Atlas Copco Stationary Air Compressors

ZR500-10-50/EX

Addendum to the Instruction Book

Serial Number: S986001 01-05

Customer: AGIP, LIBYA

This addendum must be used together with the User manual for Elektronikon® regulator,
Printed Matter No. 2920 1291 04

• Copyright 2001, 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 instruction specified by the machine
directive 98/37/EC and is valid for CE as well as non-CE labeled machines

www.atlascopco.com

2002-11
 Addendum to the Instruction Book

PREFACE
This booklet is an addendum to the standard Instruction Book, printed matter 2920 1343 03. This addendum
describes how to handle and operate the subject machine, to ensure safe operation, optimum working economy
and long service life.

Please make this addendum available for the operator(s) and ensure that the compressor is operated and
maintained in accordance with Atlas Copco to instructions. Record all operating data, maintenance work
effected, etc. in an operator’s logbook which is available from Atlas Copco. Follow all applicable safety
precautions, as well as those mentioned in this addendum.

It is highly recommended repairs are carried out by trained personnel from Atlas Copco who can be contacted
for any further information.

This book only deals with the description and instructions applicable to the machine as it was shipped ex-factory.
If special devices or control systems are installed locally, complementary instructions must be added. If the
machine is used in a special process, the user should adapt the instructions, as required.

The book is divided in three sections:

Part A - describing safety precautions – to be read before installing, operating or repairing the unit.
Part B - giving general information about constructional differences between the standard unit described in the
standard manual and the S986001 01-05 units in question.
Part C - concerning modifications regarding to the standard Instruction Book

It is recommended that the paragraph "Ownership Data" should be completed by the customer as this data will
be required by Atlas Copco for any service inquiries and will assist in the carrying out of that service request.
In all correspondence please refer to the type and the serial number of the machine. Details are shown on the
compressor data plate.

The company reserves the right to make changes without prior notice.

OWNERSHIP DATA

Unit type: .......................................................................... Owner's machine No.: ................................

Motor type: ....................................................................... Unit serial No.: ............................................
Delivery date: ................................................................... Motor serial No.: .........................................
Service Plan: .................................................................... First start-up date: ......................................

Selected lubricants
Compressor: .................................................................... Capacity:.....................................................
Bearing grease type, electric motor: ................................

Printed Matter Nos.

Atlas Copco instruction book: .......................................... Motor instruction book: ...............................
Atlas Copco parts list: ...................................................... Motor parts list: ...........................................
Atlas Copco logbook: .......................................................

Local Atlas Copco Representative

Name:...............................................................................
Address: ...........................................................................
Telephone: ................................... Contact persons: Service: .......................................................
Telex: ........................................... Parts: ..........................................................
E-mail address .............................

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 Addendum to the Instruction Book

A. SAFETY PRECAUTIONS
To be read attentively and acted upon Loose or pivoting parts shall be securely
accordingly before installing, operating or fastened before lifting. It is strictly
repairing the unit. forbidden to dwell or stay in the risk zone
under a lifted load. Lifting acceleration and
These recommendations apply to machinery retardation shall be kept within safe limits.
processing or consuming air or inert gas. 2. Wear a safety helmet when working in the
Processing of any other gas requires additional area of overhead or lifting equipment.
safety precautions typical to the application
3. Any blanking flanges, plugs, caps and
which are not included herein.
desiccant bags shall be removed before
connecting up the pipes. Distribution pipes
In addition to normal safety rules which should
and connections shall be of correct size
be observed with stationary air compressors
and suitable for the working pressure.
and equipment, the following safety directions
and precautions are of special importance. 4. Place the unit where the ambient air is as
cool and clean as possible. If necessary,
When operating this unit, the operator must install a suction duct. Never obstruct the
employ safe working practices and observe all air inlet. Care shall be taken to minimize
related local work safety requirements and the entry of moisture with the inlet air.
ordinances. 5. The aspirated air shall be free from
flammable fumes or vapours, e.g. paint
The owner is responsible for maintaining the solvents, that can lead to internal fire or
unit in a safe operating condition. Parts and explosion.
accessories shall be replaced if unsuitable for 6. Air-cooled units shall be installed in such a
safe operation. way that an adequate flow of cooling air is
available and that the exhausted air does
Installation, operation, maintenance and repair not recirculate to the inlet.
shall only be performed by authorized, trained,
competent personnel. 7. Arrange the air intake so that loose
clothing of people cannot be sucked in.
Normal ratings (pressures, temperatures, time 8. Ensure that the discharge pipe from the
settings, etc.) shall be durably marked. compressor to the aftercooler or air net is
free to expand under heat and that it is not
Any modification on the compressor shall only in contact with or close to flammable
be performed in agreement with Atlas Copco material.
and under supervision of authorized, 9. No external force may be exerted on the
competent personnel. air outlet valve; the connected pipe must
be free of strain.
If any statement in this book, especially 10. If remote control is installed, the unit shall
with regard to safety, does not comply with bear an obvious sign reading:
local legislation, the stricter of the two shall
apply. DANGER: This machine is remotely
controlled and may start without
These precautions are general and cover warning.
several machine types and equipment;
hence some statements may not apply to As a further safeguard, persons switching
the unit(s) described in this book. on remotely controlled units shall take
adequate precautions to ensure that there
is no one checking or working on the
Installation machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in
conformity with the local safety regulations, the
following directives are specially stressed: 11. On units with automatic start-stop system,
a sign stating "This machine may start
without warning" shall be attached near
1. A compressor shall be lifted only with the instrument panel.
adequate equipment in conformity with
local safety rules.

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 Addendum to the Instruction Book

12. In multiple compressor systems manual short periods only, e.g. to carry out
valves shall be installed to isolate each checks. Wear ear protectors when
compressor. Non-return valves (check opening a door.
valves) shall not be relied upon for 6. People staying in environments or rooms
isolating pressure systems. where the sound pressure level reaches
13. Never remove or tamper with the safety or exceeds 90 dB(A) shall wear ear
devices, guards or insulations fitted on the protectors.
unit. Every pressure vessel or auxiliary 7. Periodically check that:
installed outside the unit to contain air a. All guards are in place and securely
above atmospheric pressure shall be fastened
protected by a pressure-relieving device or b. All hoses and/or pipes inside the unit
devices as required. are in good condition, secure and not
14. Pipework or other parts with a temperature rubbing
in excess of 80 degrees celsius and which c. There are no leaks
may be accidentally touched by personnel d. All fasteners are tight
in normal operation shall be guarded or e. All electrical leads are secure and in
insulated. Other high-temperature good order
pipework shall be clearly marked. f. Safety valves and other pressure-relief
15. If the ground is not level or can be subject devices are not obstructed by dirt or
to variable inclination, consult Atlas Copco. paint
g. Air outlet valve and air net, i.e. pipes,
16. The electrical connections shall
couplings, manifolds, valves, hoses,
correspond to the local codes. The units
etc. are in good repair, free of wear or
shall be grounded and protected against
abuse
short circuits by fuses.
8. If warm cooling air from compressors is
used in air heating systems, e.g. to warm
Operation up a workroom, take precautions against
air pollution and possible contamination
of the breathing air.
1. Air hoses shall be of correct size and
suitable for the working pressure. Never 9. Do not remove any of, or tamper with, the
use frayed, damaged or deteriorated sound-damping material.
hoses. Use only the correct type and size
of hose end fittings and connections. Maintenance
When blowing through a hose or air line,
ensure that the open end is held securely. Maintenance and repair work shall only be
A free end will whip and may cause carried out under supervision of someone
injury. Make sure that a hose is fully qualified for the job.
depressurized before disconnecting it.
Never play with compressed air. Do not 1. Use only the correct tools for
apply it to your skin or direct an air stream maintenance and repair work.
at people. Never use it to clean dirt from 2. Use only genuine spare parts.
your clothes. When using it to clean
3. All maintenance work, other than routine
equipment, do so with extreme caution
attention, shall only be undertaken when
and use eye protection.
the unit is stopped, the main power
2. The compressor is not considered as supply is switched off and the machine
capable of producing air of breathing has cooled down. Take positive
quality. For breathing air quality, the precaution to ensure that the unit cannot
compressed air must be adequately be started inadvertently.
purified according to local legislation and In addition, a warning sign bearing a
standards. legend such as "work in progress; do
3. Never operate the unit when there is a not start" shall be attached to the
possibility of taking in flammable or toxic starting equipment.
fumes. 4. Before removing any pressurized
4. Never operate the unit at pressures below component, effectively isolate the unit
or in excess of its limit ratings as from all sources of pressure and relieve
indicated on the Principal Data sheet. the entire system of pressure.
5. Keep all bodywork doors shut during 5. Never use flammable solvents or carbon
operation. The doors may be opened for tetrachloride for cleaning parts. Take

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 Addendum to the Instruction Book

safety precautions against toxic vapours 12. Make sure that all sound-damping
of cleaning liquids. material, e.g. on the bodywork and in the
6. Scrupulously observe cleanliness during air inlet and outlet systems of the
maintenance and repair. Keep dirt away compressor, is in good condition. If
by covering the parts and exposed damaged, replace it by genuine Atlas
openings with a clean cloth, paper or Copco material to prevent the sound
tape. pressure level from increasing.
7. Never weld or perform any operation 13. Never use caustic solvents which can
involving heat near the oil system. Oil damage materials of the air net, e.g.
tanks must be completely purged, e.g. by polycarbonate bowls.
steam-cleaning, before carrying out such 14. The following safety precautions are
operations. stressed when handling refrigerant:
Never weld on, or in any way modify, a. Never inhale refrigerant vapours.
pressure vessels. Check that the working area is
Whenever there is an indication or any adequately ventilated; if required,
suspicion that an internal part of a use breathing protection.
machine is overheated, the machine shall b. Always wear special gloves. In
be stopped but no inspection covers shall case of refrigerant contact with the
be opened before sufficient cooling time skin, rinse the skin with water. If
has elapsed; this to avoid the risk of liquid refrigerant contacts the skin
spontaneous ignition of the oil vapour through clothing, never tear off or
when air is admitted. remove the latter; flush abundantly
Never use a light source with open flame with fresh water over the clothing
for inspecting the interior of a machine, until all refrigerant is flushed away;
pressure vessel, etc. then seek medical first aid.
8. Make sure that no tools, loose parts or c. Always wear safety glasses.
rags are left in or on the unit. d. Protect hands to avoid injury from
hot machine parts, e.g. during
9. Before clearing the unit for use after
draining of oil.
maintenance or overhaul, check that
operating pressures, temperatures and
Note: With stationary machine units driven by
time settings are correct and that the
an internal combustion engine, allowance has
control and shut-down devices function
to be made for extra safety precautions, e.g.
correctly. If removed, check that the
spark arrestors, fuelling care, etc. Consult
coupling guard of the compressor drive
Atlas Copco.
shaft has been reinstalled.
10. Every time the separator element is All responsibility for any damage or injury
renewed, examine the discharge pipe and resulting from neglecting these
the inside of the oil separator vessel for precautions, or by non-observance of
carbon deposits; if excessive, the ordinary caution and due care required in
deposits should be removed. handling, operating, maintenance or repair,
11. Protect the motor, air filter, electrical and even if not expressly mentioned in this
regulating components, etc. to prevent book, will be disclaimed by Atlas Copco.
moisture from entering them, e.g. when
steam-cleaning.

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 Addendum to the Instruction Book

B. General
This addendum refers to the ZR500 machines with • Canopy side extension (150 mm) at motor cable
Serial Numbers S986001 01-05 only, and must be box side.
accompanied by the Instruction Book for Stationary • High resisting coating for exposed surfaces
Compressors, Printed matter No. 2920 1343 03. (canopy and frame) to obtain an increased
In the first section of this document, reference will resistance against aggressive atmosphere.
be made to the constructional differences between * Canopy:
the standard unit described in the standard Paint instruction 9821 1565 18,
Instruction Book and the S986001 01-05 units in minimum TDFT = 150 µ (2x powder coating
question. with polyester powder) colour RAL 7001.
* Frame:
1.1 Additional Paint instruction 9821 1563 15,
minimum TDFT = 150 µ (Superglacethane
The following modifications have been made to the coating) colour remains std black.
standard ZR500 compressor version: Remarks: tolerance on TDFT acc. to Atlas
Copco standard.
COMPRESSOR
MOTOR
Standard options:
• Pressure vessel approval ASME The installed motor meets the following
• With aftercooler specifications:
• ANSI flanges
• Elektronikon • Standard Siemens, type: 1LA3 450-4
• Control voltage 230 V • Shaft power: 598 kW
• COM1 communication module installed for • Service factor: 1
Elektronikon® MKIII – factory version • Voltage (± 10 %): 6.600V
• Duplex oil filter with manual change-over valve • Frequency: 50 Hz
• Anchor pads and bolts • Speed: 1.489 rpm
• Motor protection IP 55 • Max. cooling air temperature: 55 °C
• Connection of windings: STAR
Special mechanical items: • Insulation class: F
• Unit re-geared with special gears (one spare set • Enclosure: IP55
included). Gearcasing: • Construction form: IM3001 + SUPPORT
- Bull gear (117 teeth) • Full load efficiency: 96,3 %
- LP pinion (48 teeth) • Power factor: 0,84
- HP pinion (30 teeth) • Nominal current: 68 Amp
• Prefilter on air inlet. • Startingcurrent: 510 %
Supplier Donaldson, type FTG • Nominal torque: 4.040 Nm
The prefilter is supplied as a loose mounting kit • Starting torque: 80 %
with the following parts: • Weight: 3.700 Kg
- Metal housing and cover • Max. Altitude: 1.000 masl
- 3 cartridges (i.e. main cartridge + safety • Motor power derated by 5 % for voltage
cartridge) tolerance ± 10 %
- Vacuator valve
• Bigger motor size on customer request.
- rain cap
Filter efficiency: SAE coarse 99,9 %.
Standard / Special motor options
• Earthing bosses diagonally positioned on
• Anti condensation heaters (220V)
baseframe
• 2x 3 PT100 elements in windings (not
• Weathterproof version (simplified):
connected to Elektronikon module)
- Special protection cap above Elektronikon
• 2 PT100 elements in motor bearings (not
module
connected to Elektronikon module)
- Mastic sealant between canopy panels
• Special main terminal box with removable
• Extra diff. pressure sensor over duplex oil
undrilled gland plate.
filter
• Additional tagplate (supplied by customer)
• Condensate drians with NPT thread
• Special colour RAL 5017 (incl. 2 kg of spare
• Air outlet adapter 5” à 6”
paint for touch-up)
• Drilling holes in motor main terminal box
• One spare set of main motor bearings.
gland plate

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 Addendum to the Instruction Book

ELECTRICS
• Electrical cubicle: excluding starter for main 1.2 Attachments
drive.
• Elektronikon® regulation, 230 V - 50Hz The following drawings are an integral part of this
• Supply voltage for control addendum and must always accompany this
voltage or auxiliary voltage 400V publication:
• Solenoid valve 24 V - 50 Hz
• Dimension drawing: 9821 1618 08 (v.1)
• Service diagram: 9821 1436 09 1-2 (v.0)
Special electrical items / additional information: • Flow diagram: 9821 1624 73 (v.0)
• Auxiliary circuits for motor heaters (included
in standard option) • Parts list – ASL: 2930 1246 02
• Extra diff. pressure sensor on duplex oil filter, • Addendum to ASL for serial number S986001
programmed for alarm/trip function 01
• Anti condensation heater in cubicle, • Instruction book – AIB: 2920 1343 03
hygrostatically controlled.

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 Addendum to the Instruction Book

C. Modifications
As explained in the introduction, the ZR500 Cooling water temperature rise 10 °C
compressors supplied for this contract have been Volume flow rate (± 4 %) 1.053 l/s
modified. As this contract is for a ZR500 all Normal capacity 3.179,7 Nm3/h
references to any other type of compressor in the Shaft input 409,5 kW
standard Instruction Book should be ignored. Specific shaft input (± 5 %) 388,8 J/l
The following modifications to the standard Shaft input at no load (± 20 %) 60,1 kW
Instruction Book are cross-referenced by section, Drive speed 1.485 rpm
sub-section and paragraph and indicate the relevant MRS Stage LP 3.620 rpm
page number. MRS Stage HP 5.792 rpm
Total cooling water flow 13,12 l/s
1 Leading particulars Pressure drop cooling water 1,52 bar
LP outlet temperature. 197 °C
1.1 General description (p. 3) HP inlet temperature 35 °C
HP outlet temperature. 185 °C
Fig’s 1 and 2 are applicable as typical examples, Air/gas discharge temperature 33 °C
also concerning the compressor in question. For
information about added and replaced accessories CONDITION 2 – MAXIMUM PRESSURE
and specifications about the electric connections, Ambient pressure 1,01 bar(a)
see Section B, Dimension drawing 9821 1618 , Air/gas abs. inlet pressure 1,01 bar(a)
Service diagram 9821 1436 09 and Flow diagram Air/gas outlet pressure 10 bar(g)
9821 1624 73. Air/gas inlet temperature 50,2 °C
Air/gas inlet relative humidity 60 %
Cooling water inlet temperature 32 °C
2 Installation Cooling water temperature rise 10 °C
Volume flow rate (± 4 %) 1.049,5 l/s
2.1 Dimension drawings (p. 16) Normal capacity 3.169,5 Nm3/h
Shaft input 433 kW
Consult Dimension drawing no. 9821 1618 . Specific shaft input (± 5 %) 412,6 J/l
Shaft input at no load (± 20 %) 60,1 kW
2.3 Electric cables (p. 21) Drive speed 1.485 rpm
2.3.2 Connection (p. 21) MRS Stage LP 3.620 rpm
For specifications about the connections, see MRS Stage HP 5.792 rpm
Service diagram no. 9821 1436 09. Total cooling water flow 13,67 l/s
Pressure drop cooling water 1,64 bar
LP outlet temperature. 198 °C
HP inlet temperature 35 °C
7 Principal data HP outlet temperature. 201 °C
Air/gas discharge temperature 33 °C
7.5 Compressor specifications (p. 41)
General information CONDITION 3 – TEST CONDITION
Compressed medium Air Ambient pressure 1 bar(a)
Stage size – LP / MP / HP Air/gas abs. inlet pressure 1 bar(a)
STAGE 6 / NOT APPL. / STAGE 4 Air/gas outlet pressure 9 bar(g)
Max. working pressure 10 bar(g) Air/gas inlet temperature 20 °C
Max. ambient temperature 50,2 °C Air/gas inlet relative humidity 0%
Pressure vessel approval C.E. Cooling water inlet temperature 20 °C
Pressure vessel approval ASME Cooling water temperature rise 15 °C
Volume flow rate (± 4 %) 1.122,2 l/s
For data concerning the motor, see Section B - Normal capacity 3.715,9 Nm3/h
paragraph 1.1 of this addendum. Shaft input 427,9 kW
Specific shaft input 381,3 J/l
Performance data Package power input 444,3 kW
CONDITION 1 – SITE CONDITIONS Specific package power input (± 5 %) 396 J/l
Ambient pressure 1,01 bar(a) Shaft input at no load (± 20 %) 59,6 kW
Air/gas abs. inlet pressure 1,01 bar(a) Drive speed 1.485 rpm
Air/gas outlet pressure 9 bar(g) MRS Stage LP 3.620 rpm
Air/gas inlet temperature 50,2 °C MRS Stage HP 5.792 rpm
Air/gas inlet relative humidity 60 % Total cooling water flow 6,58 l/s
Cooling water inlet temperature 32 °C Pressure drop cooling water 0,38 bar

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 Addendum to the Instruction Book

LP outlet temperature. 163 °C Power input at no load (± 20 %) 67 kW

HP inlet temperature 24 °C Intercooler pressure 3,18 bar(a)
HP outlet temperature. 161 °C
Air/gas discharge temperature 22 °C

Additional parameters

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Dimension drawing

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Service Diagram 1 of 2

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 Addendum to the Instruction Book

Service Diagram 2 of 2

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Addendum to the Instruction Book

Flow diagram

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