ZR-ZT55-90 VSD-FF
ZR-ZT55-90 VSD-FF
ZR-ZT55-90 VSD-FF
The shortest route to superior productivity is to minimize operational cost while maintaining an uninterrupted supply of the right quality of air. The Atlas Copco Z compressor series is focused on effectively saving energy, ensuring product safety only oil-free machines exclude contamination risks
Core technology
Atlas Copco masters each compression principle and offers the most energy efficient technology for the application.
Fixed speed machines are efficient at full load but when air demand fluctuates, a Variable Speed Drive ensures substantial savings.
The integrated IMD adsorption dryer offers high quality dry air with the lowest pressure drop and uses the heat of the compressor for regeneration. Two features that lead to significant energy savings.
Optimal use
Central control of a multi-compressor installation reduces the pressure band and achieves the lowest overall energy cost. Optimization also covers operation of machines at their most optimal point.
Oil-free compression
Atlas Copco oil-free screw compressors have compressor chambers completely free of oil. This is possible because there is no metal contact between the precision cut rotors and hence no need for lubrication.
Complete safety
Process, products and environment are safeguarded from contamination. The first air compressors TV-certified as oil-free (ISO 8573-1 CLASS 0).
Expertise
Since 1903, Atlas Copcos philosophy has been to continually improve our products through intensive R&D, with the aim to maximize the value for our customers.
Internal piping, high end design features, Variable Speed Drive, 100 % matched components... the only way to ensure total reliability.
Energy recovery
Heat of compression can be recovered and put to good use in industrial processes like pre-heating of boiler feed water, heating of buildings etc.
Shaft power 100%
Energy
Radiant losses 2%
Safety
Service Contracts will ensure maximal machine uptime, preventive maintenance, immediate response and genuine spare parts all over the globe.
Reliability
CLASS
0 1 2 3 4
As specified by the equipment user or supplier and more stringent than class 1 0.01 0.1 1 5
TV (Technische berwachungsverein/Technical Monitoring Association) reporting on the Atlas Copco Z range of oil-free screw compressors
Can oil-injected compressors with oil removal filters deliver oil-free air?
Often referred to as technically oil-free air, this system relies on air cooling devices (e.g. refrigeration dryers) and several stages of oil removal with multiple components. A failure of any of these components or inadequate maintenance can result in oil contamination of a process. Therefore, with oil-injected compressors there will always be a risk of contamination and the possibility of severe consequences for your business.
Z Oil-free rotary screw compressor
Oil content:
Stage 1
Intercooler
Stage 2
Aftercooler
Oil content:
CLASS ZERO 0 mg/m 3
Oil content:
Stage 1
Aftercooler
Oil content*
* If low ambient temperature + clean filters = Class 2 edition 2001 ( 0.1 mg/m 3 ) If high ambient temperature + saturated filters = Class 3 edition 2001 ( 1 mg/m 3 )
1 2 3
High efficiency cooling Element bearings Water separator Electronic water drains Gearbox breather High precision gears Advanced Elektronikon control and monitoring system Energy Recovery system
4 5 6 7
5 8 2 1 3 4 6
ZR/ZT 55-90 FF and ZR/ZT 90 VSD-FF Capacity range (50 & 60 Hz)
ZR 55-90 FF ZR 75-90 VSD-FF ZT 55-90 FF ZT 75-90 VSD-FF
75 4.5 159
Aircooled ZT 55-90 VSD-FF Integrated VSD, Full Feature version with IMD dryer
1 2
Oil-free screw compression element Advanced Elektronikon control and monitoring system Gearbox breather High precision gears Electronic water drains
3 4 5
3 1 4 5
ZR 55-750 ZR 75-900 VSD ZT 55-275 ZT 75-315 VSD Low pressure element High pressure element
500 30 1060
1000 60 2120
1500 90 3180
ZT: Aircooled / ZR: Watercooled / VSD: Variable Speed Drive / FF: Full Feature. See data pages for range details.
Effective electronic water drains sensitive and precise operation reliable solid state actuation no loss of air alarm for malfunction on the Elektronikon display
Superior element bearings high stability under varying load conditions easily adapt to changing loads no need for pre-lubrication/stabilisation time
Totally enclosed motor IP55 TEFC protection against dust and humidity highly efficient conforming to EFF1
Integrated gearbox breathing system simple filter combined with venturi system keeps the oil inside the gearbox no oil fumes vented to the atmosphere
Air out
Oil return
High efficiency + high reliability air cooling (ZT) stainless steel pre-cooler with fins excellent heat transfer easy access for cleaning low noise + low energy radial cooling fans
Gearbox
Advanced Elektronikon control and monitoring system overall system performance status with pro-active service indications, alarms for malfunctions and safety shutdowns multi-language selectable display all monitoring and control functions via one interface wide communication possibilities integration possible in many process control systems (field bus system)
Unload losses are reduced to a minimum No blow-off of compressed air to the atmosphere Load/no load transition losses are eliminated The precise pressure control of the VSD compressor allows for a tighter pressure band and a lower average working pressure, resulting in reduced energy consumption
The lower system pressure obtained by VSD results in up to 10 % additional yearly savings: lower energy consumption of (other) base load machines leak losses are significantly reduced: e.g. leakage at 6 bar is 13 % lower than at 7 bar most compressed air applications consume less air at a reduced pressure
The stable system pressure provides stability for all processes using compressed air.
Pressure - standard load-unload - 0.5 bar Pressure - turbo-modulating - 0.2 bar Pressure - VSD - 0.1 bar
Predicting your savings Call upon the expertise of Atlas Copco specialists and have an assessment carried out in your factory. A detailed report will show your current operation and the achievable savings when adding a VSD solution to your compressed air system.
No current peaks during start-up unlimited starting and stopping no risk of current peak penalties upon starting
800
400
10
Seconds
20
AC input 50 or 60 Hz
AC output 42-115 Hz
Elektronikon controls compressor and inverter maximum machine safety easy networking of the compressor EMC tested and certified no influence of external sources no emissions to other equipment Mechanical enhancements proper lubrication to gears and bearings for all speeds all components operate below critical vibrations Inverter duty motor specifically designed for VSD bearings protected against induced bearing currents motor & converter perfectly tuned to obtain best efficiency
over entire speed range
optimized cooling air flow, preventing overheating maximum operating range without torque starvation
Tested over complete speed range elimination of speed windows, ensuring stable pressure and
consistent energy savings
Operating range
maximum
The Full Feature concept is a total installation, providing dry compressed air. Integrating the IMD dryer and its Variable Speed Drive on VSD models, this compact package offers high quality air at the lowest cost. The IMD adsorption dryer eliminates the moisture before it enters the air net, ensuring a reliable process and an impeccable end product. No external energy is needed to dry the air, resulting in large savings in comparison to conventional dryers.
The pressure drop through the dryer is minimal, which again cuts down the operating cost. The IMD dryer needs no purge air: no compressed air is wasted. The Full Feature compressor is a pre-wired and pre-piped solution, ready to use.
Hot air in for regeneration Cold wet air in Cold dry air out Regeneration area Drum rotation
1 3
Watercooled ZR 90 VSD-FF
Air compression creates heat that is normally wasted in the coolers. Atlas Copco has designed energy recovery systems which enable most of this heat to be recovered. Energy recovery could be as high as 94 % of the shaft input of the compressor.
Radiant losses 2%
Recoverable energy 94 %
Price /liter ()
How do I benefit?
You save energy wherever you add the recovered energy as an auxiliary source to reduce your operating costs. The investments needed for linking the hot water from the compressor to existing circuits are relatively modest and the payback period can be very short.
Lifecycle cost
320,000
60,000
30,000
The energy recovery system is paid back in less than 6 months Compressor is paid back in less than 3 years Net gain of 230,000 in 10 years * * Only includes calculation on energy as maintenance will remain almost the same as a standard compressor
Assumptions example chosen is a 90 kW ZR compressor 8,000 running hours/year at full load and full energy recovery cost of fuel oil: 0.55 /l The figures shown are an example. Price calculations can be made case by case.
8000 Energy savings* (/$/year) 7000 6000 5000 4000 3000 2000 1000 0 0 0 500 1060 1000 2120 1500 3180 IMD savings Refrigerant dryer Heat reactivated dryer Heatless dryer
2000 4240
I/s cfm
Flow
Indirect savings Other than direct energy input, the pressure drop in dryers causes indirect energy consumption as well. IMD dryers have a very low pressure drop, which leads to a further reduction in energy cost.
4000 Yearly savings* (/$) 3500 3000 2500 2000 1500 1000 500 0 0 500 1060
for each 0.1 bar (1 .4 psi ) press S avings ure drop
Overall system control and monitoring One integrated control system for compressor and dryer Monitoring of the IMD dryer includes: Temperature readings of IMD dryer inlet and outlet regeneration air inlet and outlet mix air inlet
1000 2120
1500 3180
2000 4240
2500 5300
3000 6360
I/s cfm
Flow
CustomDesign
The new generation of Z-compressors is designed as standard to perform in a wide range of operating and site conditions. However, some environments call for additional measures. For all those special requests Atlas Copcos CustomDesign department offers an adequate solution.
Customizing the standard products to fit your local plant standards. Meeting these standards on electrical voltage, colour coatings, explosion proof zones, documentation, test and inspection requirements Designing products to secure operation in harsh environments. Allow outdoor installation in sub-zero temperatures, increase corrosion resistance for windy coastal and offshore applications or ensure performance in hot, moist or dusty environments Extending the range to nitrogen compressors and booster units to suit your specific application
Our Aftermarket product portfolio is designed to add maximum value for our customers by ensuring the optimum availability and reliability of their compressed air equipment with the lowest possible operating costs. We deliver this complete service guarantee through our extensive Aftermarket organization, maintaining our position as the leader in compressed air.
Product*
Atlas Copco Service kits & oils AIRXtend ServicePlan AIRScan AIRConnect AIROptimizer Upgrade programs
* More information is available from your local Atlas Copco customer centre
Numerous features are included as standard. Some applications may also need or benefit from one of the factory installed options. Standard
Air intake filter and silencer Air intake flexible Stainless steel inter and aftercooler cores* Inter and aftercooler water traps and electronic drains Outlet air silencer Terminal expansion joints air and water side Outlet air flange Complete water circuit* Single point inlet and outlet connection Back-flush arrangement for cooler cleaning* Complete oil circuit pre-piped Built-in oil breather system AGMA class 13, DIN class 5 gears Electric motor pre-mounted IP 55 motors Starters Pre-mounted electrical and VSD cubicles Silencing canopy Skid with no need for foundations Electronic drains Suppression of emissions/harmonic distortions (in VSD)
ZR 75-90 VSD-FF
Option/Model
SPM monitoring equipment (loose kit) Kit for purge of dry air during standstill (for tropical environment) High ambient temperature version (required when ambient temperature is above 40 C) Energy recovery Teflon-free elements Water shut-off valve Material certificates (check if you require pressure vessel approval certificates) Test certificate Witnessed performance test High resolution display for Elektronikon MkIV (required for Chinese, Korean and Japanese characters) Wooden case protection packaging Thermistors in motor windings Anti-condensation heaters in main motor Anchor pads Earthing system IT, TT or TN network PDP sensor Low load kit
* **
For watercooled versions Only for watercooled versions with free-standing MD dryers
ZT 75-90 VSD-FF
ZR 75-90 VSD
ZT 75-90 VSD
ZR 55-90 FF
ZT 55-90 FF
ZR 55-90
ZT 55-90
Technical data
True performance
Intake volume
Atlas Copco Z-compressors are measured according to ISO 1217, Edition 3, Annex C stipulating the FAD (Free Air Delivery) measurement at the outlet of the package, net of all losses. Atlas Copco specifications correspond to the capacity and pressure that are effectively available to the user, not to the air volume that is sucked in. Differences can be substantial.
External leakages
A ZR 55 ZR 75 ZR 90 ZR 75 VSD ZR 90 VSD ZT 55 ZT 75 ZT 90 ZT 75 VSD ZT 90 VSD 2180 2180 2180 2630 2630 2180 2180 2180 2630 2630
B 1450 1450 1450 1450 1450 1450 1450 1450 1450 1450
C 2184 2184 2184 2184 2184 2184 2184 2184 2184 2184
Weight 1640 1715 1780 2030 2030 1760 1835 1900 2100 2100 ZR 55 FF ZR 75 FF ZR 90 FF ZR 75 VSD-FF ZR 90 VSD-FF ZT 55 FF ZT 75 FF ZT 90 FF ZT 75 VSD-FF ZT 90 VSD-FF
A 2180 2180 2180 2630 2630 2880 2880 2880 3330 3330
B 1450 1450 1450 1450 1450 1450 1450 1450 1450 1450
C 2184 2184 2184 2184 2184 2184 2184 2184 2184 2184
Weight 1890 1965 2030 2280 2280 2360 2475 2500 2700 2700 ZR 55 * ZR 75 * ZR 90 * ZR 75 VSD * ZR 90 VSD * ZR 55 FF * ZR 75 FF * ZR 90 FF * ZR 75 VSD-FF * ZR 90 VSD-FF *
A 2180 2180 2180 2630 2630 2880 2880 2880 3330 3330
B 1450 1450 1450 1450 1450 1450 1450 1450 1450 1450
C 2184 2184 2184 2184 2184 2184 2184 2184 2184 2184
Weight 1640 1715 1780 2030 2030 1990 2065 2130 2370 2370
(1)
Reference conditions: - dry air - absolute inlet pressure 1 bar(a) - cooling and air intake temperature 20 C - nominal working pressure - performance of the compressor package measured according to ISO 1217, Third Edition, Annex C Cooling water temperature rise of 15 C Max. capacity is at reference pressure and not at max. pressure
(4)
Pressure dewpoint is specified for - 20 C cooling air/water temperature - relative humidity of 60 % - nominal working pressure - load level of minimum 50 % For VSD: at reference speed 3 dB(A) measured at a distance of 1 m and according to ISO 2151:2004 and using ISO 9614-2 Maximum intake / cooling air temperature is 50 C for HAT versions
(6)
ZR/ZR FF
50 Hz units ZR 55 - 7.5 ZR 55 - 8.6 ZR 55 - 10 60 Hz units ZR 55 - 7.25 ZR 55 - 9 ZR 55 - 10.4 50 Hz units ZR 75 - 7.5 ZR 75 - 8.6 ZR 75 - 10 60 Hz units ZR 75 - 7.25 ZR 75 - 9 ZR 75 - 10.4 50 Hz units ZR 90 - 7.5 ZR 90 - 8.6 ZR 90 - 10 60 Hz units ZR 90 - 7.25 ZR 90 - 9 ZR 90 - 10.4 262 235 224 15.7 14.1 13.4 555 498 475 90 90 90 120 120 120 1.6 1.6 1.6 2.3 2.3 2.3 -26 -28 -29 65 65 65 234 220 209 14.0 13.2 12.5 496 466 443 90 90 90 120 120 120 1.4 1.4 1.4 2.1 2.1 2.1 -27 -28 -28 65 65 65 213 194 185 12.8 11.6 11.1 452 411 392 75 75 75 100 100 100 1.3 1.3 1.3 1.9 1.9 1.9 -26 -27 -27 65 65 65 194 184 174 11.6 11.0 10.4 411 390 369 75 75 75 100 100 100 1.2 1.2 1.2 1.8 1.8 1.8 -26 -26 -27 65 65 65 155 138 128 9.3 8.3 7.7 329 293 271 55 55 55 75 75 75 1 1 1 1.4 1.4 1.4 -24 -25 -25 65 65 65 143 131 121 8.6 7.9 7.3 303 278 257 55 55 55 75 75 75 0.9 0.9 0.9 1.3 1.3 1.3 -24 -24 -25 65 65 65
(1)
Reference conditions: - dry air - absolute inlet pressure 1 bar(a) - cooling and air intake temperature 20 C - nominal working pressure - performance of the compressor package measured according to ISO 1217, Third Edition, Annex C Cooling water temperature rise of 15 C
(3)
Max. capacity is at reference pressure and not at max. pressure Pressure dewpoint is specified for - 20 C cooling air/water temperature - relative humidity of 60 % - nominal working pressure - load level of minimum 50 % For VSD: at reference speed
(5)
3 dB(A) measured at a distance of 1 m and according to ISO 2151:2004 and using ISO 9614-2 Maximum intake / cooling air temperature is 50 C for HAT versions
(4)
(6)
(2)
ZR VSD / ZR VSD-FF
Watercooled oil-free compressors Types 50/60 Hz
l/s
m3/min
cfm
l/s
ZR 75 VSD-9 bar (e) Max (3) Min ZR 75 VSD-10.4 bar (e) Max (3) Min ZR 90 VSD-9 bar (e) Max (3) Min ZR 90 VSD-10.4 bar (e) Max (3) Min 232 98 13.9 5.9 492 208 258 75 15.5 4.5 547 159 198 98 11.9 5.9 420 208 220 75 13.2 4.5 466 159
1.25
1.92
-30
65
1.25
1.92
-30
65
1.25
1.92
-30
65
1.25
1.92
-30
65
ZT/ZT FF
50 Hz ZT 55 - 7.5 ZT 55 - 8.6 ZT 55 - 8.6 HAT (6) ZT 55 - 10 60 Hz ZT 55 - 7.25 ZT 55 - 8.6 HAT (6) ZT 55 - 9 ZT 55 - 10.4 50 Hz ZT 75 - 7.5 ZT 75 - 8.6 ZT 75 - 8.6 HAT (6) ZT 75 - 10 60 Hz units ZT 75 - 7.25 ZT 75 - 8.6 HAT (6) ZT 75 - 9 ZT 75 - 10.4 50 Hz units ZT 90 - 7.5 ZT 90 - 8.6 ZT 90 - 8.6 HAT (6) ZT 90 - 10 60 Hz units ZT 90 - 7.25 ZT 90 - 8.6 HAT (6) ZT 90 - 9 ZT 90 - 10.4 261 222 236 222 15.7 13.3 14.2 13.3 553 470 500 471 90 90 90 90 120 120 120 120 3.8 3.8 3.8 3.8 5.6 5.6 5.6 -32 -32 -33 72 72 72 72 233 220 208 208 14.0 13.2 12.5 12.5 494 466 441 441 90 90 90 90 120 120 120 120 3.6 3.6 3.6 3.6 4.7 4.7 4.7 -31 -32 -32 72 72 72 72 212 184 194 184 12.7 11.1 11.6 11.0 449 390 411 390 75 75 75 75 100 100 100 100 3.8 3.8 3.8 3.8 5.6 5.6 5.6 -30 -31 -31 72 72 72 72 193 184 174 174 11.6 11.0 10.4 10.4 409 390 369 369 75 75 75 75 100 100 100 100 3.6 3.6 3.6 3.6 4.7 4.7 4.7 -30 -30 -31 72 72 72 72 154 127 137 127 9.2 7.6 8.2 7.6 326 269 290 269 55 55 55 55 75 75 75 75 2 2 2 2 3.6 3.6 3.6 -28 -28 -29 72 72 72 72 142 130 120 120 8.5 7.8 7.2 7.2 301 276 254 254 55 55 55 55 75 75 75 75 2 2 2 2 3.1 3.1 3.1 -28 -28 -28 72 72 72 72
ZT VSD / ZT VSD-FF
Aircooled oil-free compressors Types 50/60 Hz
l/s
m3/min
cfm
dB(A)
ZT 75 VSD-9 bar (e) Max (3) Min ZT 75 VSD-10.4 bar (e) Max (3) Min ZT 90 VSD-9 bar (e) Max (3) Min ZT 90 VSD-10.4 bar (e) Max (3) Min 232 98 13.9 5.9 492 208 258 75 15.5 4.5 547 159 198 98 11.9 5.9 420 208 220 75 13.2 4.5 466 159
-30
72
-30
72
-30
72
-30
72
needs and objectives. It means having the flexibility to adapt to the diverse demands of the people we cater for.
ISO 14001
Atlas Copcos Environmental Management System forms an integral part of each business process.
Never use compressed air as breathing air without prior purification in accordance with local legislation and standards.
www.atlascopco.com