOOLER APPROACH WARNING 20.00 C LUBE OIL HOURS WARNING 8000.00 hr OIL FILTER HOURS WARNING 8000.00 hr DRIVE MOTOR REGREASING WARNING 2000.00 hr AIR FILTER HOURS WARNING 8000.00 hr OIL DEMISTER HOURS WARNING 24000.00 hr Fig. 1.21 Service submenu

ACTUAL 5315 hr

ACTUAL 5315 hr

ACTUAL 1315 hr

ACTUAL 5315 hr

ACTUAL 13315 hr

1.9.8 Service menu Function The Service menu is used: to modify settings, such as the shut-down warning and shut-down settings to call up the surge history to modify other parameters, such as the oil permissive start level The service menu is password-protected.

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1.9.8.1 Calling up this menu 1 Press main menu button (F8). The Main menu is shown:

MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 Press scroll keys (22) until symbol > is situated on the left of item SERVICE. Press return key (13) to select this menu. Enter the password and press return key (13). Following six submenus are shown

MODIFY VALVES MODIFY SETTINGS SURGE HISTORY MODIFY PARAMETERS COMMUNICATIONS SETUP OPTIONS Important The access to submenus MODIFY VALVES, COMMUNICATIONS SETUP and OPTIONS is protected by another password. The modifications in these submenus may only be carried out by Atlas Copco personnel. 1.9.8.2 Modifying settings Function The Modify settings submenu is used to modify protection settings (shut-down warning and shut-down levels). See Fig. 1.22. 1 Press scroll keys (22) until symbol > is situated on the left of item MODIFY SETTINGS. Press return key (13) to select this menu. Following menu appears (typical example): SHUTDOWN 1.00 bar

OIL PRESSURE WARNING 1.60 bar

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Figure 1.22 shows all data which can be modified. Use button (F9) for scrolling down in the menu.

To change a shut-down warning setting 3 Use scroll keys (F9 and F10) until the parameter to be changed appears. 4 Use the + and - buttons (F1 and F2) to increase and decrease the warning value respectively. To change a shut-down setting 5 Use scroll keys (F9 and F10) until the parameter to be changed appears. 6 Use the + and - buttons (F3 and F4) to increase and decrease the shut-down value respectively. OIL PRESSURE WARNING 1.60 bar ELEMENT 1 VIBRATION WARNING 27.50 micron ELEMENT 2 VIBRATION WARNING 27.50 micron GEARBOX OIL TEMPERATURE WARNING 57.00 C ELEMENT 2 INLET TEMPERATURE WARNING 52.00 C Fig. 1.22 Modify settings submenu Note: The figure shows all items spread over several screens. Use button (F9) to scroll down through the screens. All values shown are typical examples.

SHUTDOWN 1.00 bar

SHUTDOWN 42.70 micron

SHUTDOWN 42.70 micron

SHUTDOWN 63.00 C

SHUTDOWN 66.00 C

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1.9.8.3 Checking surge history Function The Surge history submenu is used to display a number of data for each time surge should have occurred. 1 2 Consult section 1.9.8.1. Press scroll keys (22) until symbol > is situated on the left of item SURGE HISTORY. Press return key (13) to select this menu. Following menu appears (typical example): 01 06/03/1999 ... TIME BOV % CLOSED ... 11:34:27 ...

SURGE HISTORY DATE IGV % OPEN SURGE NUMBER

History 01 stands for the most recent surge. 3 Use button (F9) to consult the next case of surge.

1.9.8.4 Modifying parameters Function The Modify parameters submenu is used to modify a number of parameters. 1 2 Consult section 1.9.8.1. Press scroll keys (22) until symbol > is situated on the left of item MODIFY PARAMETERS. Press return key (13) to select this menu. Following menu appears (typical example): 25 C 240 s 15 min 15 s 20 s 10 s 15 s 3 3 ...

OIL PERMISSIVE START MINIMUM STOP TIME STOP AFTER UNLOAD TIME VIBRATION DELAY AT START LOAD DELAY TIME OIL PRESS DELAY AT START DP AIR FILTER WARNING DELAY STARTS ALLOWED/DAY STARTS ALLOWED/HOUR C.T. PRIMARY RATING Fig. 1.23 Modify parameters submenu 3

To modify a setting, scroll to the parameter to be modified using keys (22) and increase or decrease the value using buttons (F4) and (F9) respectively. If required, use backspace key (12) to clear the last input or to leave the text input line.

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1.9.9 Timer menu Function The Timer menu is used to program time-based commands to start and stop the compressor automatically. 1.9.9.1 Calling up this menu 1 Press main menu button (F8). The Main menu is shown:

MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA 2 3 Press scroll keys (22) until symbol > is situated on the left of item TIMER. Press return key (13) to select this menu. The first submenu appears (typical example):

Fig. 1.24 Timer menu 4 The pictographs on the display will change; see Fig. 1.25.

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1 2 3 4 5 6 7 8 9 10

Enter Modify Change value Change value Timer active (green) or not active (white) Delete Save Main screen Scrolling down Scrolling up

Fig. 1.25 Timer pictographs

1.9.9.2 To program start/stop commands Important If pictograph (5-Fig. 1.25) is lit up green, the timer is active and the start/stop commands are not accessible. Press button (F5): pictograph (5-Fig. 1.25) will light up white, indicating that the data may be changed. Example: The compressor should start on Monday at 06:15 o'clock and stop on Friday at 18:05 o'clock 1 2 3 4 5 6 Press input button (F1); pictograph (1-Fig. 1.25) will light up green. The message "ADD A NEW EVENT" appears and the EVENT number changes to "1". Use scroll keys (22) to move symbol > to the START/STOP line. Press + button (F4) until the command START appears on the third line of the screen. Use scroll keys (22) to move symbol > to the DAY line. Press + button (F4) or - button (F3) until MONDAY appears on the third line of the screen. Use scroll keys (22) to move symbol > to the HOUR line. Press + button (F4) or - button (F3) until "6:0" appears on the third line of the screen. Use scroll keys (22) to move symbol > to the MINUTES line. Press + button (F4) or - button (F3) until "6:15" appears on the third line of the screen. Check the programmed command on the screen:

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TIMER NOT ACTIVE NUMBER OF EVENTS PROGRAMMED EVENT: 1 START 7 8 9 10 11 12 13

MONDAY

1 6:15

Press SAVE button (F7) to save this command; message CHANGES SAVED appears. Press input button (F1); pictograph (1-Fig. 1.25) will light up green. The message "ADD A NEW EVENT" appears and the EVENT number changes to "2". Use scroll keys (22) to move symbol > to the START/STOP line. Press + button (F4) until the command STOP appears on the third line of the screen. Use scroll keys (22) to move symbol > to the DAY line. Press + button (F4) or - button (F3) until FRIDAY appears on the third line of the screen. Use scroll keys (22) to move symbol > to the HOUR line. Press + button (F4) or - button (F3) until "18:0" appears on the third line of the screen. Use scroll keys (22) to move symbol > to the MINUTES line. Press + button (F4) or - button (F3) until "18:05" appears on the third line of the screen. Check the programmed command on the screen:

TIMER NOT ACTIVE NUMBER OF EVENTS PROGRAMMED EVENT: 2 STOP 14 15 16

FRIDAY

2 18:05

Press SAVE button (F7) to save this command; message CHANGES SAVED appears. Buttons (F9 and F10) allow to scroll through the programmed commands. See section 1.9.9.5 to activate the timer.

1.9.9.3 To modify a command 1 2 3 4 5 6 7 Call up the Timer submenu; see section 1.9.9.1. Check that the timer function is not active (pictograph 5-Fig. 1.25 lights up white); see Important above. Press scroll buttons (F9 or F10) until the event to be modified appears on the third line of the screen. Press modify button (F2); pictograph (2-Fig. 1.25) will light up green; message MODIFY THE CURRENT EVENT appears. Use scroll keys (22) to select the item to be modified. Modify as required using the + and - buttons (F3 and F4). Save by pressing key (F7); message CHANGES SAVED appears. See section 1.9.9.5 to activate the timer.

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1.9.9.4 To delete a command 1 2 3 4 5 6 Call up the Timer submenu; see section 1.9.9.1. Check that the timer function is not active (pictograph 5-Fig. 1.25 lights up white); see Important above. Press scroll buttons (F9 or F10) until the event to be deleted appears on the third line of the screen. Press delete button (F6); pictograph (6-Fig. 1.25) will light up green; message DELETE THE CURRENT EVENT appears. Save by pressing key (F7); message CHANGES SAVED appears. See section 1.9.9.5 to activate the timer.

1.9.9.5 To activate/de-activate the programmed time schedule Warning The start and stop commands are only carried out after activating the schedule. After activating, the compressor is started and stopped according to the schedule even if it was stopped manually. 1 Call up the Timer submenu; see section 1.9.9.1

To activate the time schedule 2 Press timer on/off button (F5): pictograph (5-Fig. 1.25) lights up green indicating that the programmed timer functions are active; message TIMER ACTIVE will appear (also on the Main screen). To de-activate the time schedule 3 Press timer on/off button (F5): pictograph (5-Fig. 1.25) lights up white indicating that the programmed timer functions are not active; message TIMER NOT ACTIVE will appear (also on the Main screen). 1.9.10 Saved data menu Function The Saved data menu is used to call up the 3 last shut-down and emergency stop data saved by the PLC. Calling up this menu 1 Press main menu button (F8). The Main menu is shown: MAIN SCREEN CONFIGURATION SETTINGS SERVICE TIMER SAVED DATA

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Press scroll keys (22) until symbol > is situated on the left of item SAVED DATA. Press return key (13) to select this menu. Following menu appears:

LAST SHUTDOWN <1> LAST SHUTDOWN <2> LAST SHUTDOWN <3> LAST EMERGENCY STOP <1> LAST EMERGENCY STOP <2> LAST EMERGENCY STOP <3> Note: (1) stands for the last event, (2) stands for the second-last event, 3 Use scroll keys (22) to move through the screen until symbol > is situated on the left of the desired item and press return key (13). A screen appears showing information (date, time,...) related to the shut-down.

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2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 and 2.2)

(1) (2) (3) (4) (5)

Compressed air outlet Cooling water outlet Cooling water inlet Motor cooling air inlet for closed motor (IP55) Motor cooling air outlet for open motor (IP23)
(6) (9)

(4) (5)

(7) (8) (10)

(1)

(2) (3)

(11) (12) (13) (14) (15) (16) (17) (18)

(19) (20) (23)

TWO STAGE

(22)
THREE STAGE

(24)

(21)

THREE STAGE (22)

TWO STAGE

(23)

(24)

9823 2462 00/1 52436D

Fig. 2.1 Dimension drawing, compressor with bodywork

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(6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)
(27) (26)

(17) (18) (19) (20) (21) (22)

(28) (29)

(23) (24) (25) (26) (27) (28)

(30) (22)
THREE STAGE

(31)

(29) (30)

(23)
TWO STAGE

(24)

(11) (12) (13) (14) (15) (16) (17) (18)

(31)

Motor cooling air outlet for closed motor (IP55) Motor cooling air inlet for open motor (IP23) Blow-off out Compressor air inlet For hot air only Condensate drains Automatic drain, blow-off silencer Manual drain, aftercooler, G " Automatic drain, aftercooler, G " Manual drain, intercooler 2, G " Automatic drain, intercooler 2, G " Manual drain, intercooler 1, G " Automatic drain, intercooler, 1 G " Not for two-stage standard and threestage hot air Not for two-stage hot air Air and water connections Compressed air outlet three-stage Compressed air outlet two-stage Water inlet and outlet Free space in canopy Cubicle For 10kV motors only Main terminal box connection Ventilation, standard motors Open motor 1RA3 (IP23) Closed motor 1LA4 (IP55)

THREE STAGE (22)

TWO STAGE (23)

(24)

(19) (20) 9823 2462 00/1 52437D

Fig. 2.2 Dimension drawing, compressor without bodywork

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2.2 Installation proposal (Fig. 2.3)

(1)

(2)

(1)

(2) (3)

(4)

(5)

(6)

(7)

(8)

(9)

9823 2494 00 52421D

(1) Totally open zone next to delivery pipe (2) Minimum free area (3) Minimum corridor width (4) Ventilation proposals (5) Motor side (6) Compressor side (7) Closed motor IP54 (8) Open motor IP23 (9) No canopy

Fig. 2.3 Installation proposal (typical example)

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Ref. 1. 2.

Description Install the compressor on a level floor suitable for taking the weight of the compressor. Recommended minimum distance between the top of the compressor and the ceiling is 150 cm for ventilation and lifting. Remove the cover from the air outlet pipe of the compressor and install the compressed air outlet valve. The valve must be provided locally. Connect the valve to the air net. See also section 2.3 for alignment tolerances. The pressure drop over the delivery pipe can be calculated as follows: dp = (L x 450 x Qc1.85) / (d5 x P) dp L d P Qc = = = = = pressure drop (recommended maximum = 0.1 bar) length of delivery pipe in m inner diameter of the delivery pipe in mm absolute pressure at the compressor outlet in bar(a) free air delivery of the compressor in l/s

3.

4.

The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor is avoided. The air velocity through the grids should be limited to 5 m/s. Consult section 7.4.2 for the compressor limitations. The required ventilation capacity to limit the compressor room temperature can be calculated as follows: Qv = Qv = N = dT = 0.1 N / dT required ventilation capacity in m /s shaft input of the compressor in kW temperature rise over ambient in C
3

5.

Fit the manual condensate drain valves (5 and 7-Fig. 3.1). Lay out the drain piping towards the condensate collector. The drain pipes must not dip into the water of the collector. It is strongly recommended to provide a funnel for each drain pipe to allow visual inspection of the condensate flow. Position of the control panel. Position of the medium voltage cable entry. Check that the electrical connections correspond to the local codes. The installation must be earthed and protected against short circuits by fuses in all phases. An isolating switch must be installed near the compressor. Position of the low voltage cable entry. Position of the condensate drain valves. Remove the covers from the water inlet and outlet pipes. Install a water inlet and outlet valve, as well as drain valves. The valves must be provided locally. It is recommended to provide a strainer in the water inlet for filtering particles larger than 0.1 mm. The strainers have to be suitable for the cooling water flow. It is also recommended to install a 1 nipple in the water inlet and outlet pipes. Connect the inlet and outlet valves to the water net. See also section 2.3 for alignment tolerances.

6. 7a.

7b. 8. 9.

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(1)

(2)

(4) (8)

(3)

(5)

(6)

(7) 9823 1514 43/1 52563D

(1) (2) (3) (4) (5) (6) (7) (8)

Customer's installation, medium voltage supply Customer's installation, low voltage supply Control voltage Compressor motor PT100 Protection in bearings (optional) PT100 Protection in windings (optional) Motor heater (optional) To be installed by customer

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F6 F21 K13 K21 K25 K27 K29 L1/2/3 M1 M25 M27 Q1 Q25 Q27 Q29 R29 R96 T1 T61 TT95a TT95b TT96a TT96b TT97a TT97b TT98 TT99 1X1 1X2 1X3

Undervoltage relay (customer's installation) Overload relay, drive motor (customer's installation) Auxiliary relay, motor starter control Starter, drive motor (customer's installation) Contactor, auxiliary oil pump motor M25 Contactor, oil demister fan motor M27 Contactor, oil heater R29 Terminals, 3-phase low voltage supply Drive motor Motor, auxiliary oil pump Fan motor, oil demister Circuit breaker, control circuit Circuit breaker, motor auxiliary oil pump Circuit breaker, demister fan motor Circuit breaker, oil heater Oil reservoir heater Anti-condensation heater (optional) Main transformer Motor current transformer/transmitter 4-20mA (customer's installation) Motor winding temperature U1-U2 (T1-T4) (optional) Spare, motor winding temperature U1-U2 (T1-T4) (optional) Motor winding temperature V1-V2 (T2-T5) (optional) Spare, motor winding temperature V1-V2 (T2-T5) (optional) Motor winding temperature W1-W2 (T3-T6) (optional) Spare, motor winding temperature W1-W2 (T3-T6) (optional) Motor bearing temperature, drive end (optional) Motor bearing temperature, non-drive end (optional) Terminal strip, AC power distribution Terminal strip, to customer's installation Earth bolt

Fig. 2.4 Voltage supply connections, compressors without starter

2.3 Mounting of outlet piping

Atlas Copco ZH6000-10000 compressors with aftercooler are equipped with rubber compensators on the air and water connections. These compensators can cope with some minor misalignment (Fig. 2.5) when the customer pipe end is mounted. The allowable alignment tolerances for the different compensators are listed in the table below. See section 2.3.1. The piping system at customer side must be designed to fulfil the stated tolerances (both static and during operation). The compensators that are used are not suitable to carry the pressure thrust load. Make sure to adequately support and anchor the piping system. The compensator must not carry the weight of the customer pipe. Adequate supporting of the piping system shall be provided to avoid weight load on the compensator. For the design of piping and supporting structures, use an approved standard code (e.g. EN 13480 or ASME 16.5/B31.3).

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(1) (2) (3) (4) (5) (6) (7) (8)

Pipe end customer Pipe end Atlas Copco Lateral alignment Angular alignment Atlas Copco side Customer side Customer air outlet pipe Compressor

Fig. 2.5 Mounting of outlet piping

2.3.1 Rubber compensator types Compensator part number DIN 1621 3098 00 1619 3120 07 ANSI 1621 8114 00 1621 9293 00 Diameter (in) 3 8 3 8 EL (mm) minimum (Fig. 2.5) 115 120 115 115 EL (mm) maximum (Fig. 2.5) 140 135 140 140

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2.3.2 Alignment tolerances (Fig. 2.5) Maximum allowed tolerance on lateral alignment: 0 5 mm The pipe ends must be mounted in such a way that they are in-line (no angular misalignment is allowed). Important: Design the piping and supporting structures in function to fulfil the requirements as stated.

2.4 Cooling water requirements

The cooling water quality must meet certain minimum requirements. No general recommendation can encompass the effects of all combinations of the various compounds, solids and gases typically found in cooling water in interaction with different materials. This recommendation is a general guideline for acceptable coolant quality.

2.4.1 Type of the system Closed system In a closed system, the same cooling water is circulating through a system without contact with air. Open system An open system is a pass-through system, or a circulating system with a cooling tower. In the latter case, the composition of the water that enters the cooler must be considered, and not the composition of the make-up water. Due to the evaporative effect in the cooling tower, much higher concentrations of ions can be obtained in the circulating water than in the make-up water.

2.4.2 Cooling water parameters The Rysnar stability index (RSI) The Rysnar Index (RSI) is a parameter for predicting whether water will tend to dissolve or precipitate calcium carbonate. The adhesion of scaling depositions and their effect are different on different materials, but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the saturation pH value (pHs). The saturation pH value is determined by the relationship between the calcium hardness, the total alkalinity, the total solids concentration and the temperature. The Rysnar Index is calculated as follows: RSI = 2*pHs - pH Where: pH = measured pH (at room temperature) of water sample pHs= pH at saturation

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The pHs is calculated by using: pHs = (9.3 + A + B) - (C + D) A: depends on the total solids concentration (mg/l). B: depends on the highest cooling water temperature (C), For ZH-units take: T = 65C C: depends on the calcium hardness (ppm CaCO3). D: depends on the HCO3- concentration or M-alkalinity (mval/l). The values from A, B, C and D are found in the table below. Total Dissolved solids (mg/l) 50 300 400 - 1000

Temperature A 0.1 0.2 (C) 0-1 2-6 7-9 10 - 13 14 - 17 18 - 21 22 - 27 28 - 31 32 - 37 38 - 44 45 - 50 51 - 56 57 - 63 64 - 71 72 - 80 B 2.6 2.5 2.4 2.3 2.2 2.1 2.0 1.9 1.8 1.7 1.6 1.5 1.4 1.3 1.2

Ca-hardness (ppm CaCO3) 10 - 11 12 - 13 14 - 17 18 - 22 23 - 27 28 - 34 35 - 43 44 - 55 56 - 69 70 - 87 88 - 110 111 - 138 138 - 174 175 - 220 230 - 270 280 - 340 350 - 430 440 - 550 560 - 690 700 - 870 880 - 1000 C 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6

M-Alkalinity (mval/l) 0.20 - 0.22 0.24 - 0.26 0.28 - 0.34 0.36 - 0.44 0.46 - 0.54 0.56 - 0.70 0.72 - 0.88 0.90 - 1.10 1.12 - 1.38 1.40 - 1.76 1.78 - 2.20 2.22 - 2.78 2.80 - 3.54 3.54 - 4.40 4.6 - 5.4 5.6 - 7.0 7.2 - 8.8 9.0 - 11.0 11.2 - 13.8 14.0 - 17.6 17.8 - 20.0 D 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0

The interpretation of the values obtained is: RSI < 6 boiler scale formation RSI 6 7 neutral water RSI > 7 corrosive water

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A more detailed interpretation follows below: RSI RSI < 3.9 4.0 < RSI < 5.5 Tendency of the water Very high scale formation High boiler scale formation Action Water cannot be used Regular control and descaling operation necessary Water treatment not necessary Occasional inspection recommended Water treatment not necessary Occasional inspection recommended Water treatment not necessary Occasional inspection recommended Regular control necessary, use of corrosion inhibitor recommended Regular control necessary, use of corrosion inhibitor required Water should not be used

5.6 < RSI < 6.2 Slight boiler scale formation 6.3 < RSI < 6.8 6.9 < RSI < 7.5 7.6 < RSI < 9.0 9.1 < RSI < 11 RSI > 11 Neutral water Slight corrosion at higher temperature Strong corrosion Very strong corrosion Very strong corrosion in complete water system

This table indicates that distilled or demineralised water should never be used, as their RSI is >11. The RSI is only indicating the equilibrium of scaling descaling. Cooling water showing good RSI conditions can still be unsuitable due to other factors. From the table above, the RSI index should be between 5.6 and 7.5, otherwise contact a specialist. pH The effect of pH is already calculated in the Rysnar index, but the pH itself has some additional limitations: 6.8 < pH < 8.5 Total Dissolved solids (TDS) This is the sum of all ions in the water. It can be derived from the dry residue after evaporation (but not including suspended solids), or it can be estimated from the electrical conductivity. In a closed system, the following limits apply: TDS < 3000 mg/l (<3800 S/cm)

For an open system, the following limits apply: TDS < 750 mg/l (< 960 S/cm)

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Chlorides (Cl-) Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited: Closed cooling system: Chlorides < 500 ppm Open cooling system: Chlorides < 150 ppm However, if the water is scaling, lower limits should be used. (See The Rysnar stability index (RSI)). Free chlorine (Cl2) Continuously, a level of 0.5 ppm should not be exceeded. For shock treatments, a maximum limit of 2 ppm for maximum 30 minutes/day applies. Sulphates (SO4--) Closed cooling system: Sulphates < 400 ppm Open cooling system: Sulphates < 150 ppm Carbonate hardness Closed cooling system: 50-1000 ppm CaCO3 Open cooling system: 50-500 ppm CaCO3 HCO3- / SO42- should be >1 Ammonia < 0.5 ppm Copper < 1 ppm Iron and Manganese < 1 ppm Organics No algae. No oil. Suspended solids Non-soluble particles, size < 1mm. < 10 ppm Remark Chloride and sulphate are interactive. In open systems the sum of the squares of these values must not exceed 85,000. For recirculating systems with proper controls and treatment, the sum of the squares may be up to 520,000. Note that the sulphate value must include any sulphite present.

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2.5 Pictographs
See also Figs. 1.9, 1.10 and 1.25.

1 2 3 4 5

Condensate drain, blow-off silencer Manual condensate drain, aftercooler Automatic condensate drain, aftercooler Manual condensate drain, intercooler Automatic condensate drain, intercooler

Fig. 2.6 Pictographs, condensate drains

1 2

Cooling water outlet Cooling water inlet

Fig. 2.7 Pictographs, water

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3 OPERATING INSTRUCTIONS
Safety precautions The operator must apply all related safety precautions including those mentioned in this book. Operating conditions If the ambient or air inlet temperatures can be beyond the limitations stated in section 7.4, precautions must be taken. In this case, and also if operating in other extreme conditions, consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment must be placed in such a way that the compressor will be lifted perpendicularly. Lift smoothly and avoid twisting.

3.1 Preparation for initial start-up

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Consult section 2 for the dimension drawings and installation proposal. Consult section 7.3 for the values of the circuit breakers and motor types. A sticker dealing in short with the operation is delivered with the compressor. Fit it next to the control panel. If not provided, stick warning labels next to the control panel and also on both sides of the compressor on an obvious place inside the bodywork indicating that the compressor is automatically controlled (started and stopped) by the PLC. A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect the compressor against corrosion. Remove the plates. Check the voltage selecting wires at transformer (T1-Fig. 1.11) for correct connection (a label is stuck on the transformer). Check that key (3-Fig. 1.11) of the CPU is in position RUN and check the setting of circuit breakers (Q1/25/27/29-Figs. 1.11 and 2.4). See section 7.3. Remove the centre part of the drive coupling (4-Fig. 1.1). Have the drive motor alignment checked by an Atlas Copco representative. Start the drive motor and stop it immediately. Check the rotation of drive motor (1-Fig. 1.1) while the compressor is coasting to a stop: the correct rotation direction is counter-clockwise when looking at the drive end shaft of the motor. If wrong, switch off the voltage and reverse two incoming electric lines. Fit the centre part of the drive coupling using new bolts (4-Fig. 1.1). Check that the oil reservoir is filled with oil to the full mark of sight-glass (3-Fig. 3.2). See section 4.3. For drive motors equipped with sleeve bearings, check that oil is visible in the bearing sight-glasses. The outlet of the demister may be ducted outside of the bodywork. The maximum pressure drop over this pipe is 0.5 mbar. Never install valves in this pipe. Avoid any obstruction or liquid lock by sagging of the pipe. Check that the cooling water drain valves (customer's installation) in the inlet and outlet piping are closed. Check that the drain valve in the water inlet pipe (1-Fig. 3.4) is closed and the drain plug (2) is fitted. Open the water inlet and outlet valves (customer's installation), as well as the flow regulating valves (2 and 4-Fig. 3.3). Check for water flow. Close the condensate drain valves (5 and 7-Fig. 3.1).

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15. 16.

17. 18. 19. 20.

Switch on the voltage and put key switch (17) in position local (vertical position). Check, if the oil temperature is below 38 C, whether the oil heater is activated (pictograph 1 is lit up green). Check that the auxiliary oil pump (7-Fig. 3.3) starts running (pictograph 6 is lit up green) (or starts after a period of time, controlled by the PLC). Check the rotation direction of the motor (8-Fig. 3.3) of the oil pump: the correct rotation direction is clockwise when looking at the drive end shaft of the motor; if wrong, switch off the voltage and reverse two incoming electric lines at circuit breaker (Q25-Figs. 1.11 and 2.4). Wait until the starting conditions are fulfilled (see section 3.3): pictograph (5) is lit up green or blinks to indicate that the compressor may be started. See section 1.8. Check the rotation of fan motor (1-Fig. 5.5) of the demister: the correct rotation direction is clockwise when looking at the drive end shaft of the motor. If wrong, switch off the voltage and reverse two incoming electric lines at circuit breaker (Q27-Figs. 1.11 and 2.4). Have the tuning of inlet guide vanes (3-Fig. 3.3) and blow-off valve (1) checked by an Atlas Copco representative. Have the settings programmed in the PLC checked by an Atlas Copco representative.

3.2 Compressor control modes

Key switch (17) allows the operator to select three control modes: 24 Compressor off: The PLC will not react to any start/stop command. The oil will not be heated and not circulated. Local control mode (remote control mode is made inactive): The compressor can only be controlled by the buttons on the control panel. The oil is kept on temperature and the oil pump is operative (started or stopped by the PLC). Remote control mode (local control is made inactive): The compressor will only react to start/stop and manual load/unload commands by external switches. Emergency stop button (18) remains active. The oil is kept on temperature and the oil pump is operative (started or stopped by the PLC).

25

26

Important The PLC will only react to a new control mode if the new position of the control mode switch is maintained for 3 seconds. To avoid unauthorized switching over to another control mode, take out the key after selecting the required mode.

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3.3 Before starting

Attention Before starting the compressor, the oil temperature must exceed 25C; immediately after pressing the start button, the oil pressure must exceed 0.2 bar(e). If these conditions are not fulfilled (pictograph 5 is not lit up green), the compressor will not start; after pressing button (F5), a message indicating the fault will appear on display (11). It is recommended to keep key switch (17) in the position local control (vertical position) or remote control (switched to the right) to keep the oil heater energized and the auxiliary oil pump operative (started and stopped by the PLC). See section 1.7.5. 1. 2. 3. 4. 5. 6. Check the oil level (3-Fig. 3.2) which must be in the green range or above. Top up, if necessary, with the correct type of oil. See section 4.3. For drive motors equipped with sleeve bearings, check that oil is visible in the bearing sight-glasses. Close condensate drain valves (5 and 7-Fig. 3.1). Open the air outlet valve. If the cooling water was drained (see section 3.7): close the drain valve (1-Fig. 3.4) in the water inlet pipe and fit the drain plug (2) fit the drain plugs (6-Fig. 3.3) underneath all coolers Open the water inlet valve and outlet valve. Open the water flow regulating valves (2 and 4-Fig. 3.3). Opening of these valves can be overlooked if, after previous operation, the settings have not been disturbed.

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1 2 3 4 5 6 7 8

Air outlet Water outlet Water inlet Automatic drain outlet, intercooler condensate drain Condensate drain valve, intercooler condensate drain Automatic drain outlet, aftercooler condensate drain Condensate drain valve, aftercooler condensate drain Condensate drain, blow-off silencer

Fig. 3.1 Air, water and condensate drain connections

3.4 Starting
3.4.1 Routine starting 1. 2. 3. Switch on the voltage. Check that voltage on lamp (15) lights up. Check whether any warnings or shut-down conditions (indicated by pictograph 2) exist. If any, consult section 1.7. Check the cause and remedy. Press reset button (16) to clear any alarm. Normally, the main screen is shown. See section 1.9.1.

The screen shows: the compressor outlet pressure the compressor setpoint (see section 1.7) the gearbox oil pressure the outlet pressure at compressor element 2 the position of inlet guide vanes (3-Fig. 3.3): the open position of the vanes is expressed in percentage the position of blow-off valve (1-Fig. 3.3): the closed position of the valve is expressed in percentage whether the compressor is controlled locally (start/stop and manual load/unload commands only possible by means of the buttons of the control panel) or controlled remotely (start/stop and manual load/unload commands only possible by means of external switches) the status of the Timer (if activated, the programmed time-based start and stop commands will be executed; see section 1.9.9) 4. 5. 6. 7. Check that permissive start pictograph OK (5) lights up or blinks (see section 1.8.3). If the compressor is not ready to start, consult section 6. Press start button (19). The compressor starts running in unloaded condition. Automatic operation pictograph (3) will light up. Auxiliary oil pump (7-Fig. 3.3) should automatically turn off after the compressor has reached full operating speed; pictograph (6) will go out. After 20 seconds (programmable), the compressor starts running loaded. If necessary, regulate the water flow with the compressor running loaded using valves (2 and 4-Fig. 3.3). Consult section 7.4 for the cooling water temperature and pressure, and for the cooling water consumption.

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3.4.2 Starting after emergency stopping or shut-down Press emergency stop button (18) (if not yet done so), switch off the voltage and depressurize the compressor. After remedying the fault, unlock the emergency stop button by pulling it out, press reset button (16) and restart the compressor as described above.

3.4.3 Number of motor starts In automatic operation, the PLC limits the number of motor starts. See section 8.4.

1 2 3 4 5 6 7

Oil filler cap Oil strainer Oil level sight-glass Oil drain valve Oil heater Oil reservoir Inspection cover, oil reservoir

Fig. 3.2 Oil reservoir

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1 2 3 4 5 6 7 8

Blow-off valve Water regulating valve, aftercooler circuit Inlet guide vanes Water regulating valve, intercooler circuit Vent plugs Drain plugs Auxiliary oil pump Motor, auxiliary oil pump

Fig. 3.3 View of coolers

3.5 During operation

1. 2. 3. 4. When pictograph (3) is lit up, starting and stopping of the motor is automatically controlled: when the motor is stopped, it may restart automatically. Check the readings on display (11). See below. To unload the compressor manually, press button (F4). To put the compressor back into automatic operation, press button (F3). Check that condensate is drained through the automatic drain outlets (4 and 6-Fig. 3.1) (the amount depends on the ambient and operating conditions).

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Important 1. If the motor is stopped and automatic operation pictograph (3) is lit up or blinking, starting and stopping of the motors is automatically controlled by the PLC. See also: section 1.8.3 for explanation of the pictograph section 1.7.7 for automatic restart after power failure section 1.9.7.1 for automatic restart after a long period of automatic completely unloaded operation section 1.9.9 for time-based start and stop commands. After stopping, the motor is prevented from restarting within a programmable time period which is set exfactory at 240 seconds (called minimum stop time). A start command during this period is ignored. The PLC will only react to a new control mode if the new position of control mode switch (17) is maintained for 3 seconds. To avoid unauthorized switching over to another control mode, take out key (17) after selecting the required mode. See also section 3.2.

2. 3.

3.5.1 Checking the display 1. 2. Regularly check the display (11) for readings and messages. Normally, the compressor main screen is shown. See section 3.4.1. Always check the display and remedy the trouble if pictograph (2) is blinking or lit up. Consult section 1.7.

Warning Before carrying out any maintenance, repair or adjustment, stop the compressor, press emergency stop button (18), switch off the voltage and depressurize the compressor.

3.6 Manual control of compressor operation

Normally, the compressor runs in automatic operation: the PLC controls the capacity and operation of the compressor. Pictograph (3) is lit up green. If required, the compressor can be unloaded manually by pressing button (F4): the compressor is switched out of automatic operation and remains running unloaded (unless button F3 is pressed). Pictograph (4) lights up and pictograph (3) goes out. Press button (F3) to switch the compressor to automatic operation again (automatic capacity regulation controlled by the PLC). Pictograph (3) lights up and pictograph (4) goes out.

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3.7 Stopping
1. 2. 3. 4. 5. 6. Press stop button (20). The compressor will follow a programmed stop sequence (run unloaded for some seconds, after which it will stop). Close the air outlet valve. To stop the compressor immediately in case of emergency, press emergency stop button (18). Pictograph (2) starts blinking. After remedying the trouble, unlock the emergency stop button by pulling it out. Open condensate drain valves (5 and 7-Fig. 3.1). Close the cooling water inlet valve. If the compressor is installed in a room where freezing temperatures are expected, drain the cooling system: remove drain plug (2-Fig. 3.4) in the water inlet pipe and open the drain valve (1) remove the drain plugs (6-Fig. 3.3) underneath all coolers

Attention It is recommended to keep key switch (17) in position local control (vertical position) or remote control (switched to the right) to keep the oil heater energized and the auxiliary oil pump operative (started and stopped by the PLC). See section 1.7.5.

1 2

Water drain valve Water drain plug

Fig. 3.4 Water piping

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3.8 Taking out of operation

At the end of the service life of the compressor, proceed as follows: 1. 2. 3. 4. 5. 6. Close the air outlet valve and stop the compressor. Switch off the voltage and disconnect the compressor from the mains. Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net. Drain the water, oil and condensate circuits. Disconnect the compressor condensate piping from the condensate drain net. Disconnect the cooling water pipes from the compressor.

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4 MAINTENANCE
Warning Before starting any maintenance or repair, press stop button (20), wait until the compressor has stopped, press emergency stop button (18), switch off the voltage and depressurize the compressor. Safeguard against unintentional "switch-on". Apply all relevant safety precautions, including those mentioned in this book.

4.1 Preventive maintenance schedule for the compressor 1)

The schedule contains a summary of the maintenance instructions. Read the related 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) Daily " " " " " Weekly " " " 6-monthly " " Yearly " " " " " " " Running hours 2) 8 8 8 24 24 4000 8000 8000 8000 8000 8000 See section 1.7 3.3 7.1 3.7 8 4.2 3.1 5.1 5.1 5.2 5.2 5.2 See notes below table 1 5 2 4 3 Operation Check operation of inlet guide vanes and blow-off valve Check for warnings Check oil level Check display readings Check that condensate is discharged from automatic drains Manually drain condensate drain receivers after stopping Check programmed settings Check for water, oil or air leaks Check for abnormal noise Drain condensate from air receiver, if installed Grease motor bearings Check pressure drop over oil demister pipe (if ducted away) Remove air filters and inspect; clean or replace if necessary Clean compressor Replace air filters Have oil analysed; change oil if necessary Change oil filter Check oil strainer; clean if necessary Check operation of oil demister Check coolers; have cleaned if necessary Have inlet guide vanes, blow-off valve and check valve inspected Have motor alignment checked

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Period 2) " " 2-Yearly 3-Yearly Notes 1. 2. 3. Copco. 4. 5.

Running hours 2) 16000 24000

See section 5.4 5.3

See notes below table -

Operation Have regulating system, shut-down and alarm functions, sensors and electrical components checked Have compressor inspected by Atlas Copco Change PLC battery Replace cartridge of oil demister

Level should be in green range or above. Any leak should be attended to immediately. In very dusty surroundings it may be necessary to check the air filters more frequently. Consult Atlas The interval depends on the ambient temperatures. Consult Atlas Copco if in any doubt. The amount of condensate depends on the working and environmental conditions. The amount discharged from the intercooler is low in relation to the condensate flow from the aftercooler.

4.2 Motor greasing

For motors with roller bearings (section 7.3.2): Type: Use Atlas Copco Roto-Glide grease. Interval: The grease interval is 2000 operating hours or more. Consult the motor data plate. Attention: Never mix different greases.

4.3 Lubricant specifications

Use Atlas Copco Roto-H Plus. This is special lubricant for ZH compressors ensuring optimum bearing lubrication. This lubricant can be ordered in following quantities: All markets except for USA and Canada 19 l can 208 l drum For USA and Canada 5 gal can 55 gal drum 2908 8509 00 2908 8510 00 2908 8507 00 2908 8508 00

Attention: Do not mix Roto-H Plus with Roto-H or other lubricants.

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4.4 Storage after installation

Open condensate drain valves (5 and 7-Fig. 3.1). Close the valves after draining. Keep key switch (17) in local (vertical position) or remote (switched to the right) control mode to keep the oil warm and pumped around preventing the internal system from rusting. If key switch (17) is left in the compressor lock mode (switched to the left), switch over to local or remote position once a week, wait until the starting conditions are fulfilled (pictograph 5 lights up or blinks), and run the compressor for about 15 minutes. Keep the compressor room well-ventilated and the compressor clean. Protect the compressor in case the ambient temperature can be beyond the limitations (see section 7.4.2). If in any doubt, consult Atlas Copco.

If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult Atlas Copco.

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.

Footnotes chapter 4 1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. 2) Whichever interval comes first. The local Atlas Copco Sales Company may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor.

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5 SERVICING PROCEDURES
5.1 Air filters (Fig. 5.1)
1. 2. 3. 4. 5. 6. 7. In dusty operating conditions where it will be necessary to replace the filters too frequently, an appropriate pre-filter of the dry type should be installed. The filters must be serviced as soon as the service warning appears on the display or yearly. Stop the compressor and switch off the voltage. Remove the cover (1) and clean the filter chamber. Remove the filters (2). Take care that no dirt drops into the filter box. Install the new filters (see section 4.5) and fit the cover. Never install damaged or clogged filters. Switch on the voltage. Reset the service warning and the actual running hours to 0 as described in section 1.9.7.3.

1 2

Cover Air filters

Fig. 5.1 Air filters

5.2 Oil and oil filter change (Figs. 5.2 and 5.3)
1. 2. 3. 4. 5. 6. Run the compressor until warm. Stop the compressor and switch off the voltage. Remove filler plug (1-Fig. 5.3). Drain the compressor sump by opening drain valve (4). Close the valve after draining. Remove the filter (Fig. 5.2) and fit a new one. Remove inspection cover (7-Fig. 5.3) and check oil strainer (2). If necessary, clean the strainer. Reinstall the cover. Fill the compressor sump to the full mark of sight-glass (3) with oil as specified in section 4.3 (approx. 220 l). Switch on the voltage. Reset the service warning and the actual running hours of the oil to 0; reset the service warning and the actual running hours of the oil filter to 0. See section 1.9.7.3.

Filter change for optional dual oil filters (Fig. 5.4) When handle (3) is switched to the left (and handle 1 perpendicular to handle 3), the right filter is in operation and vice versa. Assume that the right filter is in operation and needs to be changed: 1. 2. Loosen venting plugs (2) of the left filter until the venting holes are visible. Switch handle (1) in line with handle (3) to fill the left filter with oil and to vent it.

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3. 4. 5.

When oil flows out the venting holes, close the venting plugs. Switch handle (1) until it is perpendicular to handle (3). Switch handle (3) to the right, the left filter is in operation. Remove the right filter and fit a new one (torque 35 Nm). Replace the seals on the venting plugs.

Fig. 5.2 Oil filter

1 2 3 4 5 6 7

Oil filler plug Oil strainer Oil level sight-glass Oil drain valve Oil heater Oil reservoir Inspection cover, oil reservoir

Fig. 5.3 Oil reservoir

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1 2 3

Handle Venting plugs Handle

Fig. 5.4 Dual oil filters

5.3 Demister (Fig. 5.5)

1. 2. 3. 4. 5. 6. Stop the compressor and switch off the voltage. Loosen the clamp ring and remove the upper part (2) of the demister. Unscrew the bolt underneath the filter cartridge and take out the cartridge and gasket. Fit the new gasket and filter cartridge into the upper part of the demister and screw in the bolt underneath the cartridge to fix it. Reinstall the upper part (2) of the demister and tighten the clamp ring. Switch on the voltage. Reset the service warning and the actual running hours to 0 as described in section 1.9.7.3.

Note A demister element kit can be ordered: part number 1621 8651 00.

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1 2

Fan motor Upper part of demister

Fig. 5.5 Oil demister

5.4 PLC battery change (Fig. 5.6)

1. 2. 3. 4. 5. Make sure that all electrical supplies are switched off and that the power cannot be switched on. Press grips (3) and take out CPU card (1). Remove battery (2) and place the new one within one minute. Reinstall CPU card (1). Switch on all electrical supplies and restart the compressor.

1 2 3

CPU card Battery Grip

Fig. 5.6 CPU

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6 PROBLEM SOLVING
Warning Before starting any maintenance or repair, press stop button (20), wait until the compressor has stopped, press emergency stop button (18), switch off the voltage and depressurize the compressor. Safeguard against unintentional "switch-on". Apply all relevant safety precautions, including those mentioned in this book. Faults and suggested remedies 1 The compressor is not ready to start (pictograph 5 remains out) Press OK button (F5). Examples of messages:

Message E- STOP BUTTON COMPRESSOR SHUTDOWN PRESS RESET GEARBOX OIL TEMPERATURE

Action Release emergency stop button (18) by pulling it out. Press reset button (16) See section 1.7.2 Press reset button (16) See section 1.7.5. Check for sensor failure, oil heater overload and auxiliary oil pump motor overload Set key switch (17) in position local (vertically) or remote (switched to the right) The number of programmed starts has been exceeded (see section 8.4). Wait for timer to expire The number of programmed starts has been exceeded (see section 8.4). Wait for timer to expire The minimum stop timer is running (set exfactory at 240 s). Wait for timer to expire

LOCKED MODE STARTS ALLOWED/HOUR

STARTS ALLOWED/DAY

MINIMUM STOP TIME

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Pictograph (2) is blinking Consult section 1.7.2

3 a a b b c c 4 a a b b c c 5

Air temperature above normal Inlet temperature too high due to bad room ventilation or recirculation of cooling air Improve ventilation of compressor room Insufficient cooling water flow Check and increase cooling water flow Insufficient cooling or restriction in cooling water system due to formation of scale or settling down of dirt Consult Atlas Copco Excessive vibration and noise Unstable operation of drive motor Have vibration level measured and motor inspected. Consult Atlas Copco Alignment altered Have compressor/motor re-aligned. Consult Atlas Copco Formation of coke on the bearings Have bearings inspected by Atlas Copco Surge problems Consult Atlas Copco

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7 PRINCIPAL DATA
7.1 Readings on display (1-Fig. 1.9) 1)

Outlet pressure Setpoint pressure Oil pressure, gearbox Outlet pressure, compressor element 2 DP air filter DP oil filter Oil temperature, reservoir Oil temperature, gearbox Inlet temperature, compressor element 2 Aftercooler outlet temperature Approach temperature, intercooler Approach temperature, aftercooler Cooling water inlet temperature Drive motor cooling air inlet temperature Drive motor current Vibration level, compressor element 1 Vibration level, compressor element 2

see 7.4.4 up to 7.4.11 see 7.4.4 up to 7.4.11 approx. 2.3 bar(e) slightly above outlet pressure below 0.05 bar below 1 bar approx. 58 C approx. 50 C sum of cooling water inlet and cooler approach temperatures sum of cooling water inlet and cooler approach temperatures below 20 C below 20 C below 35 C below 50 C depends on motor type 5 to 15 micrometer 5 to 15 micrometer

7.2 Programmable settings

A number of regulation settings and protection settings are programmable. See section 8.

7.3 Circuit breakers - motor types

7.3.1 Circuit breakers

Low voltage supply V 230 400 500 220-230 380 440-460 575

Frequency Hz 50 50 50 60 60 60 60

Approval IEC IEC IEC CSA-UL CSA-UL CSA-UL CSA-UL

Main circuit Q1 A 11.0 5.5 4.5 11.0 5.6 5.0 3.7

Auxiliary oil pump Q25 A 4.7 2.7 2.2 4.7 2.7 2.7 2.2

Oil demister fan Q27 A 1.0 0.6 0.4 1.0 0.6 0.5 0.4

Oil heater Q29 A 3.8 2.2 1.8 3.8 2.1 2.5 2.0

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7.3.2 Motor types Motor IP 55 500 kW / 3-3.3-5-5.5-6-6.6 kV 560 kW / 3-3.3-5-5.5-6-6.6 kV 630 kW / 3-3.3-5-5.5-6-6.6 kV 630 kW / 10 kV 710 kW / 3-3.3-5-5.5-6-6.6 kV 710 kW / 10 kV 600 hp / 2.3-3-3.3-4.16-6-6.6 kV 700 hp / 2.3-3-3.3-4.16-6-6.6 kV 800 hp / 2.3-3-3.3-4.16-6-6.6 kV 900 hp / 2.3-3-3.3-4.16-6-6.6 kV Motor IP 23 500 kW / 3-3.3-5-5.5-6-6.6 kV 560 kW / 3-3.3-5-5.5-6-6.6 kV 630 kW / 3-3.3-5-5.5-6-6.6 kV 710 kW / 3-3.3-5-5.5-6-6.6 kV 600 hp / 2.3-3-3.3-4.16-6-6.6 kV 700 hp / 2.3-3-3.3-4.16-6-6.6 kV 800 hp / 2.3-3-3.3-4.16-6-6.6 kV 900 hp / 2.3-3-3.3-4.16-6-6.6 kV Motor type 1LA4 354-2 1LA4 400-2 1LA4 402-2 1LA4 450-2 1LA4 404-2 1LA4 450-2 1LA4 352-2 1LA4 354-2 1LA4 400-2 1LA4 402-2 Motor type 1RA3 350-2 1RA3 352-2 1RA3 354-2 1RA3 354-2 1RA3 314-2 1RA3 350-2 1RA3 350-2 1RA3 352-2 Bearing type Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Sleeve bearings Roller bearings (optional: sleeve bearings) Sleeve bearings Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings)

Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings) Roller bearings (optional: sleeve bearings)

7.4 Compressor specifications

7.4.1 Design conditions Absolute inlet pressure Relative air humidity Air inlet temperature Nominal effective working pressure Cooling water inlet temperature Motor shaft speed - 50 Hz versions Motor shaft speed - 60 Hz versions bar(a) % C bar(e) C r/min r/min 1 60 35 see sections 7.4.4 up to 7.4.11 26.7 2980 3575

7.4.2 Limitations Maximum setpoint pressure Maximum air inlet temperature Minimum air inlet temperature Maximum ambient temperature Minimum ambient temperature Maximum cooling water outlet temperature Maximum cooling water inlet temperature Maximum cooling water pressure Minimum cooling water pressure bar(e) C C C C C C bar(e) bar(e) see sections 7.4.4 up to 7.4.11 40 -10 40 5 50 35 5 2

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7.4.3 Sound pressure level 3) Sound pressure level, with bodywork Sound pressure level, without bodywork dB(A) dB(A) 70 81

7.4.4 Specific data of 3.5 bar - 50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) C kW m/hr bar l ZH10000 -1 3.5 bar 3.9 3.5 34 500 47 0.5 220 ZH10000 -2 3.5 bar 3.9 3.5 34 500 49 0.5 220 ZH10000 -3 3.5 bar 3.9 3.5 35 560 54 0.6 220 ZH10000 -4 3.5 bar 3.9 3.5 36 630 58 0.6 220 ZH10000 -5 3.5 bar 3.9 3.5 37 630 61 0.7 220 ZH10000 -6 3.5 bar 3.9 3.5 38 710 69 0.8 220

7.4.5 Specific data of 3.9 bar - 50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) C kW m/hr bar l ZH10000 -1 3.9 bar 4.3 3.9 34 500 49 0.5 220 ZH10000 -2 3.9 bar 4.3 3.9 34 560 52 0.6 220 ZH10000 -3 3.9 bar 4.3 3.9 35 560 55 0.6 220 ZH10000 -4 3.9 bar 4.3 3.9 36 630 59 0.6 220 ZH10000 -5 3.9 bar 4.3 3.9 37 710 64 0.7 220 ZH10000 -6 3.9 bar 4.3 3.9 38 710 69 0.8 220

7.4.6 Specific data of 4.2 bar - 50 Hz compressors 2) Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) C kW m/hr bar l ZH10000 -1 4.2 bar 4.6 4.2 34 500 49 0.5 220 ZH10000 -2 4.2 bar 4.6 4.2 34 560 53 0.6 220 ZH10000 -3 4.2 bar 4.6 4.2 35 630 57 0.6 220 ZH10000 -4 4.2 bar 4.6 4.2 36 630 62 0.7 220 ZH10000 -5 4.2 bar 4.6 4.2 37 710 66 0.7 220 ZH10000 -6 4.2 bar NA NA NA NA NA NA NA

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7.4.7 Specific data of 4.6 bar - 50 Hz compressors 2)

Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 6) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) C kW m/hr bar l

ZH10000 -1 4.6 bar 5.1 4.6 34 560 51 0.5 220

ZH10000 -2 4.6 bar 5.1 4.6 34 560 54 0.6 220

ZH10000 -3 4.6 bar 5.1 4.6 35 630 59 0.6 220

ZH10000 -4 4.6 bar 5.1 4.6 36 710 64 0.7 220

ZH10000 -5 4.6 bar 5.1 4.6 37 710 69 0.8 220

ZH10000 -6 4.6 bar NA NA NA NA NA NA NA

7.4.8 Specific data of 50 psi - 60 Hz compressors 2)

Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) C hp m/hr bar l

ZH60001 50 psi 3.9 3.5 34 600 47 0.5 220

ZH60002 50 psi 3.9 3.5 34 600 49 0.5 220

ZH60003 50 psi 3.9 3.5 35 700 54 0.6 220

ZH60004 50 psi 3.9 3.5 36 800 58 0.6 220

ZH60005 50 psi 3.9 3.5 37 800 62 0.7 220

ZH60006 50 psi 3.9 3.5 38 900 69 0.8 220

7.4.9 Specific data of 55 psi - 60 Hz compressors 2)

Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity bar(e) bar(e) C hp m/hr bar l

ZH60001 55 psi 4.3 3.9 34 600 49 0.5 220

ZH60002 55 psi 4.3 3.9 34 700 52 0.6 220

ZH60003 55 psi 4.3 3.9 35 700 55 0.6 220

ZH60004 55 psi 4.3 3.9 36 800 59 0.6 220

ZH60005 55 psi 4.3 3.9 37 800 64 0.7 220

ZH60006 55 psi 4.3 3.9 38 900 69 0.8 220

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7.4.10 Specific data of 60 psi - 60 Hz compressors 2)

Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) C hp m/hr bar l

ZH60001 60 psi 4.6 4.2 34 700 49 0.5 220

ZH60002 60 psi 4.6 4.2 34 700 53 0.6 220

ZH60003 60 psi 4.6 4.2 35 800 57 0.6 220

ZH60004 60 psi 4.6 4.2 36 800 62 0.7 220

ZH60005 60 psi 4.6 4.2 37 900 66 0.7 220

ZH60006 60 psi NA NA NA NA NA NA NA

7.4.11 Specific data of 65 psi - 60 Hz compressors 2)

Compressor type Maximum setpoint pressure Nominal working pressure Air outlet temperature, approx. Motor power 7) Cooling water consumption 4) Corresponding pressure drop over cooling water system Oil capacity NA: not available bar(e) bar(e) C hp m/hr bar l

ZH60001 65 psi 5.1 4.6 34 700 51 0.5 220

ZH60002 65 psi 5.1 4.6 34 700 54 0.6 220

ZH60003 65 psi 5.1 4.6 35 800 59 0.6 220

ZH60004 65 psi 5.1 4.6 36 900 64 0.7 220

ZH60005 65 psi 5.1 4.6 37 900 69 0.8 220

ZH60006 65 psi NA NA NA NA NA NA NA

7.5 Conversion list of SI units into British/American units

1 bar = 14.504 psi 1 g = 0.035 oz 1 kg = 2.205 lb 1 km/h = 0.621 mile/h 1 kW = 1.341 hp (UK and US) 1 l = 0.264 US gal 1 l = 0.220 Imp gal (UK) 1 l = 0.035 cu.ft 1 m = 3.281 ft 1 mm = 0.039 in 1 m3/min = 35.315 cfm 1 mbar = 0.401 in wc 1 N = 0.225 lbf 1 Nm = 0.738 lbf.ft x C = (32 + 1.8 x) F 5)

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Footnotes chapter 7 1) At nominal working pressure, 1 bar absolute inlet pressure, 20C air inlet temperature and 20C water inlet temperature. 2) At design conditions. 3) According to PNEUROP PN8NTC2.2 under free field conditions at 1 m. With a tolerance of 3 dB. 4) At temperature rise of 10C. 5) A temperature difference of 1C = a temperature difference of 1.8F. 6) Rated at 40C and service factor 1. 7) Rated at 40C and service factor 1.15.

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8 PROGRAMMABLE SETTINGS
8.1 Regulation settings - See section 1.9.7.1
Minimum setting Setpoint pressure (PT29) 50 Hz / 3.5 bar 50 Hz / 3.9 bar 50 Hz / 4.2 bar 50 Hz / 4.6 bar 60 Hz / 50 psi 60 Hz / 55 psi 60 Hz / 60 psi 60 Hz / 65 psi Loading pressure setpoint (PT29) 5) Unloading pressure setpoint (PT29) 5) Factory setting Maximum setting

bar(e) bar(e) bar(e) bar(e) bar(e) bar(e) bar(e) bar(e) bar bar

2 2 2 2 2 2 2 2 -0.2 0.2

3.5 3.9 4.2 4.6 3.4 3.8 4.1 4.5 -0.6 0.6

3.9 4.3 4.6 5.1 3.7 4.2 4.5 5 -1 3

8.2 Protection settings - See section 1.9.8.2

Minimum setting Gearbox oil pressure (PT49) -shut-down warning level -shut-down level Air outlet pressure, element 2 (PT22) -shut-down warning level -shut-down level Air inlet temperature, element 2 (TT18) -shut-down warning level -shut-down level Gearbox oil temperature (TT44) -shut-down warning level -shut-down level Vibration, compressor element 1 (VP10) -shut-down warning level -shut-down level Vibration, compressor element 2 (VP20) -shut-down warning level -shut-down level Oil level (LT42) -shut-down warning level -shut-down level Factory setting Maximum setting

bar(e) bar(e)

1.1 1.0

1.6 1.0

1.6 1.5

bar(e) bar(e)

0 1.0

0.9 1.0

0.9 3.0

C C

50 53

52 66

65 66

C C

50 58

57 63

62 63

micrometer micrometer

10 24.1

30.8 47.9

49.4 49.5

micrometer micrometer

10 24.1

30.8 47.9

49.4 49.5

l l

---

179 150

---

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8.3 Service settings - See section 1.9.7.3

Minimum setting Approach temperature, cooler 1 (TT18/51) Approach temperature, aftercooler (TT29/51) Air filter pressure drop (PDT02) Oil filter pressure drop (PDT46) Oil lifetime (KSH49) Oil filter lifetime (KSH48) Air filter lifetime (KSH02) Oil demister lifetime (KSH41) Drive motor regreasing time (with roller bearings) (KSH93) Drive motor regreasing time (with sleeve bearings) (KSH93) C C bar bar hr hr hr hr hr hr 15 15 -0.03 0.7 1 1 1 1 1 1 Factory setting 20 20 -0.05 1 8000 8000 8000 24000 2000 8000 Maximum setting 100 100 -0.10 1.5 2) 2) 2) 3) 4) 2)

8.4 Settings for other parameters - See section 1.9.8.4

Minimum setting Delay at start for oil pressure 1) Delay at start for vibration 1) Delay at start for air filter pressure drop 1) Delay at signal for approach temperature Number of starts per hour Number of starts per day Load delay time (DOL starter) Minimum stop time Stop after unloaded delay 5) Start failure, gearbox oil temperature (TT44) Start failure, gearbox oil pressure (PT49) s s s s 6 6 5 15 1 1 20 20 10 20 0 Factory setting 10 15 15 30 3 24 20 240 15 25 0.2 Maximum setting 25 25 120 255 15 24 99 255 60 40 0.5

s s min C bar(e)

Footnotes chapter 8 1) 2) 3) 4) 5) Is the time period after starting during which the signal is ignored. Recommended interval: yearly or 8000 running hours. Recommended interval: 3-yearly or 24000 running hours. Recommended interval: 2000 running hours ore more. Consult the motor data plate. In case the function Stop after unloaded delay is activated by Atlas Copco. See section 1.9.7.1.

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9 Options
ANSI FLANGES The flanges on the air pipes and cooling water pipes can be provided with ANSI flanges instead of DIN flanges. HOT AIR VERSION The compressors can be delivered without aftercooler for hot air delivery. In this case, the discharge compensator is made of stainless steel and is delivered loose. DUAL OIL FILTERS Dual oil filters can be delivered to replace the oil filter during operation without stopping the compressor. NOISE INSULATING BODYWORK For compressors with this option a noise level of 70 dB(A) can be met. AUTOMATIC WATER SHUT-OFF VALVE An automatic water shut-off valve (175-Fig. 1.5) may be provided loose to shut-off the system when the compressor is not in operation. COOLING WATER REVERSE FLOW VALVE A cooling water reverse flow valve (174-Fig. 1.5) may be provided loose for reversing the water flow through the intercooler, aftercooler and oil cooler in order to clean the coolers without dismantling the cooler bundles. ELECTRONIC CONDENSATE DRAIN TRAPS Electronic drain traps may be provided instead of float valve condensate drain traps (109b and 114b-Fig. 1.5). This option includes the electronic drain power supply and the high level condensate detection in case of drain trap malfunction MOTOR WINDING TEMPERATURE PROTECTION Temperature probes (PT100) can be embedded in the windings of the drive motor (TT95a, TT96a and TT97aFig. 2.4). This option includes the wiring of the sensors from the auxiliary terminal box of the main motor to the controller. Temperature read-out on display is provided. Alarm and shut-down levels are handled by the control system. MOTOR BEARING TEMPERATURE PROTECTION Temperature probes (PT100) can be embedded in the bearings of the drive motor (TT98 and TT99-Fig. 2.7). This option includes the wiring of the sensors from the auxiliary terminal box of the main motor to the controller. Temperature read-out on display is provided. Alarm and shut-down levels are handled by the control system. MOTOR ANTI-CONDENSATION HEATER An anti-condensation heater (R96-Fig. 2.7) can be mounted inside the main motor housing in order to avoid condensation during motor standstill. This option includes the anti-condensation power supply and its control. MODBUS INTERFACE A Modbus interface can be provided in order to communicate with external control systems. This option allows the operator to command the compressor remotely (start/stop, remote pressure set point...) and allows access to operating parameter values (pressures, temperatures, vibrations). PROFIBUS DP INTERFACE A Profibus DP interface can be provided in order to communicate with external control systems. This option allows the operator to command the compressor remotely (start/stop, remote pressure set point...) and allows access to operating parameter values (pressures, temperatures, vibrations). REMOTE PRESSURE SET POINT This option allows the operator to adjust the pressure set point remotely by means of a 4-20 mA signal to be delivered by the user. This option includes a galvanic protection of the PLC analog input card.

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DH+ COMMUNICATION PORT For DH+ communication, the DH+ port located on the CPU shall be used and the DH+ option activated in the PLC software settings. MAIN DRIVE MOTOR WITH SLEEVE BEARINGS This option includes the motor with sleeve bearings and the forced-feed lubrication from the compressor oil system. ES MILLENIUM CONNECTIVITY The PLC based control system is prepared for connection to a master controller ES3000. However, the option for the MODBUS interface shall be added.

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Product : ZH 6000-10000 This is a pressure assembly of cat III according to 97/23/EC. Parts of article 3.3 of 97/23/EC are subject to good engineering practice. Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of article I, section 3.6. Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC according to article I, section 3.3. The following pressure bearing parts are of category higher than I : Intercooler : Cat III Design pressure 10 bar(e), content 299 l Design code : ASME section VIII div. 1. Aftercooler : Cat III Design pressure 10 bar(e), content 261.5 l Design code : ASME section VIII div. 1.

Instruction book

Notes:

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O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: .................................... A i rd r y e rt y p e : .......................................... U n i ts e r i a lN o .d r y e r : ......................................... Motor type: ............................................. Motor serial No.: ............................................ Delivery date: ........................................... F i r s ts t a r t u pd a t e : ........................................... Service Plan: ............................................ Owner's machine No.: ........................................ Selected lubricants Compressor: ............................................ Capacity: .................................................. Bearing grease type, electric motor: ......................... Dryer gearbox ........................................... Capacity ................................................... Printed Matter Nos. Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: .......................... Atlas Copco compressor parts list: .......................... A t l a sC o p c oa i rd r y e rp a r t sl i s t : ................................ Atlas Copco logbook: .................................................................................................... Local Atlas Copco Representative Name: ............................................................................................................... Address: .............................................................................................................. Telephone: ................................... Contact persons: S e r v i c e : ......................................... Te l e x : ...................................... P a r t s : ........................................... E-mail ...............................................................................................................

SAFETY PRECA U T I O N S
To b e read attentively and acted accordingly before i n s t a l l i n g ,o p e r a t i n go r repairing the unit. These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires a d d i t i o n a ls a f e t yp r e c a u t i o n st y p i c a lt ot h ea p p l i c a t i o nw h i c ha r en o ti n c l u d e dh e r e i n .
I na d d i t i o nt on o r m a ls a f e t yr u l e sw h i c hs h o u l db eo b s e r v e dw i t hs t a t i o n a r y air compressors and equipment, the following safety directions and p r e c a u t i o n sa r eo fs p e c i a li m p o r t a n c e . When operating this unit, the operator must employ safe working practices and observe all related local work safety requirements and ordinances. The owner is responsible for maintaining the unit in a safe operating c o n d i t i o n . P a r t sa n da c c e s s o r i e ss h a l lb er e p l a c e di fu n s u i t a b l ef o rs a f e o p e r a t i o n . Installation, operation, maintenance and repair shall only be performed by authorized, trained, competent personnel. N o r m a lr a t i n g s( p r e s s u r e s ,t e m p e r a t u r e s ,t i m es e t t i n g s ,e t c . )s h a l lb e durably marked. Any modification on the compressor or air dryer shall only be performed in agreement with Atlas Copco and under supervision of authorized, competent personnel. I fa n ys t a t e m e n ti nt h i sb o o k ,e s p e c i a l l yw i t hr e g a r dt os a f e t y, d o e sn o t c o m p l yw i t hl o c a ll e g i s l a t i o n ,t h es t r i c t e ro ft h et w os h a l la p p l y. These precautions are general and cover several machine types and equipment; hence some statements may not apply to the unit(s) described i nt h i sb o o k . I fn e c e s s a r y, i n s t a l las u c t i o nd u c t . N e v e ro b s t r u c tt h ea i ri n l e t . C a r e s h a l lb et a k e nt om i n i m i z et h ee n t r yo fm o i s t u r ew i t ht h ei n l e ta i r. 4 . The aspirated air shall be free from flammable fumes or vapours, e . g .p a i n ts o l v e n t s ,t h a tc a nl e a dt oi n t e r n a lf i r eo re x p l o s i o n . 5 . A i rc o o l e du n i t ss h a l lb ei n s t a l l e di ns u c haw a yt h a ta na d e q u a t e f l o wo fc o o l i n ga i ri sa v a i l a b l ea n dt h a tt h ee x h a u s t e da i rd o e sn o t r e c i r c u l a t et ot h ei n l e t . 6 . A r r a n g et h ea i ri n t a k es ot h a tl o o s ec l o t h i n go fp e o p l ec ann o tb e s u c k e di n . 7 . E n s u r et h a tt h ed i s c h a rge pipe from the compressor to the aftercooler, a i rd r y e ro ra i rn e ti sf r e et oe x p a n du n d e rh e a ta n dt h a ti ti sn o ti n contact with or close to flammable material. 8 . N oe x t e r n a lf o r c em a yb ee x e r t e do nt h ea i ro u t l e tv a l v e ;t h ec o n n e c t e d p i p em u s tb ef r e eo fs t r a i n . 9 . I fr e m o t ec o n t r o li si n s t a l l e d ,t h eu n i ts h a l lb e a ra no b v i o u ss i g n r e a d i n g : DANGER: This machine is remotely controlled and may start without warning. As a further safeguard, persons switching on remotely controlled u n i t ss h a l lt a k ea d e q u a t ep r e c a u t i o n st oe n s u r et h a tt h e r ei sn oo n e checking or working on the machine. To t h i se n d ,as u i t a b l en o t i c e s h a l lb ea ff i x e dt ot h es t a r te q u i p m e n t . 1 0 . On units with automatic start-stop system, a sign stating "This machine may start without warning" s h a l lb ea t t a c h e dn e a rt h e instrument panel. 11 . In multiple compressor systems manual valves shall be installed to isolate each compressor. N o n r e t u r nv a l v e s( c h e c kv a l v e s )s h a l ln o t b er e l i e du p o nf o ri s o l a t i n gp r e s s u r es y s t e m s . 1 2 . Never remove or tamper with the safety devices, guards or insulations f i t t e do nt h eu n i t . E v e r yp r e s s u r ev e s s e lo ra u x i l i a r yi n s t a l l e do u t s i d e t h eu n i tt oc o n t a i na i ra b o v ea t m o s p h e r i cp r e s s u r es h a l lb ep ro t e c t e d b yap r e s s u r e r e l i e v i n gd e v i c eo rd e v i c e sa sr e q u i r e d . 1 3 . Pipework or other parts with a temperature in excess of 80 degrees celsius and which may be accidentally touched by personnel in normal operation shall be guarded or insulated. Other high-temperature pipework shall be clearly marked.
(continued on inside of cover)

Installation
Apart from general engineering practice in conformity with the local s a f e t yr e g u l a t i o n s ,t h ef o l l o w i n gd i r e c t i v e sa r es p e c i a l l ys t r e s s e d : 1 . A compressor or air dryer shall be lifted only with adequate equipment i nc o n f o r m i t yw i t hl o c a ls a f e t yr u l e s . L o o s eo rp i v o t i n gp a r t ss h a l lb es e c u r e l yf a s t e n e db e f o r el i f t i n g . I ti s s t r i c t l yf o r b i d d e nt od w e l lo rs t a yi nt h er i s kz o n eu n d e ral i f t e dl o a d . L i f t i n ga c c e l e r a t i o na n dr e t a r d a t i o ns h a l lb ek e p tw i t h i ns a f el i m i t s . W ear a safety helmet when working in the area of overhead or lifting equipment. 2 . Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the pipes. Distribution pipes and connections shall be of correct size and suitable for the working p r e s s u r e . 3 . P l a c et h eu n i tw h e r et h ea m b i e n ta i ri sa sc o o la n dc l e a na sp o s s i b l e .
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1 4 .I ft h eg r o u n di sn o tl e v e lo rc a nb es u b j e c tt ov a r i a b l ei n c l i n a t i o n , c o n s u l t Atlas Copco. 1 5 .T h ee l e c t r i c a lc o n n e c t i o n ss h a l lc o r r e s p o n dt ot h el o c a lc o d e s . The u n i t ss h a l lb eg r o u n d e da n dp r o t e c t e da g a i n s ts h o r tc i r c u i t sb yf u s e s .

(continued)

5 . Never use flammable solvents or carbon tetrachloride for cleaning p a r t s . Take safety precautions against toxic vapours of cleaning l i q u i d s . 6 . Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with a c l e a nc l o t h ,p a p e ro rt a p e . 7 . Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purg e d ,e . g .b ys t e a m c l e a n i n g , before carrying out such operations. Never weld on, or in any way modify, p r e s s u r ev e s s e l s . Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened b e f o r es u ff i c i e n tc o o l i n gt i m e h a se l a p s e d ;t h i st oa v o i dt h er i s ko fs p o n t a n e o u si g n i t i o no ft h eo i l vapour when air is admitted. Never use a light source with open flame for inspecting the interior o fam a c h i n e ,p r e s s u r ev e s s e l ,e t c . 8 . M a k es u r et h a tn ot o o l s ,l o o s ep a r t so rr a g sa r el e f ti no ro nt h eu n i t .

Operation
1 . A i rh o s e ss h a l lb eo fc o r r e c ts i z ea n ds u i t a b l ef o rt h ew o r k i n gp r e s s u r e . Never use frayed, damaged or deteriorated hoses. Use only the correct t y p ea n ds i z eo fh o s ee n df i t t i n g sa n dc o n n e c t i o n s . When blowing t h r o u g hah o s eo ra i rl i n e ,e n s u r et h a tt h eo p e ne n di sh e l ds e c u r e l y. A free end will whip and may cause injury. M a k es u r et h a tah o s ei s f u l l yd e p r e s s u r i z e db e f o r ed i s c o n n e c t i n gi t . Never play with compressed air. D on o ta p p l yi tt oy o u rs k i no r d i r e c ta na i rs t r e a ma tp e o p l e . N e v e ru s ei tt oc l e a nd i r tf r o my o u r c l o t h e s . When using it to clean equipment, do so with extreme caution and use eye protection. 2 . The compressor is not considered as capable of producing air of b r e a t h i n gq u a l i t y. F o rb r e a t h i n ga i rq u a l i t y, the compressed air must b ea d e q u a t e l yp u r i f i e da c c o r d i n gt ol o c a ll e g i s l a t i o na n ds t a n d a r d s . 3 . Never operate the units when there is a possibility of taking in flammable or toxic fumes. 4 . N e v e ro p e r a t et h eu n i t sa tp r e s s u r e sb e l o wo ri ne x c e s so ft h e i rl i m i t r a t i n g sa si n d i c a t e do nt h eP r i n c i p a lD a t as h e e t . 5 . Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e . g .t oc a r r yo u tc h e c k s . We a re a r protectors when opening a door. 6 . People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear protectors. 7 . P e r i o d i c a l l yc h e c kt h a t : a . All guards are in place and securely fastened b . A l lh o s e sa n d / o rp i p e si n s i d et h eu n i ta r ei ng o o dc o n d i t i o n ,s e c u r e and not rubbing c . There are no leaks d . A l lf a s t e n e r sa r et i g h t e . A l le l e c t r i c a ll e a d sa r es e c u r ea n di ng o o do r d e r . f S a f e t yv a l v e sa n do t h e rp r e s s u r e r e l i e fd e v i c e sa r en o to b s t r u c t e d b yd i r to rp a i n t g . A i ro u t l e tv a l v ea n da i rn e t ,i . e .p i p e s ,c o u p l i n g s ,m a n i f o l d s , v a l v e s ,h o s e s ,e t c .a r ei ng o o dr e p a i r, f r e eo fw e a ro ra b u s e 8 . If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air. 9 . Do not remove any of, or tamper with, the sound-damping material.

9 . Before clearing the unit for use after maintenance or overhaul, check t h a to p e r a t i n gp r e s s u r e s ,t e m p e r a t u r e sa n dt i m es e t t i n g sa r ec o r r e c t and that the control and shut-down devices function correctly. I f removed, check that the coupling guard of the compressor drive shaft h a sb e e nr e i n s t a l l e d . 1 0 . Every time the separator element is renewed, examine the discharg e p i p ea n dt h ei n s i d eo ft h eo i ls e p a r a t o rv e s s e lf o rc a r b o nd e p o s i t s ;i f excessive, the deposits should be removed. 11 . Protect the motor, a i rf i l t e r, electrical and regulating components, e t c .t op r e v e n tm o i s t u r ef r o me n t e r i n gt h e m ,e . g .w h e ns t e a m c l e a n i n g . 1 2 . Make sure that all sound-damping material, e.g. on the bodywork a n di nt h ea i ri n l e ta n do u t l e ts y s t e m so ft h ec o m p r e s s o r, i si ng o o d c o n d i t i o n . I fd a m a g e d ,r e p l a c ei tb yg e n u i n e Atlas Copco material to prevent the sound pressure level from increasing. 1 3 . Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls. 1 4 . The following safety precautions are stressed when handling r e f r i g e r a n t : a . Never inhale refrigerant vapours. Check that the working area i sa d e q u a t e l yv e n t i l a t e d ;i fr e q u i r e d ,u s eb r e a t h i n gp r o t e c t i o n . b . Always wear special gloves. In case of refrigerant contact with t h es k i n ,r i n s et h es k i nw i t hw a t e r. I fl i q u i dr e f r i g e r a n tc o n t a c t s t h es k i nt h r o u g hc l o t h i n g ,n e v e rt e a ro ff o rr e m o v et h el a t t e r ; flush abundantly with fresh water over the clothing until all r e f r i g e r a n ti sf l u s h e da w a y ;t h e ns e e km e d i c a lf i r s ta i d . c . Always wear safety glasses. 1 5 . Protect hands to avoid injury from hot machine parts, e.g. during d r a i n i n go fo i l .

Maintenance
Maintenance and repair work shall only be carried out under supervision o fs o m e o n eq u a l i f i e df o rt h ej o b . 1 . Use only the correct tools for maintenance and repair work. 2 . Use only genuine spare parts. 3 . All maintenance work, other than routine attention, shall only be undertaken when the unit is stopped, the main power supply is switched off and the machine has cooled down. Take positive p r e c a u t i o nt oe n s u r et h a tt h eu n i tc a n n o tb es t a r t e di n a d v e r t e n t l y. In addition, a warning sign bearing a legend such as "work in progre s s ;d on o ts t a rt "s h a l lb ea t t a c h e dt ot h es t a r t i n ge q u i p m e n t . 4 . Before removing any pressurized component, eff e c t i v e l yi s o l a t et h e u n i tf r o ma l ls o u r c e so fp r e s s u r ea n dr e l i e v et h ee n t i r es y s t e mo f p r e s s u r e .

Note: W i t hs t a t i o n a r ym a c h i n eu n i t sd r i v e nb ya ni n t e r n a lc o m b u s t i o n e n g i n e ,a l l o w a n c eh a st ob em a d ef o re x t r as a f e t yp r e c a u t i o n s ,e . g .s p a r k a r r e s t o r s ,f u e l l i n gc a r e ,e t c . C o n s u l t Atlas Copco.

A l l re s p o n s i b i l i t yf o r any damage or i n j u ryre s u l t i n gf rom neglecting these precautions, or by non-observance of ordinary caution and due c a rerequired in handling, operating, maintenance or repair, e v e ni f not expressly mentioned in this book, will be disclaimed by Atlas Copco.

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