Professional Documents
Culture Documents
ZT18-ZT22-ZT30-ZT37-ZT45-ZT55-ZT75-ZT90
ZR45-ZR55-ZR75-ZR90
with Elektronikon regulator
Instruction Book
Important: This book must be used together with the "User manual for the Elektronikon regulator , printed
matter No. 2920 1291 0x.
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.
*2920134501*
www.atlascopco.com
Instruction book
This instruction book describes how to handle and operate the subject machine(s) to ensure safe operation, optimum working
economy and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance
from the beginning. The maintenance schedule comprises measures for keeping the compressor in good repair.
Keep the book available for the operator(s) and make sure that the compressor is operated and that maintenance is carried out
according to the instructions. Record all operating data, maintenance work effected, etc. in an operator's logbook available
from Atlas Copco. Follow all applicable safety precautions, amongst others those mentioned in this book.
Repairs must be carried out by trained personnel from Atlas Copco who can also be contacted for any further information.
In all correspondence mention the type and the serial number, shown on the data plate.
The company reserves the right to make changes without prior notice.
CONTENTS
Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Elektronikon control system . . . . . . . . . . . . . . . . 8
1.2.1 Elektronikon regulator . . . . . . . . . . . . . . . 8
1.2.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.3 Compressor control modes . . . . . . . . . . . 10
1.2.4 External compressor status indication . . . 10
1.2.5 External communication . . . . . . . . . . . . . 11
1.3 Regulating system . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.1 Air flow . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Condensate drain system . . . . . . . . . . . . . 13
1.3.3 Oil system . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Cooling system . . . . . . . . . . . . . . . . . . . . 14
1.3.5 Regulating system . . . . . . . . . . . . . . . . . . 14
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . .
2.2 Installation proposals . . . . . . . . . . . . . . . . . . . . .
2.3 Electric cables . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Connection . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Cooling water requirements . . . . . . . . . . . . . . . .
2.5 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
21
28
28
29
29
33
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . .
3.1 Preparation for initial start-up . . . . . . . . . . . . . .
3.2 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Routine starting . . . . . . . . . . . . . . . . . . . .
3.3.2 Starting after emergency stopping or
shut-down . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Manual restarting . . . . . . . . . . . . . . . . . . .
3.4 During operation . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Checking the display . . . . . . . . . . . . . . . . . . . . . .
3.6 Manual unloading/loading . . . . . . . . . . . . . . . . .
3.6.1 Manual unloading . . . . . . . . . . . . . . . . . .
3.6.2 Manual loading . . . . . . . . . . . . . . . . . . . .
3.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Taking out of operation . . . . . . . . . . . . . . . . . . . .
34
34
34
35
35
36
36
36
37
38
38
38
38
38
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Preventive maintenance schedule for the
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2
Page
4.2 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.1 Fan motor bearings . . . . . . . . . . . . . . . . . 40
4.2.2 Compressor motor greasing . . . . . . . . . . 40
4.3 Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3.1 Roto-Z lubricating oil . . . . . . . . . . . . . . . 40
4.4 Storage after installation . . . . . . . . . . . . . . . . . . . 40
4.5 Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 Servicing procedures . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Oil and oil filter change . . . . . . . . . . . . . . . . . . .
5.3 Safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
41
41
41
6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Readings on display . . . . . . . . . . . . . . . . . . . . . .
7.2 Programmable settings . . . . . . . . . . . . . . . . . . . .
7.3 Settings of safety valves . . . . . . . . . . . . . . . . . . .
7.4 Motor type - settings of overload relay and
circuit breaker - main fuses . . . . . . . . . . . . . . . . .
7.4.1 Motor type - settings of motor overload
relay - main fuses for 50 Hz compressors
7.4.2 Motor type - settings of motor overload
relay - main fuses for 60 Hz compressors
(Y/D starter) . . . . . . . . . . . . . . . . . . . . . .
7.4.3 Setting of fan motor circuit breaker for
50 Hz compressors . . . . . . . . . . . . . . . . .
7.4.4 Setting of fan motor circuit breaker for
60 Hz compressors . . . . . . . . . . . . . . . . .
7.5 Compressor specifications . . . . . . . . . . . . . . . . .
7.5.1 Reference conditions . . . . . . . . . . . . . . . .
7.5.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . .
7.5.3 Specific data of ZT18/37 - 50 Hz . . . . . .
7.5.4 Specific data of ZT18/37 - 60 Hz . . . . . .
7.5.5 Specific data of ZT/ZR 45/55 - 50 Hz . .
7.5.6 Specific data of ZT/ZR 45/55 - 60 Hz . .
7.5.7 Specific data of ZT/ZR 75/90 - 50 Hz . .
7.5.8 Specific data of ZT75/90 - 60 Hz . . . . . .
7.5.9 Specific data of ZR75/90 - 60 Hz . . . . .
7.6 Conversion list of SI units into British/
American units . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
43
43
44
44
45
46
47
47
47
47
47
48
49
49
50
50
50
51
2920 1345 01
Instruction book
1 LEADING PARTICULARS
Type
Frequency
Hz
ZT18 HAT
ZT22 HAT
ZT30 HAT
ZT18
ZT22
ZT30
ZT37
ZT/ZR 45
ZT/ZR 55
50 or 60
50 or 60
50 or 60
50 or 60
50 or 60
50 or 60
50 or 60
50 or 60
50 or 60
8.6
8.6
8.6
7.5 or 8.6
7.5 or 8.6
7.5 or 8.6
7.5 or 8.6
7.5 or 8.6
7.5 or 8.6
ZT75/90
ZT75/90
ZR75/90
ZR75/90
50
60
50
60
8
7.5 or 8.6
8 or 10
7.5, 8.6 or 10
1
2
3
5
51217F
1
2
3
4
5
6
Instruction book
16
17
18
21
20
19
12
11
13
10
14
15
51218F
1
2
3
4
5
6
7
8
9
10
Aftercooler
Intercooler
Full-load/no-load valve
Loading solenoid valve
Oil filler plug
Oil level sight-glass
Oil filter
Oil drain valve
Compressor motor
Moisture trap, aftercooler
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Elektronikon regulator
Air filter
Pulsation damper
Low-pressure safety valve
Moisture trap, intercooler
Vibration damper
Pre-aftercooler
Regulating valve, water flow
through oil cooler/intercooler
29 Regulating valve, water flow
through aftercooler
2920 1345 01
Instruction book
16
17
18
21
20
19
12
4
13
11
15
10
51219F
14
22
21
23
12
13
1
2
20
51220F
6
8
10
11
Instruction book
22
14
23 24
12
1
21
20
25
7
11
10
5
51221F
18
17
18
27
21
22
20
19
11
4
25
10
14
26
51223F
2920 1345 01
Instruction book
28
29
22
21
20
3
4
14
18
11
10
51224F
29
24
22
3
14
51225F
18
26
25
Instruction book
general alarm LED (3) will light up, to warn the operator that
the shut-down warning level is exceeded. The shut-down
warning level is a programmable setting below the shut-down
level.
The message disappears as soon as the cause of the trouble is
remedied.
Warning
Warning
Voltage on LED
Indicates that the voltage is switched on.
2920 1345 01
Instruction book
10
11
12
S5
13
8
S2
50112F
Display
Indicates messages concerning the compressor
operating condition, a service need or a fault. See
"User manual for Elektronikon regulator", sections
"Status data submenu" and "Service submenu".
Function keys
Keys to control and program the compressor. See
below.
Scroll keys
Keys to scroll through the display.
Tabulator key
Key to go to the next field of the display.
Start button
Push button to start the compressor. LED (1) lights
up indicating that the electronic regulator is operative
(in automatic operation). The LED goes out after
unloading the compressor manually.
2920 1345 01
Stop button
Push button to stop the compressor. LED (1) goes
out. The compressor will run unloaded for 3 seconds
before stopping.
Selecting a menu
To facilitate controlling the compressor, menu-driven programs
are implemented in the electronic regulator. Use the function
keys (5) to select the menus in order to program and monitor
the compressor. The "User manual for Elektronikon
regulator" deals elaborately with all regulator functions.
Function keys
The functions of the keys vary depending on the displayed
menu. The actual function is indicated just above the relevant
key. The most common functions are listed below:
9
Instruction book
Designation
(4-Fig. 1.9)
Function
Add
Cancel
Delete
Limits
List
Load
Main Screen
Menu
Modify
Show More
Program
Reset
Return
Select
Unload
Compressor outlet
Oil
Automatically Loaded
Menu
Show More
7.5 bar
2.1 bar
F1
F3
F2
Key
position
10
Compressor off.
11
12
13
Important
- The control module 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.
Unload
Status data
Main Screen
Select
F1
F2
F3
Indication
Relay
Terminals on
strip 1X1
Automatic operation
Warning
Shut-down
Compressor loaded
Control mode REMOTE 1
K06
K07
K08
K11
--
11-12
13-14
15-16
17-18
21-22
2920 1345 01
Instruction book
1
2
3
4
Guide
Slot
Plate
Cable
11
Instruction book
F1/2
T2
F3/5
K22
K23
1X1
Q25
50258F
T1
1X3
K21
F21
1X3
K21
F21 K22
T1
T2
F3/5
F1/2
F1/2
F3/5
F21
K11
K21
K22
K23
Q25
Fuses
Circuit breakers
Compressor motor overload relay
Auxiliary relay, loading
Line contactor
Star contactor
Delta contactor
Fan motor circuit breaker (ZT18/37
and ZT75/90 only)
T1/T2 Transformers
1X1
Terminal strip
1X3
Terminal strip, supply from main
Figs. 1.13 and 1.14 Electric cabinet
12
K23
1X1
K11
50259F
Instruction book
13
Instruction book
During unloading
If the air consumption is less than the air delivery of the
compressor, the net pressure increases. When the net pressure
reaches the upper limit of the working pressure (unloading
pressure), solenoid valve (8) is de-energized. The plunger of
solenoid valve (8) moves downwards by spring force shutting
off the supply of control air to unloader (4):
1. Control pressure is vented from chamber (7) of unloader
(4) through solenoid valve (8) and chamber (6) towards
the inlet of low-pressure compressor element (12).
2. As there is no longer any pressure difference between
chambers (6 and 7), plunger (5) returns by spring force
2920 1345 01
Instruction book
1
2
3
4
5
6
7
8
9
10
11
Air filter
Unloading valve
Full-load/no-load valve
Unloader
Plunger
Chamber
Chamber
Loading solenoid valve
Elektronikon regulator
Diaphragm
Silencer
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Fan
Oil pump
Oil cooler
Oil filter
Oil cooler by-pass valve
Moisture trap, intercooler
Regulating valve, aftercooler
water circuit
30 Regulating valve, intercooler
water circuit
31 Silencer
32 Pre-aftercooler
15
Instruction book
Footnotes chapter 1
1) This function is called the Timer function. See "User manual
for Elektronikon regulator", section "Timer submenu".
2) Not installed on all compressor types.
2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 up
to 2.7)
2920 1345 01
Instruction book
17
Instruction book
2920 1345 01
Instruction book
2920 1345 01
19
Instruction book
20
2920 1345 01
Instruction book
Description
1.
4.
2.
Remove the plastic plug from the air outlet pipe and fit
the air outlet valve (7-Fig. 3.2). Close the valve and
connect it to the air net.
3.
dP =
L
d
P
=
=
=
Qc =
V =
dP =
p
Q
C
=
=
=
0.9
0.8
0.7
0.5
0.3
0.2
0.1
0.10
0.15
0.20
0.25
0.20
0.15
0.10
Example:
2920 1345 01
6.
7.
8.
9.
(30 x C x p x Q) / dP
recommended air net volume in l
pressure difference between unloading and
loading pressures in bar (recommended
minimum = 0.5)
compressor inlet pressure in bar absolute
free air delivery of compressor in l/s
correction factor, see below
21
Instruction book
22
2920 1345 01
Instruction book
2920 1345 01
23
Instruction book
24
2920 1345 01
Instruction book
2920 1345 01
25
Instruction book
26
2920 1345 01
Instruction book
2920 1345 01
27
Instruction book
ZT18 HAT
ZT18
ZT22 HAT
ZT22
ZT30 HAT
ZT30
ZT37
ZT/ZR 45
ZT/ZR 55
ZT75
ZR75
ZT90
ZR90
230 V
400 V
500 V
-3x25 mm + 16 mm
-3x35 mm + 16 mm
-3x50 mm + 25 mm
3x70 mm + 35 mm
3x70 mm + 35 mm
3x95 mm + 50 mm
3x150 mm + 95 mm
3x150 mm + 95 mm
3x240 mm + 120 mm
3x185 mm + 95 mm
3x10 mm + 10 mm
3x10 mm + 10 mm
3x16 mm + 16 mm
3x10 mm + 10 mm
3x16 mm + 16 mm
3x16 mm + 16 mm
3x25 mm + 16 mm
3x35 mm + 16 mm
3x50 mm + 25 mm
3x95 mm + 35 mm
3x70 mm + 35 mm
3x95 mm + 50 mm
3x95 mm + 50 mm
-3x6 mm + 6 mm
-3x10 mm + 10 mm
-3x10 mm + 10 mm
3x16 mm + 16 mm
3x25 mm + 16 mm
3x25 mm + 16 mm
3x50 mm + 25 mm
3x50 mm + 25 mm
3x70 mm + 35 mm
3x70 mm+ 35 mm
Mains + earth cable for 60 Hz compressors (except for Canada and USA)
For cable PVC 70 degrees Celsius, at ambient temperature 40 degrees Celsius according to EN60204.
ZT18 HAT
ZT18
ZT22 HAT
ZT22
ZT30 HAT
ZT30
ZT37
ZT/ZR 45
ZT/ZR 55
ZT/ZR 75
ZT/ZR 90
28
220/230 V
380 V
440/460 V
3x25 mm + 16 mm
3x25 mm + 16 mm
3x50 mm + 16 mm
3x35 mm + 16 mm
3x70 mm + 35 mm
3x70 mm + 35 mm
3x70 mm + 35 mm
3x95 mm + 50 mm
3x120 mm + 70 mm
3x185 mm + 95 mm
3x240 mm + 120 mm2
3x10 mm + 10 mm
3x10 mm + 10 mm
3x16 mm + 16 mm
3x10 mm + 10 mm
3x25 mm + 16 mm
3x25 mm + 16 mm
3x25 mm + 16 mm
3x35 mm + 16 mm
3x50 mm + 25 mm
3x95 mm + 50 mm
3x120 mm + 70 mm
3x10 mm + 10 mm
3x10 mm + 10 mm
3x16 mm + 10 mm
3x10 mm + 10 mm
3x16 mm + 16 mm
3x16 mm + 16 mm
3x25 mm + 16 mm
3x35 mm + 16 mm
3x35 mm + 16 mm
3x70 mm + 35 mm
3x95 mm+ 50 mm
2920 1345 01
Instruction book
ZT18 HAT
ZT18
ZT22 HAT
ZT22
ZT30 HAT
ZT30
ZT37
ZT/ZR 45
ZT/ZR 55
ZT/ZR 75
ZT90
ZR90
440/460 V
575 V
3xAWG6 + AWG6
3xAWG6 + AWG6
3xAWG4 + AWG4
3xAWG6 + AWG6
3xAWG3 + AWG3
3xAWG4 + AWG4
-3xAWG3 + AWG3
3xAWG2 + AWG4
3xAWG00 + AWG4
3xAWG3/0 + AWG1
3xAWG3/0 + AWG1
-3xAWG8 + AWG8
-3xAWG8 + AWG8
-3xAWG6 + AWG6
3xAWG6 + AWG6
3xAWG4 + AWG4
3xAWG3 + AWG3
3xAWG1 + AWG4
3xAWG00 + AWG4
3xAWG0 + AWG3
2.3.2 Connection
The connections are shown on Figs. 2.14 up to 2.16.
Recirculating system
Open system
Chloride (Cl-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sulphate (SO4--) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Total solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suspended solids (as SiO2) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free chlorine (Cl2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ammonia (NH4+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manganese . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carbonate hardness (as CaCO3) . . . . . . . . . . . . . . . . . . . . . . .
Organics (KMnO4 Consumption) . . . . . . . . . . . . . . . . . . . . . .
< 600
< 400
< 3000
< 10
<4
< 0.5
< 0.5
< 0.2
< 0.1
<3
50-1000
< 25
< 150
< 250
< 750
< 10
<2
< 0.5
< 0.5
< 0.2
< 0.1
<3
50-500
< 10
Remarks
- No algae nor oil.
- 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.
2920 1345 01
29
Instruction book
30
2920 1345 01
Instruction book
2920 1345 01
31
Instruction book
32
2920 1345 01
Instruction book
26
1
2
3
4
5
Automatic operation
Voltage on
Start
Stop
Compressor locked (in off
position)
6 Local control
7 Remote control (by external
switches)
8 Remote control (by computer)
9 Emergency stop
10 Keys to scroll through display
11 Key to go to next field on display
12 Alarm
13 Automatic condensate outlet,
intercooler
27
13
15
14
16
33
Instruction book
3 OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all related safety precautions
including those mentioned in this book.
Outdoor/altitude operation
If the compressor is installed outdoors or if the air inlet
temperature can be below 0 degrees Celsius, precautions must
be taken. In this case, and also for altitude operation, 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.
2920 1345 01
Instruction book
1
2
Bolt
Nut
Important
- If the motor is stopped and automatic operation LED
(1) is alight, the motor may start automatically.
- If the start/stop timer is active (see section 1.2.1), the
compressor can start automatically, even if it was
stopped manually.
3
4
Bolt
Nut
35
Instruction book
51226F
1
1 4)
2 4)
3 3)
4 3)
5
6
7
2920 1345 01
Instruction book
51229F
51227F
4
1
2
3
1
2
Warning
3
1
2
3
51228F
Notes
- Whenever a warning, service request, sensor error or motor
overload message is displayed, the free spaces on the
display between the function keys (5-Fig. 1.9) are filled
with blinking indicators (**).
- When more than one message needs to be displayed (e.g.
both warning and service), the messages are continuously
displayed for 3 seconds each.
37
Instruction book
Footnotes chapter 3
1) Condensate drains for the intercooler moisture trap are only
provided on ZR and ZT75/90
2) If the <<Load>> or <<Unload>> function is not indicated on
the bottom line of display (4), press key <<Menu>> (5) until
the function <<Main Screen>> appears above key (F1), then
press the key <<Main Screen>>.
3) ZR and ZT75/90 only.
4) ZR only.
5) If the function <<Show More>> is not indicated on the bottom
line of display (4-Fig. 1.9), press key <<Menu>> (5) until
function <<Main Screen>> appears above key (F1), then press
the key <<Main Screen>>.
6) The compressor is automatically started and stopped if these
start/stop commands are programmed and activated; consult
section 1.2.1.
2920 1345 01
Instruction book
4 MAINTENANCE
Attention
Before carrying out any maintenance or repair, stop the compressor, press the emergency stop button and switch off the
voltage. Safeguard against unintentional "switch-on". Apply all relevant safety precautions, including those mentioned in this
book.
Period 2)
Running
hours 2)
Consult
section
See notes
below table
Operation
Daily
"
-8
-3.5/7.1
1
--
"
"
8
--
-3.7
---
Weekly
"
"
----
7.2
---
--4
3-monthly -"
--
4.5/5.1
5.4
5
--
Yearly
"
"
"
"
"
"
"
8000
8000
8000
------
--4.5/5.2
4.5/5.1
5.3
----
-2
--3
----
2-Yearly
16000
4.3/5.2
--
Notes
1. Maintain the level in the middle of the oil level sight-glass.
2. See "User manual for Elektronikon regulator".
3. Preferably to be carried out by an Atlas Copco Service representative.
4. Any leak should be attended to immediately.
5. More frequently in very dusty surroundings.
2920 1345 01
39
Instruction book
4.2 Motors
Run the compressor, e.g. twice a week, until warm. Load and
unload the compressor a few times.
Compressor
type
Interval
(hours)
Quantity
(g)
ZT18 HAT
ZT18
ZT22 HAT
ZT22
ZT30 HAT
ZT30
ZT37
ZT/ZR 45
ZT/ZR 55
ZT/ZR 75
ZT/ZR 90
3000
3000
3000
3000
3000
3000
3000
2000
2000
2000
2000
15
15
15
15
15
15
15
20
20
20
20
Compressor type
ZT18/37
ZT18/37
ZT/ZR 45/55
ZT/ZR 75/90
Ordering number
5 l can
20 l can
209 l drum
2908 8503 00
2908 8501 01
2908 8500 00
40
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.
3) See "User manual for Elektronikon regulator", section "Service
submenu".
2920 1345 01
Instruction book
5 SERVICING PROCEDURES
5.1 Air filter
1. For ZT18/37, the filter must be replaced yearly or when
the red piston of the service indicator (1-Fig. 5.1) shows
completely.
2. For ZT/ZR 45/90, the filter must be replaced as soon as
the service warning appears on display (4-Fig. 1.9) or
yearly.
3. Stop the compressor, press the emergency stop button and
switch off the voltage.
4. Remove the filter. Take care that no dirt drops into the
inlet pipe.
5. Install the new filter. Never install damaged or clogged
filters.
6. Switch on the voltage and unlock the emergency stop
button.
7. For ZT/ZR 45/90, reset the air filter service warning. 1)
For ZT18/37, reset the service indicator (1-Fig. 5.1) by
pushing the reset knob.
5.4 Coolers
1
On ZT, keep the fins of the coolers clean. Remove any dust
from both sides of the coolers with a fibre brush. Never use a
wire brush or metal objects. Clean by air jet. Consult Atlas
Copco if it should be necessary to wash the coolers.
On ZR, consult Atlas Copco for cleaning.
51222F
1
2
Vacuum indicator
Air filter
Footnote chapter 5
1) See "User manual for Elektronikon regulator", section "Service
submenu".
41
Instruction book
6 PROBLEM SOLVING
Warning
3. Compressor is shut-down
LED (3-Fig. 1.9) will blink indicating that the compressor
is stopped due to a shut-down function. A message appears
on the display. Remedy the trouble. Consult the "User
manual for Elektronikon regulator" to reset the message
(section "Status data submenu")
4. Compressor capacity or working pressure lower than
normal
a. Air consumption exceeds capacity of compressor
a. Check pneumatic plant
b. Safety valve(s) leaking
b. Remove leaking valve and have it inspected
c. Unloading pressure incorrectly set
c. See "User manual for Elektronikon regulator", section
"Modify settings submenu"
5. Oil pressure too low
a. Oil level too low
a. Top up level to the middle of the oil level sight-glass
b. Oil filter clogged
b. Replace filter
42
2920 1345 01
Instruction book
7 PRINCIPAL DATA
7.1 Readings on display 1) (Fig. 1.9)
Maximum working pressure . . . . . . . . . .
Outlet pressure . . . . . . . . . . . . . . . . . . . .
dP air filter . . . . . . . . . . . . . . . . . . . . . . .
Intercooler pressure . . . . . . . . . . . . . . . .
Oil pressure . . . . . . . . . . . . . . . . . . . . . . .
Air temperature element 1 out . . . . . . . .
Air temperature element 2 out . . . . . . . .
Air temperature element 2 in . . . . . . . . .
Air outlet temperature . . . . . . . . . . . . . . .
Cooling water inlet temperature . . . . . . .
Cooling water outlet temperature . . . . . .
2920 1345 01
43
Instruction book
7.4 Motor type - settings of overload relay and circuit breaker - main fuses
7.4.1 Motor type - settings of motor overload relay - main fuses for 50 Hz compressors
Compressor
type
Motor
type
Supply
voltage
(V)
Maximum setting of
overload relay F21
(A)
ZT18 HAT
1LA5 183-2
400
25
3x50
ZT18
ZT18
ZT18
1LA5 166-2
1LA5 166-2
1LA5 166-2
230
400
500
38
22.5
18
3x100
3x50
3x50
ZT22 HAT
1LA5 206-2
400
33.5
3x80
ZT22
ZT22
ZT22
1LA5 183-2
1LA5 183-2
1LA5 183-2
230
400
500
43
25
20
3x100
3x80
3x50
ZT30 HAT
1LA5 207-2
400
42
3x100
ZT30
ZT30
ZT30
1LA5 206-2
1LA5 206-2
1LA5 206-2
230
400
500
58
33
27
3x125
3x80
3x80
ZT37
ZT37
ZT37
1LA5 207-2
1LA5 207-2
1LA5 207-2
230
400
500
72
42
33
3x160
3x100
3x80
Compressor
type
Motor
type
Supply
voltage
(V)
Maximum setting
of overload relay
F21 (A)
ZT/ZR 45
ZT/ZR 45
ZT/ZR 45
1LA6 223-2
1LA6 223-2
1LA6 223-2
230
400
500
84
49
39
3x160
3x100
3x80
----
ZT/ZR 55
ZT/ZR 55
ZT/ZR 55
1LA6 228-2
1LA6 228-2
1LA6 228-2
230
400
500
105
61
48
3x224
3x125
3x100
----
ZT/ZR 75
ZT/ZR 75
ZT/ZR 75
1LA6 258-2
1LA6 258-2
1LA6 258-2
230
400
500
143
83
67
2x (3x200)
3x200
3x160
3x315
---
ZT/ZR 90
ZT/ZR 90
ZT/ZR 90
1LA6 250-2
1LA6 250-2
1LA6 250-2
230
400
500
169
96
77
2x (3x224)
3x200
3x160
3x400
---
44
2920 1345 01
Instruction book
7.4.2 Motor type - settings of motor overload relay - main fuses for 60 Hz compressors (Y/D starter)
Compressor
type
Motor
type
Supply
voltage
(V)
Maximum setting
of overload relay
F21 CSA/UL (A)
ZT18 HAT
ZT18 HAT
ZT18 HAT
1LA5 183-2
1LA5 183-2
1LA5 183-2
220-230
380
440-460
54
31
27
3x80
3x60
3x60
3x70
3x60
3x60
ZT18
ZT18
ZT18
ZT18
1LA5 166-2
1LA5 166-2
1LA5 166-2
1LA5 166-2
220-230
380
440-460
575
47
27
23
18
3x80
3x60
3x60
3x60
3x70
3x60
3x60
3x60
ZT22 HAT
ZT22 HAT
ZT22 HAT
1LA5 206-2
1LA5 206-2
1LA5 206-2
220-230
380
440-460
70
40
35
3x125
3x80
3x80
3x150
3x70
3x70
ZT22
ZT22
ZT22
ZT22
1LA5 183-2
1LA5 183-2
1LA5 183-2
1LA5 183-2
220-230
380
440-460
575
54
31
27
20
3x80
3x60
3x60
3x60
3x70
3x60
3x60
3x60
ZT30 HAT
ZT30 HAT
ZT30 HAT
1LA5 207-2
1LA5 207-2
1LA5 207-2
220-230
380
440-460
87
50
43
3x200
3x80
3x80
3x175
3x70
3x70
ZT30
ZT30
ZT30
ZT30
1LA5 206-2
1LA5 206-2
1LA5 206-2
1LA5 206-2
220-230
380
440-460
575
70
40
35
27
3x125
3x80
3x80
3x80
3x150
3x70
3x70
3x70
ZT37
ZT37
ZT37
ZT37
1LA5 207-2
1LA5 207-2
1LA5 207-2
1LA5 207-2
220-230
380
440-460
575
87
50
43
33
3x200
3x80
3x80
3x80
3x175
3x70
3x70
3x70
2920 1345 01
45
Instruction book
Compressor Motor
type
type
Supply
voltage
(V)
Maximum
setting of
overload relay
F21 (A)
gL/gG
Type 2 6)
(A)
UL Class K5
(A)
ZT/ZR 45
ZT/ZR 45
ZT/ZR 45
ZT/ZR 45
1LA6 223-2
1LA6 223-2
1LA6 223-2
1LA6 223-2
220-230
380
440-460
575
97
57
48
38
3x200
3x125
---
-----
--3x80
3x80
--3x70
3x70
ZT/ZR 55
ZT/ZR 55
ZT/ZR 55
ZT/ZR 55
1LA6 228-2
1LA6 228-2
1LA6 228-2
1LA6 228-2
220-230
380
440-460
575
121
70
60
47
3x224
3x125
---
-----
--3x125
3x80
--3x125
3x70
ZT/ZR 75
ZT/ZR 75
ZT/ZR 75
ZT/ZR 75
1LA6 258-2
1LA6 258-2
1LA6 258-2
1LA6 258-2
220-230
380
440-460
575
165
93
83
64
2x (3x200)
3x200
---
3x355
----
--3x150
3x125
--3x150
3x125
ZT/ZR 90
ZT/ZR 90
ZT/ZR 90
ZT/ZR 90
1LA6 250-2
1LA6 250-2
1LA6 250-2
1LA6 250-2
220-230
380
440-460
575
201
115
100
77
2x (3x224)
3x200
---
3x355
----
--3x200
3x175
--3x175
3x175
Maximum setting of
circuit breaker Q25 (A)
Maximum setting of
circuit breaker Q26 (A)
ZT18/30 HAT
380-415
2.6
2.0
ZT18/37
ZT18/37
ZT18/37
200-240
380-415
500
4.5
2.6
1.75
----
ZT75/90
ZT75/90
ZT75/90
200-240
380-415
500
12.1
7.0
4.7
----
46
2920 1345 01
Instruction book
Maximum setting of
circuit breaker Q25 (A)
Maximum setting of
circuit breaker Q26 (A)
ZT18/30 HAT
ZT18/30 HAT
ZT18/30 HAT
220-230
380-460
575
5.9
2.8
2.8
9.3
2.25
1.96
ZT18/37
ZT18/37
ZT18/37
220-230
380-460
575
4.8
2.8
2.15
----
ZT75/90
ZT75/90
ZT75/90
220-230
380-460
575
10.5
5.9
4.4
----
bar(a)
%
Celsius
bar(e)
Celsius
1
0
20
see sections 7.5.3 up to 7.5.9
20
Celsius
Celsius
Celsius
bar(e)
50
40
0
see sections 7.5.3 up to 7.5.9
Celsius
Celsius
bar(e)
35
50
7
7.5.2 Limitations
Maximum air inlet temperature
- ZT18/30 HAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum ambient temperature . . . . . . . . . . . . . . . . . . . . . . . .
Maximum effective working pressure . . . . . . . . . . . . . . . . . . .
Maximum cooling water temperature:
At inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
At outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum cooling water inlet pressure . . . . . . . . . . . . . . . . . .
7.5.3 Specific data of ZT18/37 - 50 Hz 1)
ZT18/30 HAT
2920 1345 01
bar(e)
bar(e)
Celsius
r/min
kW
l
dB(A)
ZT18
ZT22
ZT30
8.6
8
26
2940
22.8
21
79
8.6
8
27
2945
26.5
21
79
8.6
8
28
2945
35.3
21
79
47
Instruction book
Others
ZT18
ZT22
ZT30
ZT37
ZT18
ZT22
ZT30
ZT37
bar(e)
bar(e)
7.5
7
7.5
7
7.5
7
7.5
7
8.6
8
8.6
8
8.6
8
8.6
8
Celsius
r/min
26
2930
27
2940
28
2945
30
2945
26
2930
27
2940
28
2945
30
2945
kW
l
dB(A)
21.8
21
70
25.4
21
72
34.4
21
75
42.6
21
76
21.3
21
70
25
21
72
34.3
21
75
41.6
21
76
bar(e)
bar(e)
Celsius
r/min
kW
l
dB(A)
ZT18
ZT22
ZT30
8.6
8
26
3540
26
21
79
8.6
8
27
3545
29.8
21
79
8.6
8
28
3545
39.3
21
79
Others
48
ZT18
ZT22
ZT30
ZT37
ZT18
ZT22
ZT30
ZT37
bar(e)
bar(e)
7.5
7
7.5
7
7.5
7
7.5
7
8.6
8
8.6
8
8.6
8
8.6
8
Celsius
r/min
26
3530
27
3540
28
3545
30
3545
26
3530
27
3540
28
3545
30
3545
kW
l
dB(A)
24.2
21
70
27.9
21
72
37.7
21
75
44.1
21
76
24.4
21
70
28.2
21
72
37.7
21
75
44.7
21
76
2920 1345 01
Instruction book
ZT45
ZT55
ZT45
ZT55
ZR45
ZR55
ZR45
ZR55
bar(e)
bar(e)
7.5
7
7.5
7
8.6
8
8.6
8
7.5
7
7.5
7
8.6
8
8.6
8
Celsius
r/min
30
2960
30
2965
30
2960
30
2965
30
2960
32
2965
30
2960
32
2965
kW
l
dB(A)
49.4
34
75
61.2
34
76
48.2
34
75
60.4
34
76
49.8
34
75
58.8
34
76
48.4
34
75
60.4
34
76
l/s
--
--
--
--
0.68
0.80
0.66
0.82
ZT45
ZT55
ZT45
ZT55
ZR45
ZR55
ZR45
ZR55
bar(e)
bar(e)
7.5
7
7.5
7
8.6
8
8.6
8
7.5
7
7.5
7
8.6
8
8.6
8
Celsius
r/min
30
3560
30
3570
30
3560
30
3570
30
3560
32
3570
30
3560
32
3570
kW
l
dB(A)
48.5
34
75
61.2
34
76
48.4
34
75
60.1
34
76
48.7
34
75
60.9
34
76
48.6
34
75
60.8
34
76
l/s
--
--
--
--
0.71
0.89
0.71
0.89
ZT45
ZT55
ZT45
ZT55
ZR45
ZR55
ZR45
ZR55
bar(e)
bar(e)
7.5
7
7.5
7
8.6
8
8.6
8
7.5
7
7.5
7
8.6
8
8.6
8
Celsius
r/min
30
3545
30
3555
30
3545
30
3555
30
3545
32
3555
30
3545
32
3555
kW
l
dB(A)
51.4
34
75
64.8
34
76
51.4
34
75
63.6
34
76
51.9
34
75
64.9
34
76
51.8
34
75
64.7
34
76
l/s
--
--
--
--
0.71
0.89
0.71
0.89
Others
2920 1345 01
49
Instruction book
ZT75
ZT90
ZR75
ZR90
ZR75
ZR90
bar(e)
bar(e)
Celsius
r/min
8
7.5
28
2970
8
7.5
30
2970
8
7.5
29
2970
8
7.5
32
2970
10
9.5
30
2970
10
9.5
32
2970
kW
l
dB(A)
84.1
34.5
75
100.6
34.5
76
82.6
29.5
75
97.7
29.5
76
83.2
29.5
75
98.3
29.5
76
l/s
--
--
1.1
1.4
1.1
1.4
bar(e)
bar(e)
Celsius
r/min
kW
l
dB(A)
ZT75
ZT90
ZT75
ZT90
7.5
7
28
3565
92.6
34.5
75
7.5
7
32
3565
105.6
34.5
76
8.6
8
28
3565
90.6
34.5
75
8.6
8
34
3565
106
34.5
76
50
ZR75
ZR90
ZR75
ZR90
ZR75
ZR90
bar(e)
bar(e)
Celsius
r/min
7.5
7
30
3565
7.5
7
32
3565
8.6
8
30
3565
8.6
8
32
3565
10
9.5
30
3565
10
9.5
32
3565
kW
l
dB(A)
90.6
29.5
75
107
29.5
76
88.9
29.5
75
107
29.5
76
90.3
29.5
75
109
29.5
76
l/s
1.2
1.5
1.2
1.5
1.2
1.5
2920 1345 01
Instruction book
Footnotes chapter 7
1)
2)
3)
4)
5)
6)
7)
8)
9)
2920 1345 01
51