Atlas Copco AIF999999, Instruction Book

Page 1: ...Instruction book AIF999999 ZS 4 VSD ...

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Page 3: ... thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2020 11 www atlascopco com ...

Page 4: ...l description 11 2 1 INTRODUCTION 11 2 2 ELECTRICAL SYSTEM 13 2 3 REGULATION 13 2 4 FLOW DIAGRAM AND COOLING SYSTEM 17 3 Elektronikon Touch controller 19 3 1 CONTROLLER 19 3 2 CONTROL PANEL 21 3 3 ICONS USED 22 3 4 MAIN SCREEN 26 3 5 QUICK ACCESS SCREEN 27 3 6 MENU SCREEN 28 3 7 DATA MENU 30 3 8 SERVICE MENU 32 3 9 WEEK TIMER MENU 34 3 10 EVENT HISTORY MENU 35 3 11 MACHINE SETTINGS MENU 36 3 12 CO...

Page 5: ...5 2 BEFORE STARTING 58 5 3 STARTING 59 5 4 DURING OPERATION 60 5 5 CHECKING THE DISPLAY 61 5 6 STOPPING 62 5 7 TAKING OUT OF OPERATION 62 6 Maintenance 64 6 1 PREVENTIVE MAINTENANCE SCHEDULE 64 6 2 MOTOR GREASING 66 6 3 OIL SPECIFICATIONS 66 7 Servicing procedures 67 7 1 AIR FILTER 67 7 2 OIL AND OIL FILTER CHANGE 68 7 3 SAFETY VALVE 69 8 Problem solving 70 8 1 PROBLEM SOLVING 70 Instruction book ...

Page 6: ...ta 72 9 1 READINGS 72 9 2 SETTINGS FOR OVERLOAD RELAY AND FUSES 72 9 3 REFERENCE CONDITIONS AND LIMITATIONS 72 9 4 MACHINE DATA 73 10 Pressure equipment directives 74 11 Documentation 75 Instruction book 4 AIF999999 ...

Page 7: ...f the voltage Depressurize the machine Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and check ...

Page 8: ...siccant bags must be removed before connecting the pipes 5 Air hoses must be of correct size and suitable for the working pressure Never use frayed damaged or worn hoses Distribution pipes and connections must be of the correct size and suitable for the working pressure 6 In case the device is a compressor the aspirated air must be free of flammable fumes vapors and particles e g paint solvents th...

Page 9: ...ystem is present in the air net close to the dryer safety valves must be installed in the vessels of the dryer Also consult following safety precautions Safety precautions during operation and Safety precautions during maintenance These precautions apply to machinery processing or consuming air or inert gas Processing of any other gas requires additional safety precautions typical to the applicati...

Page 10: ... tamper with the sound damping material 12 Never remove or tamper with the safety devices guards or insulations fitted on the machine Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure relieving device or devices as required 13 Yearly inspect the air receiver Minimum wall thickness as specified in the instruct...

Page 11: ...with open flame for inspecting the interior of a machine pressure vessel etc 14 Make sure that no tools loose parts or rags are left in or on the machine 15 All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out of action 16 Before clearing the machine for use after maintenance or overhaul check that operating pressures tem...

Page 12: ...ents e g drain oil from oil containing parts 4 Refer to the disposal topic mentioned below Disposal of electrical and electronic appliances WEEE This equipment falls under the provisions of the European Directive 2012 19 EU on waste electrical and electronic appliances WEEE and may not be disposed as unsorted waste The equipment is labelled in accordance with the European Directive 2012 19 EU with...

Page 13: ...hich delivers oil free pulsation free air A VSD Variable Speed Drive unit is continuously matching the speed of the drive motor to the air net pressure The unit optimizes energy consumption and reduces the operating pressure band The unit is enclosed in a sound insulated bodywork General views Front view Instruction book AIF999999 11 ...

Page 14: ...n damper SG Oil level sight glass SV BLV Safety valve blow down valve 2 Vibration dampers The unit includes mainly ElektronikonTM control system Air filter Blower element Pulsation damper Drive coupling Motor Gear casing Safety valve Blow down valve Oil cooler with cooler fan Instruction book 12 AIF999999 ...

Page 15: ...d wired and require only connection to the mains The system includes mainly Elektronikon control system including an electronic regulator and a control panel Pressure and temperature sensors Blower motor An electric cabinet including the starting equipment of the motor VSD cabinet including the variable speed drive unit 2 3 Regulation Valve description The start up safety valve combination is an a...

Page 16: ... forms the main valve disc The inner area of the bellows 2 is connected to the control valve 5 When getting pressurized with process air the movable base 7 seals off the valve seat The pressure in the bellows 2 is relieved by releasing the air in the control valve 5 Valve function The valve has two functions Starting valve function while the blower is starting the valve ensures gradual pressure an...

Page 17: ...is open while it is not under load If the valve was not open in the unloaded state it would not be able to perform the starting valve function Safety valve function While the blower is in normal operation i e after start up the main valve disc is closed and the pressure in the control valve is on both sides of its cone small ball The force generated by pressure against the membrane the surface of ...

Page 18: ...be reduced the pressure in the air net will rise up to the indirect stop level set value the unit will be unloaded If the unit stays unloaded for a certain period of time set value the unit will stop The machine will start again if the pressure in the air net decreases below the pressure set point In case the net pressure should rise to the direct stop level set value the blower will be stopped im...

Page 19: ...ke filter C Flexible connection D Blower element E Flexible connection F Start up and safety element G Check valve H Pulsation damper I Air outlet J Oil carter K Breather L Oil pump M Bypass valve N Oil cooler O Oil filter P Oil injection to bearings and gears Q Gears Instruction book AIF999999 17 ...

Page 20: ...ystem Oil is circulated by pump L from the integrated oil reservoir J through cooler N and oil filter O to the gear wheels and bearings of the blower element D By pass valve M opens when the oil pressure rises above a given value Cooling system The unit is provided with an air cooled oil cooler N the cooling air is generated by an electric motor driven fan Instruction book 18 AIF999999 ...

Page 21: ...ammable settings e g the unloading and loading pressures for fixed speed units the setpoint for units with frequency converter the minimum stop time the maximum number of motor starts and several other parameters are taken into account The controller stops the unit whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases If the expected unload...

Page 22: ... stop button to stop the unit and wait until the unit has stopped Switch off the voltage inspect the unit and remedy if necessary The warning message will disappear as soon as the warning condition disappears Service warning A number of service operations are grouped as a Service Plan Each Service Plan has a programmed time interval If the service timer exceeds a programmed value this will be indi...

Page 23: ... by touch 2 Warning sign Flashes in case of a shut down and is lit in case of a warning condition 3 Service sign Lit when service is needed 4 Operation sign Lit when the unit is running in automatic operation 5 Voltage sign Indicates that power is switched on 6 Stop button Stops the unit 7 Start button Starts the unit The operation sign 4 lights up The controller is operative Instruction book AIF9...

Page 24: ...con Data Status Inputs Outputs Counters Aux Equipment Parameters Converters Service Service Overview Service Plan Service History Service functions Clean Screen Week Timer Week Remaining Running Time Event History Saved Data Instruction book 22 AIF999999 ...

Page 25: ...s Aux Equipment Parameters Converter s Fan Internal SmartBox Auto Restart Controller Settings Network Settings Ethernet Settings CAN Settings Localisation Language Date Time Units User Password Help Information Status icons Icon Description Motor Stopped Instruction book AIF999999 23 ...

Page 26: ...iled to Load Running Loaded Wait Manual Stop Machine Control Mode Local Machine Control Mode Remote Machine Control Mode LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description Basic User Advanced User Service User Antenna 25 Instruction book 24 AIF999999 ...

Page 27: ...tenna 100 Change between screens indication Energy recovery Dryer Element Drain s Analogue Output Menu Reset Auto Restart Filter s Cooler Valve s Power Meter Input icons Icon Description Pressure Instruction book AIF999999 25 ...

Page 28: ...cally after a few minutes when there is no touch input Description Reference Designation Function 1 Home button The home button is always shown and can be tapped to return to the main screen 2 Screen information On the main screen the screen information bar shows the serial number of the machine When scrolling through menus the name of the current menu is shown 3 Access level button The access lev...

Page 29: ...11 These fields can contain a history chart an input or a counter value depending on the type of the machine Tap the field to view the type of measurement This will be shown in the screen information bar Examples of inputs Ambient temp Outlet Dryer dewpoint Examples of counters Running hours Load relay Loaded hours 12 Menu button The menu button is always shown and can be tapped to go to the menu ...

Page 30: ...maining running time can be set and modified by tapping this icon Internal SmartBox The reception quality of the internal antenna can be monitored Each bar represents 25 reception strength If the four bars are filled the reception strength is 100 If only one bar is filled the reception strength is just 25 Auto restart Auto restart can be activated by tapping this icon 3 6 Menu screen Function This...

Page 31: ...rol parameters can be changed through this menu Auxiliary equipment parameters can also be changed The Auto restart function can be set through this menu This function is password protected 6 Controller settings Network settings Localisation settings and a User password can be set through this menu There is also a Help page available and the Controller information can be shown Menu structure Opera...

Page 32: ...y tapping the icons Procedure To enter the Data menu screen 1 Tap the Menu button 2 Tap the Data icon Description Reference Designation 1 Status menu 2 Inputs menu 3 Outputs menu 4 Counters menu 5 Auxiliary equipment menu Status menu Tap the Status icon to enter the Status menu This menu shows the current status of the unit Instruction book 30 AIF999999 ...

Page 33: ... This menu shows information about all the inputs Outputs menu Tap the Outputs icon to enter the Outputs menu This menu shows information about all the outputs Voltage free outputs may only be used to control or monitor functional systems They should NOT be used to control switch or interrupt safety related circuits Check the maximum allowed load on the label Stop the unit and switch off the suppl...

Page 34: ...s menu shows an overview of all auxiliary equipment fitted 3 8 Service menu Function This screen is used to display the following submenus Service Service functions Only visible as advanced user Clean screen These submenus can be entered by tapping the icons Procedure To enter the Service menu screen 1 Tap the Menu button 2 Tap the Service icon Instruction book 32 AIF999999 ...

Page 35: ... tapping icon 1 The service plan can be viewed by tapping icon 2 Through this menu the service plan can be modified 1 Tap the desired service plan A selection screen will pop up 2 Change the Running Hours by tapping or 3 Confirm by tapping V or decline by tapping X The service history can be viewed by tapping icon 3 When a service plan interval is reached a message will appear on the screen When s...

Page 36: ... of the touchscreen The touchscreen and the start and stop button become inactive for 15 seconds 3 9 Week timer menu Function This screen is used to set up to 4 different week timers with each up to 8 settings per day The week timers can be activated through this screen A Remaining Running Time can be set from 5 up to 240 minutes Procedure To enter the Week Timer menu screen 1 Tap the Menu button ...

Page 37: ...lection screen pops up The user can change the remaining time by tapping or and can confirm by tapping V or decline by tapping X 5 Add setting A selection screen pops up The user can change the setting by swiping up or down and confirm by tapping V or decline by tapping X 3 10 Event history menu Function This screen is used to display the saved data in case of an alarm These submenus can be entere...

Page 38: ...ormation reflecting the status of the unit when the shutdown occurred 3 11 Machine settings menu Function This screen is used to display the following submenus Alarms Regulation Control Parameters Only visible if the machine has adaptable parameters Aux Equipment parameters Auto Restart These submenus can be entered by tapping the icons Procedure To enter the Machine settings menu screen 1 Tap the...

Page 39: ...ap the Alarms icon to enter the Alarms menu A list of all alarms is shown When pressing on one of the items in this list the warning and or shutdown levels are shown for this alarm Regulation menu Tap the Regulation icon to enter the Regulation menu Setpoints or pressure bands can be modified through this menu Modify a setting Instruction book AIF999999 37 ...

Page 40: ...ing When tapping a list item a selection screen pops up The user can modify the setting by tapping or and can confirm by tapping V or decline by tapping X Auxiliary equipment parameters menu Tap the Aux Equipment Parameters icon to enter the auxiliary equipment parameters menu This menu shows an overview of all the auxiliary equipment fitted Through this menu the parameters of the auxiliary equipm...

Page 41: ...by tapping V or decline by tapping X Modify a setting When clicking a list item a selection screen pops up The user can modify the setting by tapping or and can confirm by tapping V or decline by tapping X 3 12 Controller settings menu Function This screen is used to display the following submenus Network Settings Localisation User Password Help Information These submenus can be entered by tapping...

Page 42: ...turned off the settings can be modified Modify a setting When tapping a list item a selection screen pops up The user can modify the setting by tapping or and can confirm by tapping V or decline by tapping X Change a selection When tapping a list item a selection screen pops up The user can change the selection by swiping up or down and confirm by tapping V or decline by tapping X Localisation men...

Page 43: ...the User Password icon to enter the User Password menu The user password can be activated or deactivated through this menu Enter and confirm a user password to activate repeat to deactivate Enter a password When tapping a password protected item a selection screen pops up The user can enter the password by swiping up or down to select the desired number Once the 4 digits are entered the user can c...

Page 44: ... Access Level button at the upper right corner of the screen Description Reference Designation Function 1 User A basic set of parameters is visualized no password required 2 Service A basic set of parameters can be modified no password required 3 Full This access level is not accessible to end users 4 Decline Tap to decline the selected user level 5 Confirm Tap to confirm the selected user level I...

Page 45: ...1 now shows the current status of the unit instead of the machine serial number The Received Signal Strength Indicator RSSI value is now shown in the Internal SmartBox menu See Quick access screen In the service menu an extra menu item is now available See Service menu Instruction book AIF999999 43 ...

Page 46: ...4 Installation 4 1 Dimension drawing Dimension drawing metric units Text on figure Instruction book 44 AIF999999 ...

Page 47: ... and cubicle cooling 3 Air inlet for blower cooling and oil cooler cooling 4 Air inlet for blower cooling and motor cooling 5 Air inlet for blower 6 Electrical cable passage 7 Compressed air outlet 8 Center of gravity 9 View A 10 View D Instruction book AIF999999 45 ...

Page 48: ...4 2 Installation proposal Unit room example Blower room example metric units Instruction book 46 AIF999999 ...

Page 49: ...are minimum 2 The maximum total length of the air delivery pipe can be calculated as follows For SI Units Lmax dp x d5 x p 450 x Qc1 85 d inner diameter of the delivery pipe in mm dp pressure drop recommended maximum 0 1 bar L length of delivery pipe in m p absolute pressure at the unit outlet in bar a Qc free air delivery of the unit in l s 3 Avoid recirculation and intake of hot air in compresse...

Page 50: ...led unit power kW Q The ventilation flow leaving the unit room m s For a temperature difference of 5 C this results in following ventilation flow Power kW Ventilation flow m s 90 3 731 10 Common ducting for multiple units is not allowed Side by side unit installation All guidelines of the unit installation proposal are still valid Metric units The numbered list items below refer to the balloon ref...

Page 51: ...tallation of VSD units Electrical equipment from Atlas Copco Compressor is designed in accordance with the safety regulations described in IEC60204 1 and CENELEC EN60204 It is the responsibility of the customer to install the unit according to the safety regulations in order to protect people from electric shocks from direct or indirect contact In drives with frequency converters leakage currents ...

Page 52: ...ds that customers install BENDER IRDH 275 435 http www bender org prod html Atlas Copco strongly recommends that customers do not connect the neutral conductor from the power supply to the compressor unit The exposed conductive parts of the installation must be earthed locally EN 60204 1 par 7 2 3 Power distribution systems TN TT IT According to IEC 60950 there are three main types of power distri...

Page 53: ...are combined to some degree in a single conductor a direct earth to the exposed conductive parts of the installation exists in part The connection is achieved through the PEN conductor A Power system earth B Exposed conductive parts Network type TT Terra Terra The TT power distribution system has one point that is directly earthed In addition the exposed conductive parts of the installation are co...

Page 54: ...to UL508a Industrial control panels For CSA designed control panels calculations for cable sections and fuses are done according to CSA 22 2 Canadian electrical code Standard conditions refer to maximum 3 copper conductors in raceway or cable with 85 90 C 185 194 F insulation at ambient temperature 30 C 86 F operating at nominal voltage cables not grouped with other cables Worst case conditions re...

Page 55: ...Electrical connections ZS 4 VSD blower with starter Drawing reference Description 1 Main motor Please refer to the electrical cabinet door for the entire service diagram Instruction book AIF999999 53 ...

Page 56: ... current A Maximum fuse A 90 95 mm 159 213 3 250 90 AWG 0 159 188 0 250 4 4 Quality of safety components When installing a remote emergency button or a motor contactor the following B10d values are advised Emergency stop button 500 000 Main contactor 1 333 333 Instruction book 54 AIF999999 ...

Page 57: ...ure on 2 Pictograph warning blow off 3 Pictograph warning under tension 4 Pictograph warning hot surface 5 Pictograph transport instructions 6 Stop the unit before maintenance or repair 7 Pictograph earthing 8 Rotation direction arrow 9 Only use Roto Z oil 10 Check the air flow direction Instruction book AIF999999 55 ...

Page 58: ...nect from the electrical supply before opening Pictographs on control panel Refer to the chapter Controller panel for pictographs of the Elektronikon controller Torque instruction Please refer to the label in the electrical cabinet for the torque values of the electrical connections Instruction book 56 AIF999999 ...

Page 59: ...a lift truck use the slots in the frame Make sure that the forks protrude from the other side of the frame When moving the unit with a lifting device insert beams in the slots Make sure that the beams cannot slide and that they protrude from the frame equally The chains must be held parallel to the bodywork by chain spreaders in order not to damage the unit The lifting equipment must be placed in ...

Page 60: ...art the motor and stop it immediately Check for correct direction of rotation as indicated by the arrow on the motor Consult Atlas Copco if the rotation direction is wrong Running the motor in the wrong direction of rotation may damage the element 6 Run the unit for a few minutes stop the unit and check the oil level which must be in the middle of sight glass 1 Top up if necessary 5 2 Before start...

Page 61: ...the middle of the sight glass Top up if necessary with the correct type of oil 2 Open the air outlet valve customer s installation 3 Switch on the voltage and check that voltage sign 5 lights up 5 3 Starting Control panel Instruction book AIF999999 59 ...

Page 62: ... The unit starts running and operation sign 4 lights up Manual restarting In automatic operation the regulator limits the number of motor starts 5 4 During operation Control panel Procedure If the motor is stopped and operation sign 4 is alight the motor may start automatically If the start stop timer is active the unit can start automatically even if it was stopped manually Check the readings on ...

Page 63: ... or if a service level for a monitored component has been exceeded Carry out the service actions of the indicated plans or replace the component and reset the relevant timer 4 Regularly call up the actual unit condition The unit control status automatic or manual local or remote The status of the unit start stop timer active or not The unit is automatically started stopped if these start stop comm...

Page 64: ...out or by turning it to the right depending on the model of the switch 5 7 Taking out of operation Procedure At the end of the service life of the unit proceed as follows Step Action 1 Close the air outlet valve stop the unit and press the emergency stop button 2 Switch off the voltage and disconnect the unit from the mains 3 Shut off and depressurize the part of the air net which is connected to ...

Page 65: ...ep Action 5 Drain the oil catch the oil in a receptacle Dispose of the oil according to local regulations 6 Also read section Used material for the disposal of used material Instruction book AIF999999 63 ...

Page 66: ...y plan Contact your Customer Centre to agree on a tailor made service agreement It will ensure optimum operational efficiency minimize downtime and reduce the total life cycle costs Warranty Product Liability Use only authorized spare parts Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability Service kits Atlas Copco Customer Centres wil...

Page 67: ...ature and pressure of air oil and water X X X X X Check cooler functionality X X X X Clean oil cooler block X X X X Check for air and oil leakage X X X X X Check sensitive bolt coupling connections X X X X Check for presence of water in lube oil X X X X Change compressor oil X Change compressor oil filter X X X Check condition of air intake chamber X X X X Check air filter element s X X X X Change...

Page 68: ...specifications Roto Z lubricating oil Use only Atlas Copco Roto Z oil which is specially developed for oil free rotary units This oil has a long service life and ensures optimum lubrication Atlas Copco Roto Z oil can be ordered in following quantities Quantity l Ordering number 5 l can 2908 8503 00 20 l can 2908 8501 01 209 l drum 2908 8500 00 Instruction book 66 AIF999999 ...

Page 69: ...emove the covers 1 4 Remove the air filters 2 Take care that no dirt drops into the inlet pipe 5 Clean and inspect the element sealing surface of the filter chamber 6 Install the new or cleaned filters 2 fit the covers 1 and close the doors Never install damaged or clogged filters 7 Open door 3 of the electrical cabinet and clean replace the filter mat 8 Switch on the voltage unlock the emergency ...

Page 70: ...and screw the filter into place until the gasket contacts the seat Then tighten by hand 6 Fill the oil sump to the middle of the oil level sight glass SG See section Oil specifications for the correct type of oil 7 Reinstall the filler plug 8 Switch on the voltage unlock the emergency stop button and reset the oil and oil filter service warnings 9 Run the unit for a few minutes 10 Stop the unit ch...

Page 71: ... exceeds the limits the control valve opens and releases air into the atmosphere The pressure in the bellows is reduced and the main valve disk starts to open When the pressure enters the limits the control valve closes and no more air is released into the atmosphere and the pressure in the bellows rises causing the disk valve to close fully Instruction book AIF999999 69 ...

Page 72: ...al Air consumption exceeds capacity of unit Check pneumatic plant Safety starting valve leaking Have valve inspected Oil pressure too low Oil level too low Top up level to the middle of the oil level sight glass Oil filter clogged Replace filter Oil temperature above normal Oil shut down temperature incorrectly set Correct setting to trip at the specified temperature Insufficient cooling air flow ...

Page 73: ...The service switch may only be used for a test run and not for continuous running Instruction book AIF999999 71 ...

Page 74: ... unit type Item Reading Outlet pressure Depends on unit type dp of air filter Below 0 044 bar Oil pressure 2 5 bar e Air outlet temperature 98 C Oil temperature Approx 40 C 9 2 Settings for overload relay and fuses Settings for overload relays and fuses are available in the electrical diagram 9 3 Reference conditions and limitations Reference conditions Item Condition Absolute inlet pressure 1 bar...

Page 75: ...ature 20 C For working points exceeding these limitations please contact your customer centre 9 4 Machine data ZS 4 VSD 90 kW input power with starter Nominal maximum working pressure bar 1 5 Mean sound pressure level dB A 78 5 Oil capacity approximately l 20 Mass kg 1775 Minimum motor speed rpm 1000 Maximum motor speed rpm 3909 Gear K Instruction book AIF999999 73 ...

Page 76: ...neering Practice SEP Parts of category I according to 2014 68 EU are integrated into the machine and fall under the exclusion of article 1 2 f i Parts subject to the Simple Pressure Vessel Directive 2014 29 EU are excluded from 2014 68 EU according to article 1 2 c Instruction book 74 AIF999999 ...

Page 77: ...Documentation Declaration of conformity Typical example of a Declaration of Conformity document 1 Manufacturer 2 Applicable directives 3 Standards used 4 Technical file holder Instruction book AIF999999 75 ...

Page 78: ...eclaration of Conformity the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity is part of the documentation that is supplied with this device Instruction book 76 AIF999999 ...

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Page 80: ...ke performance stand the test of time This is what we call Sustainable Productivity Atlas Copco Airpower Oil free Air Division Boomsesteenweg 957 2610 Wilrijk Belgium Phone 32 0 3 870 21 11 Atlas Copco Airpower NV All rights reserved Designs and specifications are subject to change without notice or obligation ...