zh_centrifugal_compressor.pdf
TRANSCRIPT
-
ZH 4000-26000
Atlas Copco
Oil-free centrifugal compressors
400-2750 kW/500-3500 hp
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 16:03 Pagina 1
-
guara nteed
10
0%oil-free
air
exclude any contamination risk for 100% and guaranteeing
the utmost reliability around the clock for many years.
Minimal maintenance, few service interventions and long
overhaul intervals sustain true peace-of-mind.
The shortest route to maximum profitability is to
minimize operational cost. The design of the Atlas Copco ZH
centrifugal compressors is focused on substantially saving
energy, ensuring product safety only oil-free machines can
The thorough needs assessment
Real savings rely on facts. Atlas Copco
consultants assess the air demand profile
of your application and suggest the best
compressor selection for the job.
Safe
Process, products and environment
free from contamination
Simple
100 % oil-free air = no filters needed
Efficient
No filter pressure drop = less energy
Choice
Atlas Copco masters each compression
principle and offers the most energy
efficient technology and solution for the
application.
The innovative accessories
For each ZH there's a matching XD dryer
offering high capacity quality dry air.
Negligible use of energy and the lowest
pressure drop lead to further energy
savings.
The experienced partner
Atlas Copco is the world leader in compressed
air technology, with over 100 years of
experience in air compression systems.
For over 50 years, Atlas Copco has been
building turbo compressors for air separation,
chemical, process and plant air applications.
The ZH is the ultimate development from this
widely accepted technology.
A complete package
Internal piping, integrated coolers, motor,
lubrication, inlet guide vanes, control system,
100 % matched components,... an integrated
design to ensure total reliability.
Trouble-free installation & commissioning
An oil-free ZH compressor is truly plug-and-
run. Put it on a flat floor, connect the power line,
the cooling water circuit and the compressed air
outlet and push the start button.
Extending the limits in energy efficiency,
safety and reliability
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 2
-
ZH the complete solution for the industry
ning
d-
r line,
d air
The professional follow-up
Service Contracts will ensure you of the
right preventative maintenance,
immediate response and genuine spare
parts all over the globe.
Optimal use
Central control of a multi-compressor
installation can reduce the pressure
band and achieve the lowest overall
energy cost.
Energy
Safety
Reliability
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 3
-
Excellence by design
Two and three-stage models
Clear capital costs, no surprises
A complete, plug-and-run compressed air system
Easy and low cost installation no foundations
Low energy consumption at full and partial load
High reliability and peace-of-mind
Low maintenance cost and service friendly
Caring for the environment
Completely oil-free air no risk of oil contamination
No seal air consumption
No instrument air required for actuators
Silenced versions (optional)
Energy saving Elektronikon
control system
Turbo power -
more value for the customer
The ZH range is the most advanced centrifugal
compressor series on the market. Its a unique package,
meeting customer expectations for low installation,
operating and maintenance costs, with high reliability and
ease-of-use. No other turbo equals its efficiency and
economy and is supplied so complete.
ZH oil-free turbo power from Atlas Copco is your
guarantee for a continuous, cost-efficient and highly
reliable air supply.
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 4
-
Air
Oil
Water
2-stage ZH air/oil/coolant flow
Air in
Air out
Air filter
Low pressureelement
Aftercooler
High pressure element
Intercooler Oil cooler
Two-stage centrifugal compressors
Horizontally-split hydrodynamic bearing
Oil seal
Air seal
Impeller
Low speed hydrodynamic bearing
Horizontally-split gearbox
Main oil pump
ZH 10000
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 5
-
3-stage ZH air/oil/coolant flow
Air in
Air out
Air filter
Low pressureelement
Aftercooler
High pressureelement
Intercooler
Oil coolerAir
Oil
Water
Three-stage centrifugal compressors
Air seal
Oil seal
Impeller
Horizontally-split hydrodynamic bearing
Low speed hydrodynamic bearing
Horizontally-split gearbox
Main oil pump
ZH 4000
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 6
-
HM7
HA7
HL7
HM8
HL8
HA8 HA10HA9
HL10HL9
HM10
HM9
HR10HR9
ZH 2-stages
ZH 3-stages
See data page for range details
16.0
26.0
cfm x 1000
m3/h x 1000
bar(e) psig
10.4 150
7.0 100
4.6 65
3.5 50
ZH
40
00
/70
00
ZH
60
00
/10
00
0
ZH
90
00
/15
00
0
ZH
16
00
0/2
60
00
41-
30-
20-
13-
10-
5-4-
3-
2-
-600
-400
-300
-190
-150
-75
-50
-25
cfm x 1000
m3/h x 1000
barg psig
A complete scope
meeting all needs
Many features are included as standard. Some applicationsmay also need or benefit from additional options.
Standard
Air intake filter and silencer
Inlet guide vanes
Aftercooler
Check valve and flexible discharge compressor
Cooling water manifold
Drain traps on all coolers
Compensators on air and water in and outlet
Main motor
Complete lubrication system
Control and safety system
Integrated modulating blow-off valve silencer
Options
PLC based control system
Silencing canopy
Duplex oil filter
Hot air version
Electronic drains
ANSI flanges for air and water terminals
MODBUS interface
PROFIBUS interface
DH+ (PLC control only)
IP55 / TEFC enclosure for medium voltage motors
PT100 motor winding protection
PT100 motor bearing protection
Anti-condensation heater for motor
Water reverse valve
Water shut-off valve
ZH Pressure/capacity range
2.5
4.4
3
5.5
5
8.5
7
11.5
9
15.3
11
18.7
13
22.1
15
25.4
17
28.9
19
32.2
21
35.6
25
42.5
Complete centrifugal compressor range
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 7
-
LABYRINTH WATER SEPARATOR
% flow
140
130
120
110
100
90
80
% d
isc
ha
rge
pre
ss
ure
< by-pass >
surge line
< turn-down range >
70 80 90 100
In every detail Atlas Copco ZH compressors are
designed and manufactured to the highest standards of
quality and reliability. There are no hidden extras or
complicated installation requirements: every unit is
delivered as a complete and integrated package, ready
to run.
Blow-off regulation & silencer
Innovative design in every detail
Precision balanced impeller assembly
Smooth running, low noise and low vibration operation
balancing of individual rotating components
balancing of assembled rotor
stainless steel impellers with precision micro-spline mounting
Highly efficient operation
Maximum efficiency and excellent response to plant load variations
exclusive backward lean impeller design
highest efficiency at full load
large turndown capability
High efficiencymotor
Inlet guide vanes
AdvancedElektronikoncontrol andmonitoring system
Integrated inter &
aftercoolers
Efficient air intake filtration
Air intake silencer
Cooling watermanifold & flexible
connections
Check valve
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 8
-
WATER SEPARATOR
Integrated discharge
check valve
high quality, corrosion resistant
check valve internals
discharge compensator for
stress-free connection to the
compressed air net
Regulating blow-off for constant pressure applications
Auto-dual control for cost-effective response
to variable air demands
Integrated inter and aftercoolers
coolers with tubes and end plates
of special corrosion resistant
stainless steel
enhanced water separation
drain traps standard on
every cooler
10 20 30 40 50 60 70 80 90 100
% flow
m3/h
9
8
7
6
5
4
3
2
1
0
bar(e)
alt. blow-off
operating curve
surg
e li
ne
< u
nlo
ad
load
>
Energy saving inlet guide vanes
Inlet guide vanes save up to 9% in energy at reduced air demand.
They increase the turndown capacity of the compressor due to
accurate regulation of pressure and flow close to surge.
60 70 80 90 100 110
capacity %
150
100
pre
ss
ure
% b
ar(
e)
inlet throttle
valve at 100 %
pressure
100
90
80
70
po
we
r %
kW
plant demand
inlet guide vanes
at 100 % pressure
energy savings
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 in many process control systems (field bus system)
maximized turndown range
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 9
-
Superior seals and durable bearings
Minimal air leakage and uncontaminated air, combined
with easy maintenance
carbon ring air seals, combined with labyrinth oil seal or
stainless steel labyrinth sleeves rotating on the impeller,
ensure 100% oil-free air compression without buffer air
horizontally split low speed shaft sleeve bearings
horizontally split high speed flexible pad pinion bearings
Easily accessible gearbox
Rugged and precise, yet easy to maintain
horizontally split gearbox
easy access to gears and low/high speed bearings
minimal downtime for inspection / maintenance
maintenance-free flexible disk coupling
High precision gears for increased lifetime
both pinions and bull gear according to
AGMA Q13/DIN Class 5/6
high stability under varying load
low transmission losses, low noise, low vibration
easy maintenance
Maintenance friendly
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 10
-
Optimize your installation
Tailored to the application, Atlas Copco has
developed complementary equipment for the optimal
quality air solution and the lowest cost compressed air.
Energy-free XD adsorption dryers
If your process needs dry air, add the unique and environment
friendly XD adsorption dryer, combining the best technologies
heat of compression regeneration and twin tower design.
dewpoints down to -70 C / -100 F
very low energy use
as an option, ZERO PURGE models available
for even further energy savings
very low pressure drops
integrated heater for stable dewpoint
Elektronikon
controlled
ES Energy Saving control and monitoring systems
The Energy Saver compressor room controller communicates
with the individual Elektronikon
controllers and optimizes the
energy efficiency of the complete system, reducing the overall
pressure band. Each compressor operates in its optimum
working zone and the net pressure is kept within tight
boundaries. The benefits are multiple: substantial energy
savings, improved reliability and increased lifetime of the
machines.
For each ZH hot air variant, there is a matching XD to
obtain the most stable dewpoint.
General range: 1400 - 7000 l/s (2900 - 14800 cfm).
The XD-S model uses the heat of compression for regeneration,
resulting in a negligible energy consumption; the dewpoint
is -10 to -20 C, depending on the ambient conditions.
The XD-G model combines heat of compression and internal
heaters to offer a constant dewpoint of -40 C, regardless of
the ambient conditions.
The ES allows for remote monitoring and condition based
maintenance: Atlas Copcos AIRConnect TM and AIROptimizer TM
contracts provide for the ultimate peace-of-mind and the
lowest energy cost throughout the life cycle of your compressed
air system.
Contact Atlas Copco for an energy audit... and see what ES
can do for you!
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 11
-
Global presence
Local service
Atlas Copco offers a complete portfolio of Aftermarket
products, unrivalled in todays compressed air industry.
High quality service is delivered locally: Atlas Copco
is present in 150 countries around the world.
A sophisticated logistics concept brings genuine parts
to your doorstep in record times, across the globe.
Service Plans perfectly meet the needs of your business
and ensure a constant productivity at peak level.
Three levels are available: Total Responsibility Plan,
Preventative Maintenance Plan and Inspection Plan.
Consultancy services and on-site measurements help
optimizing the complete air net, minimizing leak losses
and maximizing energy savings. Following packages
can be included individually or combined:
in-depth system audits based on
actual measurements
remote monitoring via the Internet
energy savings via system control
and management.
External
leakages
Net
usable air
True performance
When specifying the true performance of an air
compressor, at least three parameters must be considered:
Capacity
The standard to which the capacity is measured
Working pressure
The point where the delivery pressure is measured
Power consumption
The compressor package power required at an effective
working pressure (including all internal losses from inlet
to outlet).
The main drive motor efficiency.
Atlas Copco ZH compressors are measured according to
ASME PTC 10, stipulating the FAD measurement at the
outlet of the package, net of all losses.
Atlas Copco specifications correspond to the capacity and
pressure which the customer receives, not to what the
compressor sucks in. Differences are substantial.
Intake volume
Inlet flow referred tocompressor element inlet
conditions. Seal leakages andinlet losses should not deprive
you the air you paid for.
Delivered volume
FAD according to ASME PTC 10.
A ZH compressor truly giveswhat is promised.
FAD - l/s - m3/min - cfm
Site
conditions
External leakages
Intake volume - l/s - m3/min - cfm
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 12
-
50 Hz Free air delivery (1) Installed motor (2) Weight (3) Dimensions in mm (4)
m3/h kW kg A B C
Three-stage, watercooled
ZH 7000 4400 to 7200 400 to 800 8000 4060 2120 2400
ZH 10000 6800 to 11000 630 to 1120 12000 5250 2120 2400
ZH 15000 10700 to 17000 1000 to 1850 18000 5800 2370 2630
ZH 26000 17000 to 26500 1600 to 2750 30000 7300 3120 3500
Two-stage, watercooled
ZH 7000 4400 to 7200 315 to 500 6500 4060 2120 2400
ZH 10000 6800 to 11000 450 to 800 10500 5250 2120 2400
ZH 15000 10700 to 17000 700 to 1250 15000 5800 2370 2630
ZH 26000 17000 to 26500 1250 to 2000 30000 7300 3120 3500
60 Hz Free air delivery (1) Installed motor (2) Weight (3) Dimensions in in (4)
cfm hp lbs A B C
Three-stage, watercooled
ZH 4000 2550 to 4200 500 to 1000 17600 162 85 96
ZH 6000 4000 to 6500 800 to 1500 26500 207 85 96
ZH 9000 6300 to 10000 1250 to 2250 40000 229 94 104
ZH 16000 10000 to 16000 2000 to 3500 66000 287 123 138
Two-stage, watercooled
ZH 4000 2550 to 4200 400 to 700 14300 162 85 96
ZH 6000 4000 to 6500 600 to 1000 23000 207 85 96
ZH 9000 6300 to 10000 900 to 1500 33000 229 94 104
ZH 16000 10000 to 16000 1500 to 2500 66000 287 123 138
Sound pressure level:
Acc. to ISO 2151:2004 and using ISO 9614-2
Depending on model:
- 80 to 85 dB(A) without silencing canopy
- 70 to 74 dB(A) with silencing canopy
(1) Reference conditions:
- barometric pressure: 1 bar(a) / 14.5 psia
- air intake temperature: 35 C / 95 F
- relative humidity: 60 %
- cooling water inlet temperature: 26.7 C / 80 F
(2) Depending on pressure variant
(3) With silencing canopy and standard M.V. motor
(4) With silencing canopy
Technical data
ZH 7000-26000 (50 Hz) & ZH 4000-16000 (60 Hz)
BA
C
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 13
-
www.atlascopco.com
2935 0
396 1
3 -
Pri
nte
d i
n B
elg
ium
- S
ubje
ct
to a
ltera
tions w
ithout
pri
or
noti
ce
What sets Atlas Copco apart as a company is our
conviction 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 simply call
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.
It's the commitment to our customers' business that
drives 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 customer's bottom line and peace-of-mind.
That is how Atlas Copco will strive to remain the first
choice, to succeed in attracting new business and to maintain
our position as the industry leader.
Never use compressed air
as breathing air without
prior purification in
accordance with local
legislation and standards.
IISSOO 99000011
A consistent quality earned
us the industrys leadership
and the customers trust.
IISSOO 1144000011
Atlas Copcos
Environmental Management
System forms an integral part
of each business process.
2935 0396 13_ZH_brochure_EN final.qxp 18/08/2006 13:16 Pagina 14