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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

Page : 1/9

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 Pt100s 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

Page : 2/9

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

2946 0282 02

Atlas Copco Airpower n.v


Oil -free Air division
Service department

Registration code
Collection: ASC ZR(T)160-900VSD
TAB 04

Page : 3/9

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

2946 0282 02

Atlas Copco Airpower n.v


Oil -free Air division
Service department

Registration code
Collection: ASC ZR(T)160-900VSD
TAB 04

Page : 4/9

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.

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

Page : 5/9

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

2946 0282 02

Atlas Copco Airpower n.v


Oil -free Air division
Service department

Registration code
Collection: ASC ZR(T)160-900VSD
TAB 04

Page : 6/9

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

675V (with 500 V supply).

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

Page : 7/9

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.

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

Page : 8/9

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

2946 0282 02

Atlas Copco Airpower n.v


Oil -free Air division
Service department

Registration code
Collection: ASC ZR(T)160-900VSD
TAB 04

Page : 9/9

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.

------=====+++++++======------

PM:
replaces: 2946 0282 01

2946 0282 02