ZE-ZA Compressor brochure

Atlas Copco Air Compressors

ZE/ZA 3-6 & ZE 4 VSD 50 Hzlow pressure oil-free air compressorswith Variable Speed Drive variant

ANY PRESSUREANY FLOW IN ONE NEAT PACKAGE

Low Pressure, Oil-free Airis Vital for your Process

ISO 9001From design to

production and delivery,Atlas Copco compressorsadhere to the ISO 9001

quality standard.

ISO 14001Atlas Copco's

Environmental Management Systemforms an integral part

of each business process.

Low pressure compressed air is often a vital ingredient in yourproduction process. It is a means to an end, yet so vital that youcannot run the risk of product contamination, disturbing pulsations,performance degradation, or even worse, a production standstill.Through interaction with customers just like you, Atlas Copco hasmade the ZE/ZA range the ideal compressor choice for lowpressure applications such as powder and bulk handling, mixingof materials, aeration, air separation, fermentation, cooling anddrying processes.

ZE: Aircooled / ZA: WatercooledVSD: Variable Speed DriveSee data pages for range details.

424

200

Operating range ZE/ZA 3-6 / ZE 4 VSD 50 Hz & 60 Hz

ZE4 ZA5ZE32.0 28.6

3.0 42.9

4.0 57.2

bar(e) psig

1.0 14.3

848

400

1272

600

1696

800

2120

1000

2544

1200

2968

1400

3392

1600

3816

1800

cfm

l/s

ZA6

ZE 4 VSD

The oil-free low pressure ZE/ZA3-6 compressor range gives you all this,and much more. The back-up of an organisation that truly understands what

air compression is about. After all, we have over a century of learning behind us.

Close interaction, innovation and commitment the benchmarks that earnedAtlas Copco the industry leadership and a high customer loyalty.

ZE/ZA 3-6 Series Any Pressure, Any Flow In One Neat Package

ZE 4 VSD

Variable Speed Drive variantfor optimal process stability andthe lowest cost compressed air.

ZE/ZA 3-6 Facts

Completely oil-free air no risk of oil contamination

Complete, ready-to-use package

Water and aircooled versions

Designed for easy integration of accessories

Designed for easy integration into other systems using compressed air

Wide range of pressure & capacity variants and gear ratios

Guaranteed performance ISO1217, Annex C, Ed. 3

High efficiency, direct-driven IP55 motor

Advanced control and monitoring Elektronikon regulation

Variable Speed Drive (VSD) variant optimal process stability

Secure operation under all circumstances

Durable quality components

Low sensivity to dusty environments

Proven, standard Atlas Copco product

Backed by a global sales & service organisation

ZE/ZA Complete Scope No Costly Additions

Excellence by design

Silenced units to work at any location

- flexible, vibration-free compressor mounting

- silencing canopy protects against noise emissions

(beyond CE directives and US OSHA standards)

Easy, low cost installation

- no foundations, no bolting required

- compact and complete unit put in place and connect

Designed for easy integration of additional

components to suit particular application needs

Advanced Elektronikon control and monitoring system

Air intake filter and silencer

Air intake flexible

Outlet air silencer

Discharge expansion joints

Outlet air flange

Complete water circuit

Single point inlet and outlet connections

Back-flush arrangement for cooler cleaning

Check valve

Safety valve

IP55 water & dust proof motor

Built-in starter

Oil filled at delivery

Complete oil circuit pre-piped

Built-in oil breather system

AGMA class 13 ; DIN class 5 gears

Pre-mounted electric motor

Pre-mounted electrical cubicle

Silencing canopy (standard version)

Skid with no need of foundations

Vibration absorbing outlet

Full load / no load regulator

Integral blow off

Coated rotors

Elektronikon control and monitoring system

As standard included

Global Presence

Local Service

Service Worldwide

Service friendly

- Easy access for quick

routine service

- Due service predicted on

Elektronikon control panel

ZE/ZA A Ready-to-useSolution

Caring for energy

ZE 4VSD - Variable Speed

Drive variant for the lowest

cost compressed air

Reduced internal pressure

drops through integrated

design

Power saving cooling system

Energy-less MD

adsorption dryer

Thermistors n.r.

Anti-Condensation Heaters

PT100 Motor Thermal Protection n.r.

Central Controller Communication Module COM1 st.

MODBUS Communication Module st.

PROFIBUS Communication Module

Heavy-Duty Inlet Filter n.a. n.a.

ANSI Flanges

ASME Approval n.r. n.r.

DIR Approval n.r. n.r.

Automatic Water Shut-off n.a.

Integrated Stainless Steel Aftercooler st.

Separate Stainless Steel Aftercooler n.a.

Watercooled Variant st. n.a.

Excluding Canopy n.a.

Excluding Motor n.a.

Excluding Full load / No load Regulator n.a.

Canopy Extension for High Voltage Motor n.a. n.a.

Anchor Pads

Seaworthy Packaging

Witness Performance Test

Performance Test Certificate

SPM bearing monitoring

n.r.: not requiredst.: standardn.a.: not available

Standard Options

ZA 5

-6

ZE 4

VSD

ZE 3

-4

R

ZE/ZA Proven Low Pressure Air Technology

Easy supervision and total reliable

monitoring

Advanced Elektronikon control and

monitoring system with text display on the

status of the entire system performance.

It is designed for integration into processes

with remote controls.

Ambient motor protection

Direct drive efficiency

The IP55 high efficiency motor protects

against dusty, humid ambients. It is

directly coupled to the compression

element for the best energy balance and

permanent alignment.

System integrity safeguarded

High efficiency air intake filters prevent dust

damage and cut power consumption costs.

Filter selection is based on internal compressor

protection and reduction of pressure drop at the

intake. Approved 99.5% for 1 micron particles.

Unique gearbox breathing system

avoids compressor contamination

Oil and oil fumes remain where they

belong: in the gearbox. Internal pressure

build-up is prevented. Without any

moving component, air and oil are

separated mechanically.

Bearing condition monitoring

Motor and element bearing condition

for pro-active service indications via

the optional SPM monitoring box

Stress absorbing,

stainless steel air

outlet connection

for safe operation

Secure compressor start

under all circumstances

Atlas Copco rotor elements are coated with a

unique carbon/Teflon mixture to eliminate

corrosion or motor blocking after stand still.

This allows for operation at 3.5 bar in high

temperature conditions.

Designed to economically

adapt to air demand

For processes with varying air demand,

the full load / no load regulation system

controls air production to best match air

requirement.

The regulator operates either at 100 %

capacity (fully open) or 0 % capacity,

using less power than a conventional

blow-off system.

Liquid cooled compression

elements for highest efficiency

Unlike aircooled elements, liquid

cooling jackets ensure an even spread

of heat over the compression elements,

reducing material tension, maintaining

clearance control and extending the

bearing lifetime.

Silencer

Controlsystem

Regulationvalve

Compressionelement

Checkvalve

Pressuretransducer

Cost structure of a fixed speed compressor

Cost structure of a ZE 4 VSD compressor

Many low pressure air processesmust rely on a stable systempressure. A vital requirementearlier achieved in using eitherlarge size air receivers or withblow-off systems an energywasting solution banned tohistory with the ZE 4 VSD.The Variable Speed Drive com-pressor with integrated frequencyconverter controls the pressureexactly to the process needs andconsiderably saves on energy.ZE 4 VSD is the perfect matchbetween air supply and airdemand.

Call upon the expertise of Atlas Copco to assessyour process and analyse the air demand andenergy consumption in your plant. Based on theresults, the implementation of a VSD compressorin a typical installation can be simulated bysoftware. Future energy savings can beestimated.

Total compressor life cycle costWith a fixed speed compressor, energyconsumption represents over 70% of the totallife cycle cost. The integrated frequencyconverter of the ZE 4 VSD will vary the speed ofthe compressor to closely follow the air demand,thereby saving enough energy to payback theadditional investment in possibly one to twoyears depending on the energy tariffs and thedemand patterns. Slashing power consumptionby installing a VSD compressor results in a lifecycle cost saving of 15 to 25 %.

A typical air demand profile, measured over oneweek. Measurements on existing applicationshave shown a decrease in energy demand from25 to 35 % with an increased process stability.

ZE 4 VSD Variable Speed Drive= Optimized Process Stability= Saving on Energy

% of air demand

Time of day

MondayTuesdayWednesdayThursdayFridaySaturdaySunday

Maintenance

Investment

Energyconsumption

Maintenance

Investment

Energyconsumption

Savings

VSD a Very Smart Decision

0200

400

600

800

0 2 4 6 8 10 12 14 16 18 20 22 24

No current peaksCompressor starts are even smoother than withso called soft starters. This greatly simplifiesthe electrical installation. No current peaks.No risk of penalties from the utility company.Investment in the electrical system can bereduced.

% full load current

Star Delta

DOL

Soft Starter

VSD

Seconds

ZE 4 VSDUnique Integration

Absolute Torque NM

Motor Torque NM Star

Compressor Torque NMVSD Torque NM

Speed Ratio n/nsnominal

Motor Torque NM Delta

No torque peaksThe Super Soft start and load/unload transitionensure a long lifetime of all moving parts:coupling, bearings, valves.

Constant pressureThe output pressure is virtually constant over awide capacity range (narrow pressure bandwithin 0.1 bar). Unlike traditional regulationsystems, it optimizes energy consumption andensures high process stability.

Process Pressure

0.5 bar

Standard load/no load control 0.5 bar

Modulation control

VSD 0.1 bar

Select your outlet temperatureVSD controlled aftercooler fansallow for selection of the approachtemperature via the Elektronikon

control system.

Built-in VSD converterAllows single point electrical connectionsComplies with EMC standardsHighest possible efficiency in combinationwith VSD motor

Compressor type (incl. aftercooler) ZE 4 VSD ZE 4 VSD2 bar 3.5 bar

Capacity (FAD)- minimum l/s - cfm 228 - 483 218 - 462- maximum l/s - cfm 855 - 1813 812 - 1721

Max. working pressure bar(e) 2.5 3.5

Power requirement- minimum kW 46 72- maximum kW 159 236

Unloaded power kW 21 21

Noise level dB(A) 75 77

Dimensions- Length mm 3540 3540- Width mm 1750 1750- Height mm 2175 2175

Technical data ZE 4 VSD

Variants for tailored applications

With the ZE-ZA range specific applications' needs are anticipated.

The ability to add optional or remove standard equipment is

incorporated.

ZE/ZA pre-engineeredfor full integration

Pre-engineered for cost-saving installation

Pressure drop risks are avoided

Time saving & adequate selection

A standard option

ZE3 with aircooled aftercoolerincorporated

When noise levels are less critical

A standard option

Non-silenced ZE3

Full scope non-silenced version

Designed to easily add an aftercooler

ZA5 with watercooledaftercooler incorporated

Air/oil/cooling flows

Aircooled low pressure ZE compressor

Air

Oil

Water

Watercooled low pressure ZA compressor

Air in

Air out

Air in

Air out

Oil

Air

Dry quality air tailored to the need

Many low pressure air applications rely on dry quality air, free

from moisture, to help avoid the risk of product contamination and

to eliminate damage to the compressed air system. Along the

application and air purification criteria, Atlas Copco offers a wide

selection of air dryers for an optimal air treatment system.

Energy Saving Control and Monitoring System

Latest Elektronikon controllers have an Integrated Multiple

Compressor Control System as an option.

To further optimize your compressor room, install an ES energy

saving system or contact Atlas Copco for an energy audit.

ES Millennium

NODRYER

ADSORPTION DRYER MD PRESSURE DEWPOINT -20C

ADSORPTION DRYER BD PRESSURE DEWPOINT -40C

ADSORPTION DRYER BD PRESSURE DEWPOINT -70C

REFRIGERANT DRYER FD +3C

Basic Pros for an oil-free

dry air combination

high quality dry compressed air

a quality end product

an undisturbed production process

a simple, low cost installation

reliability from one supplier

FOR GENERAL PLANT AIRINSTALLATIONS,NOT SUBMITTED TO FROST

DEPENDING ON CLIMATICCONDITIONS, APPLICATIONSWHICH DEMAND ABSOLUTELYDRY AIR MAY NEED DIFFERENTDEWPOINTS.

AS STANDARD, THE BD DRYERDELIVERS AIR WITH ADEWPOINT OF -40C.

AS AN OPTION, THE BD DRYERCAN DELIVER AIR WITH ADEWPOINT OF -70C,TO MEET EXTREME DRY AIRREQUIREMENTS

RISKS WITHOUT A DRYER:- PIPE CLOGGING, FREEZING,

CORROSION- END PRODUCT SPOILAGE- HIGH MAINTENANCE COST

If your process needs air with

a pressure dewpoint of -20C ,

add the unique and environmentally

friendly MD adsorption dryer.

Tailored to your installation, air

and watercooled versions are available.

Very low energy requirement

Very low pressure drops

No need for filters

For the ZE 4 VSD there is a matching MD VSD

for the most stable dewpoint.

Technical data ZE 3 series - 50 HzAircooled low pressure oil-free air compressors

Gear designation A B C D E F G H I J K L MUnloaded power kW 15 16 17 19 20 21 23 24 25 27 29 31 33Sound pressure level **

Pressure at max 2 bar dB(A) 74 74 74 74 74 74 74 74 74 75 75 75bar(e) at max 3.5 bar dB(A) 76 76 76 76 76 76 76 76 76 76 77 77

1.00 Free Air Delivery* l/s 160 176 194 214 229 245 263 283 305 330 357 387cfm 340 374 412 454 486 520 558 601 648 701 758 822

Outlet temperature C 102 103 104 105 106 107 107 108 109 110 112 114Shaft power kW 26.0 28.2 30.6 33.5 35.6 38.0 40.7 43.8 47.2 51.1 55.6 60.8Motor size kW 30 30 37 37 45 45 55 55 75 75 75 75





















* Reference conditions- Dry air- Absolute intake pressure 1 bar (a)- Cooling and intake air temperature 20 C- Capacity of the compressor package

measured according toISO1217, Third edition, Annex C

** 3 dB(A) according toPneurop PN 8 NTC 2.2test code measured ata distance of 1 m,excluding aftercooler

Dimensions mm ZE

Length 2780

Width 1750

Height 1990

Technical data ZE 4 series - 50 HzAircooled low pressure oil-free air compressors

Gear designation C D E G H I J K L M NUnloaded power kW 34 38 41 44 47 51 53 57 60 62 65Sound pressure level **

Pressure at max 2 bar dB(A) 76 76 76 76 77 77 77 77 77 77bar(e) at max 3.5 bar dB(A) 79 79 79 79 79 79 79 79 79

1.00 Free Air Delivery* l/s 419 452 488 528 572 596 648 677 707 739cfm 888 958 1034 1119 1212 1263 1373 1434 1498 1566

Outlet temperature C 110 110 111 112 113 113 114 114 115 115Shaft power kW 50.9 55.4 60.4 66.1 72.5 76.0 83.9 88.2 92.9 97.9Motor size kW 75 75 75 75 90 90 132 132 132 132









2.25 Free Air Delivery* l/s 360 404 436 472 512 555 579 631 659cfm 763 856 924 1000 1085 1176 1227 1337 1396

Outlet temperature C 168 167 166 165 166 166 166 168 170Shaft power kW 74.1 83.0 89.7 97.2 105.6 114.9 120.1 131.4 137.6Motor size kW 75 90 110 110 110 132 132 200 200














Dimensions mm ZE

Length 2780

Width 1750

Height 1990

Technical data ZA 5 series - 50 HzWatercooled low pressure oil-free air compressors

Gear designation B C D E F G HUnloaded power kW 50 56 62 67 72 79 86Sound pressure level **

Pressure at max 2 bar dB(A) 70 70 70 70 70 70bar (e) at max 3.5 bar dB(A) 73 73 73 73 73 73

1.00 Free Air Delivery* l/s 817 897 958 1025 1101 1187cfm 1731 1900 2030 2172 2333 2515

Outlet temperature C 94 95 95 96 97 98Shaft power kW 94 105 113 122 133 145Motor size kW 160 160 160 160 160 160
























Dimensions mm ZA

Length 3700

Width 2120

Height 2400

Technical data ZA 6 series - 50 HzWatercooled low pressure oil-free air compressors

Gear designation C D E F G H J M K LUnloaded power kW 89 99 107 116 126 137 151 158 166 175Sound pressure level **

Pressure at max 2 bar dB(A) 73 73 73 73 73 76 76 76 76bar(e) at max 3.5 bar dB(A) 72 73 73 74 75 77 79 79


Outlet temperature C 93 94 94 95 95 96 96 97 97Shaft power kW 139 153 168 186 206 229 242 256 271Motor size kW 160 160 200 200 250 250 250 315 315









2.25 Free Air Delivery* l/s 1101 1242 1343 1450 1563 1681 1806 1870cfm 2333 2631 2845 3072 3311 3561 3826 3962

Outlet temperature C 153 152 151 151 151 150 151 151Shaft power kW 209 232 250 270 293 318 346 362Motor size kW 250 250 315 315 315 355 500 500














Dimensions mm ZA

Length 3700

Width 2120

Height 2400

Never use compressed air asbreathing air without priorpurification in accordancewith local legislation and

standards.

2935

040

2 11

- P

rint

ed in

Bel

gium

- S

ubje

ct to

alt

erat

ions

wit

hout

pri

or n

otic

e

What sets Atlas Copco apart as a company is ourconviction that we can only excel in what we do if we

provide the best possible know-how and technology to

really help our customers produce, grow and succeed.

There is a unique way of achieving that - we simplycall it the Atlas Copco way. It builds on interaction, on

long-term relationships and involvement in the customers

process, needs and objectives. It means having the

flexibility to adapt to the diverse demands of the people

we cater for.

Its the commitment to our customers business thatdrives our effort towards increasing their productivity

through better solutions. It starts with fully supporting

existing products and continuously doing things better, but

it goes much further, creating advances in technology

through innovation. Not for the sake of technology, but

for the sake of our customers bottom line and peace-of-

mind.

That is how Atlas Copco will strive to remain the firstchoice, to succeed in attracting new business and to

maintain our position as the industry leader.

The

face

of i

nnov

atio

n

www.atlascopco.com

ZE-ZA Compressor brochure

Documents

Transcript of ZE-ZA Compressor brochure