ZH_Centrifugal_Compressor.pdf

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


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


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.


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


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


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


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


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


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


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!


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


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


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.


Documents

ZH_Centrifugal_Compressor.pdf