Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Commissioning procedure ZR900 VSD 1. Build up of the compressor. The ZR900 VSD has been conceived, starting from the regular 'load/unload' design of ZR750. The compressor part has remained the same, excluding some special options. The ZR900 VSD has some options that have become standard, e.g. electronic water drains on intercooler and aftercooler. SPM measuring devices have also become standard on these compressors. Optional on the ZR900VSD are the Pt100 sensors in the motor windings. These sensors are connected to two extra AIE 3 modules in the elektronikon system. The ZR900VSD is a compressor with Variable Speed Drive. For this reason, a standard electric motor is no longer suitable as prime mover. A special motor has been chosen in combination with a converter. This motor has two sets of windings, each energized by a separate power supply. The application calls for the use of two coupled frequency converters. This also explains why two extra AIE 3 modules are needed. Six Pt100 sensors are also available, for use in the two sets of windings (6 windings in total). Note: The option of Pt100’s in the motor windings is always available but is not always connected to the elektronikon system. This implies that the sensors can always be installed afterwards (internal note for A.C.use - not for the customer). The power supply system of the ZR900VSD is a point of particular interest. A supply voltage of 500V AC is required at the incoming side of the converter during full load. This means that a separate transformer is to be installed to convert the customer's power supply (e.g.11kV) to 500V. This transformer must comply with the specifications issued by Atlas Copco Airpower.
2. How the compressor functions The complete principle functionality of Variable Speed Drive compressors has been explained during the Technical Service Course of 2001. This compressor functions in a similar way to the ZR315 VSD, under the same load/unload conditions. For more information, you are referred to the binder of the Technical Service Course of 2001.
PM: replaces: 2946 0282 01
2946 0282 02
Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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3. Commissioning of the compressor. Cubicles At the rear side of the compressor, you will find the frequency converter for the main motor. This cubicle is accessible via two doors (LH & RH). Always bear in mind that there are two frequency converters for the main drive motor. The two are interlinked and they each serve as dedicated power supply to the corresponding motor winding set. When opening the left door of the converter cubicle, you will notice the master frequency converter. The slave frequency converter is located on the right side of the cubicle. Opening the elektronikon cubicle reveals the normal layout. This location also houses the "Micromaster" module, which is required when an MD2500VSD is being installed after the converter. The "Micromaster" regulates the speed of the MD dryer motor).
With the MkIV elektronikon system, we have a dedicated SPM box. SPM Compressor compartments Open the remaining compressor doors to gain access to the compressor and motor assembly. Carry out the standard preparatory steps related to the start-up of the machine (removal of transport bolts, silica gel bags in the cooler shells, taking away the VCI corrosion inhibitor paper, etc …)
Start-up of the compressor It is necessary to carry out certain tests before starting up the compressor. These tests will serve as a safety precaution and they will also ensure proper functioning of the compressor. Firstly: There are several transformers incorporated in the system (see further). Check the settings of each transformer, before switching on the main power supply. This needs to be done to ensure that the settings comply with the directives on the pertaining service diagram. You will need to check either 3 or 4 transformers (depending on whether an MD dryer is being installed).
PM: replaces: 2946 0282 01
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Transformer T1 (provides control voltage to relays and solenoid valves) ˚ ˚
Primary .......... 500V AC Secondary ..... 230V AC or 115V AC
Transformer T2 (provides supply voltage to the elektronikon system) ˚ ˚
Primary ........... 230V AC or 115 V AC Secondary ...... 24V AC
Transformer T3 (provides supply voltage to the micromaster) ˚ ˚
Primary ............ 500 V AC Secondary ... .... 230 V AC
Transformer T4 (provides power to the main supply) ˚ ˚
Primary .......... input from customer installation Secondary ..... 500 V AC (to each secondary side)
PM: replaces: 2946 0282 01
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Once the tappings on the transformers are set correctly, the main power supply can be switched on. But before doing so, make sure that all fuses are switched off (F3, F4, F5, F7, F17 and F47). With the main transformer switched on, you should measure 500 V (preferably higher (520 V) between pin 31 and 32 on terminal 1X5 (see photo on right). If this is not the case then check the settings of transformer T4. Now you can switch on F3. Measure the voltage between pin 1 and 2 on 1X1. This should represent the control voltage (230 or 115 V). If this is not the case, check the settings of transformer T1. After this, activate F4 and F5. At this point you should be able to measure 24V between pins 6 and 7 on 1X1. If this is not the case, then check the settings of transformer T2. At this point, also the elektronikon should be “alive”. If the screen is not active, then check to see whether you have 24V between pin1 and pin 2 on 2X9. Once all these values prove to be correct and within the specified limits, then you may proceed to the next step.
Checking the VACON converter To begin with, when opening the converter cabinet inspect the converter for any visible signs of damage. No damage or breakage of any kind should occur during transport. If you find any damages upon arrival of the unit, immediately inform Atlas Copco Airpower and/or the local VACON supplier. When the inspection has proved to be satisfactory, switch on the two big circuit breakers, Q20 and Q21.
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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There is a special procedure for doing this: Both switches have to be in the “Off” position (pushed down). Make sure that both switches (Q20 and Q21) are down before proceeding to the next step. When this is done, proceed with the first test of the converter. On the master side, activate Q20 (push / pull it all the way up in one go). If the switch does not stay up, then, if all previous measurements are correct, there must be something wrong with the wiring. Check whether everything is carried out according to the service diagram. At this moment, you have one switch standing up (the one belonging to the master converter). This one should fall off within 20 seconds after switching on Q20. If this is not the case, then check the wiring and the setting of K30. Push both circuit breakers back to the off position (down). Pull Q20 all the way up and - within 20 seconds - also pull up Q21. At this moment, both converters (master and slave) are powered up (note: you should be able to hear the converter fans running).
Proceed with the next test: Check whether the emergency stop is functioning according to specification. After activating the emergency stop, check whether circuit breakers Q20 and Q21 move to the neutral position. Execute the previous actions to again power up both converters. Now measure the voltage on the different line voltages coming out of circuit breakers Q20 and Q21. You should have about 500 V between 2 lines. Activate F7, F17, F28 and F47. and measure the voltage between the incoming line in the micromaster and ground. Here you should measure 230 V. If this is not the case, then check the settings of transformer T3. PM: replaces: 2946 0282 01
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Check whether the difference in voltage between the average voltage on the master side and the average voltage on the slave side. This difference should not be bigger than 0.3% of the supply voltage (500V). This corresponds to 1.5V.
At this moment, all electronic and electric circuits are now powered up. Before starting the compressor, first check whether the application of the converter is correct. Firstly, move all the way to the left (using the “left”-arrow on the converter panel). Then move “up”, until the display reads “Parameters”. Move right, to access this menu. Then, move down (using the “down” arrow, until the display reads “System parameters”. Again move right, to access this menu. Press the “up” arrow, until you see “Application”. Here, you should see ZR900 VSD, (as you are dealing with a ZR900VSD compressor). If the display does not mention ZR900VSD, then please contact Atlas Copco Airpower, mentioning the serial number of the compressor.
Check the DC link voltage, on the display panel. To do this, move all the way to the left on the display, and move down until the display reads “Monitor”. Then move one position to the right. Now move upwards until the display reads “DC-link Voltage”. Here you will find the DC link voltage. This should be equal to
3x 2 x Uin ≈ π
675V (with 500 V supply).
PM: replaces: 2946 0282 01
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Starting the compressor Main motor: Check the direction of rotation, as you would on a standard compressor. On a standard compressor, this would be done by giving a start command on the elektronikon, immediately followed by a stop command. On this VSD compressor, we have a better procedure, which will also verify the correct functioning of different parts of the compressor. Firstly, activate the service switch. This switch can be found in the elektronikon cubicle, on terminal 1X1 (see arrow on right). At this stage, it is not possible to start the compressor using the elektronikon panel. This implies that no protections are active at this point in time. Proceed with caution. Procedure for starting the compressor using the converter panel To start the machine using the converter panel, the compressor must first be switched to the [service switch] mode. Once this is done, you can proceed with the next step. After switching to the [service switch] mode, you go to the panel of the converter. If you want to start the ZR machine using the panel, you first have to switch to [panel control] (provides extra safety). To do this, move all the way to the left, then use the “up”-arrow until the display reads “Buttons”. Move one position to the right (using the “right” button). Press the “up”-arrow until it reads “panel control”. Press “enter” ( ↵ ) to confirm this command. At this moment, you can start the machine using the panel of the converter.
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Now is the time to check the direction of rotation of the drive motor. Give a start signal on the converter panel, followed by a stop signal (after you have heard the compressor starting). Check the motor for correct direction of rotation. If the compressor does not start, or if the direction of rotation of the drive motor is incorrect, then check whether the wiring is connected according to the information given in the service diagram. Once this procedure has been carried out successfully, you can be sure that the converter and the motor are functioning correctly. Now is the time to check whether the compressor is also OK, when regulated via the elektronikon system. Deactivate the service switch (1X1). You do not have to change the converter into “remote control”, as this is done automatically when the service switch is deactivated.
Final check of the functioning of the compressor At this point, you can check whether the elektronikon itself is still OK, and also check whether the communication between the elektronikon module and the converter is OK. To do this, just press the start button on the elektronikon, and check whether the compressor starts to run. Normally, the compressor should be running in unload condition now. After 15 seconds, the compressor should load. When the compressor loads: check whether the rotation direction of the dryer motor (if installed) is OK, Check whether the loading solenoid valve is activated Check whether the water shut-off valves (if installed) are opened. If this is not the case, then verify that the wiring corresponds with the service diagram.
PM: replaces: 2946 0282 01
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Atlas Copco Airpower n.v Oil -free Air division Service department
Registration code Collection: ASC ZR(T)160-900VSD TAB 04
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Readings to take, & items to check during operation When the machine is running, you should check whether the voltage on the incoming side of both converters is still within specification. This means that the voltage difference between master and slave converter should not be bigger than 1.5V. When this is OK, then both converters are equally loaded. This makes sure that both converters will accumulate equal wear. Now, check all the readings on the elektronikon. A special 'VSD' logbook has been compiled for this specific compressor. Fill in all relevant data at the moment of commissioning. This will prove useful for further reference and for the interception and/or prevention of e.g. bearing failures. Please send the filled out logbook to Airpower (Kevin Laurent) after the commissioning. Also include the commissioning sheet for the ZR900 VSD (can be found on the service website) and the commissioning sheet of the MD dryer (if installed) together with the logbook. Any comment on the compressor, dryer or installation is appreciated.
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PM: replaces: 2946 0282 01
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