Compressor Specification

Two-Stage, Water-Cooled
Variable-Speed, Oil-Free Rotary Screw
1. Scope

1.1. This specification is for an oil-free, air-cooled rotary screw air compressor. The compressor shall be a
145 kW Atlas Copco model ZR145VSD+ or pre-approved equivalent.

1.2. The compressor shall deliver 77.4 to 360.6 l/s at 10.4 bar in accordance with ISO 1217, Annex E. L/s is
FAD litres per second at inlet conditions.

1.3. The units shall be manufactured in accordance with this specification. The construction as described in
this specification is considered essential and critical to the application. The vendor shall state in his
quotation any and all exceptions to the specification.

2. General

2.1. A positive displacement rotary screw compressor capable of delivering 100% oil-free air. There shall be
no lubricant within the compression chamber. Unit to be delivered fully packaged including air
compressor, prime mover, coolers, lubrication system, regulation, and control system mounted on a
common base frame and fully enclosed steel sound-dampening canopy. Silencers, lubricating system,
cooling system, control system, and driver shall be mounted as a part of the package.

2.2. The compressor shall consist of two compressor stages flanged to an integral speed increaser. Each
stage is to be driven from a common bull gear to insure optimum speed and highest possible efficiency.
Multi-stage compressors have an inter-cooler placed between stages and an after-cooler installed in the
package

2.3. There shall be provisions for an optional heat of compression dryer to be mounted within the compressor
canopy. Interconnecting piping, pressure dewpoint sensor, and wiring between the compressor and
dryer shall be included.

3. Compressor Unit

3.1. Casing - The compressor element enclosure shall be a cast iron, one-piece casing housing two
precision-made screw-type rotors. The housing shall have integral passages for lubrication and cooling
medium. It shall be designed with a dedicated and optimized cooling jacket to prevent irregular
deformation and overheating Increases turndown capacity.

3.2. Rotors - Rotors and shaft shall be of one-piece carbon steel construction. Internal rotor cooling shall not
be required. Rotors are to have a corrosion-resistant coating. The rotors shall have an asymmetric
profile that keeps leakage losses at a minimum to ensure high efficiency. Rotors must be balanced in
accordance to ISO 1940 to guarantee the dynamic and static tolerances.

3.3. Timing Gears - Timing gears shall be fitted on the rotor shafts to maintain the rotors in correct position
relative to each other. The compressor shall be of such design that the timing gears eliminate any
contact between the rotors

3.4. Bearings - Bearings shall be of the high precision anti-friction type. Radial loads shall be carried by
roller bearings and axial loads by ball bearings.

3.5. Seals - The seals shall be a restrictive-ring type design. The seal rings and retainers shall be stainless
steel construction and be free for radial self-adjustment along the rotor shafts. The seals shall have an
atmospheric vent to prevent air and oil leakage along the shaft into the elements.

3.6. Lubrication - Lubrication and cooling on the precision bearings shall be by forced oil jet directly into the
bearing to reduce bearing losses and heat generation in the bearings.
 Compressor Specification
Two-Stage, Water-Cooled
Variable-Speed, Oil-Free Rotary Screw

3.7. Coolers - The compressor package shall be equipped with all required coolers as follows:
3.7.1. A high-performance oil cooler, inter-cooler and after-cooler shall be provided and mounted via
couplings for stress free connections. All coolers will receive the same temperature cooling air
(one pass design). The inter- and after-coolers shall have a separator and drain for optimal
efficiency and ease of maintenance. Zero air loss drains with high level alarm shall be included.
3.7.2. The coolers shall be designed for 150 psig operation and include stainless steel pre-coolers for
optimum lifetime and shall be capable of providing approach temperatures of less than 15°F at
design conditions.

3.8. Motor - The motor shall be ultra-premium high efficiency (IE5), water-cooled, permanent magnet motor
with class H insulation. For increased reliability, the insulation temperature rise shall be limited to 125°C.
IP 66 protection rating allows no dust or water ingress. There is no shaft seal resulting in no required
shaft seal replacement during the entire lifetime of the motor. The oil lubricated bearings will require no
lubrication or frequent maintenance.

3.9. Motor Gears - Unit is to be provided with long lasting helical gears in accordance to Standard AGMA
2015 A5.

3.10. Electrical Drive System

3.10.1. Drive - Inverter for variable speed drive compressor shall be of Atlas Copco NEOS design and will
have quantity of (2), one for the low pressure and one for the high-pressure elements

3.10.1.1. The variable speed drive shall comply with IEC 62061: SIL Level 3
3.10.1.2. The variable speed drive for the main motor must be IP5X (power electronics) / IP2X
(control board) / IP1X (connection terminals)
3.10.1.3. The variable speed drive shall comply with IEC 62061: SIL Level 3
3.10.1.4. Cooling shall be forced ventilation – air-cooled
3.10.1.5. The variable speed drive shall be CE, cULus and RCM certified.
3.10.2. Electrical Cubicle
3.10.2.1. Constructed as IP 54 enclosure
3.10.2.2. SCCR rated cubicle as standard, 65kA (60Hz/CSA-UL), and 50 kA (50Hz/IEC)
3.10.2.3. Fast acting fuses installed in cubicle.
3.10.3. Control Panel
3.10.3.1. Maximum operating temperature shall be 50°C standard with a 55°C option
3.10.3.2. Anti-condensation heater installed in motor
3.10.3.3. Control panels complies with IEC61800-3
3.10.3.4. Thermal, bearing currents, and magnetic overload protection standard

3.11. Control System

3.11.1. Protections
3.11.1.1. Standard sensors shall be pressure and temperature, oil level gauge, and SPM and PT 100
(motor)

3.11.2. Control Panel

3.11.2.1. Screen shall be touch screen TFT-LCD 4.3’’ graphic display
3.11.2.2. Shall be included with 533MHz and 32 RAM
3.11.2.3. Ethernet-Bus, CAN-Bus slot, RS485-Bus, IO-Bus
3.11.2.4. Shall be of protection type IP54 front
 Compressor Specification
Two-Stage, Water-Cooled
Variable-Speed, Oil-Free Rotary Screw

3.12. Air Circuit

3.12.1. Filters - High efficiency paper filter in accordance with SAE fine 1μm 98%, 2μm 99.5%, 3μm
99.9%
3.12.2. Blow Off Valve - Included standard is a low and high pressure blow off with no unloader valve

3.13. Water Circuit

3.13.1. Water Separator - The compressor shall be equipped with a labyrinth style water separator

3.13.2. ERD Drains

3.13.2.1. The compressor will have a zero-loss electronic water drain plumbed to the aftercooler.

3.13.2.2. These drains shall discharge no compressed air during removal of the condensate.
3.13.2.3. The zero loss drains shall be monitored by the microprocessor controller.
3.13.2.4. A manual condensate drain shall also be included.

3.13.3. Water Valve – Factory installed water shutoff valve shall be standard inside the canopy at the
water outlet

3.14. Oil System – The entire oil system shall be copper free and supply oil to the bearings and gears

3.14.1. Oil Pump – The oil pump shall be a gerotor type gear pump mounted on a main shaft
3.14.2. Oil Level Indication – The oil circuit shall contain an integrated oil level sight glass
3.14.3. Oil Cooler – The oil cooler shall be made of stainless-steel plates and copper brazed 3.14.4.

Oil Filter – The oil filter shall be “click” system (bayonet coupling) and element will be high efficiency
with a β12 ≥ 200 rating

3.14.5. Oil Fume Breather – The filter element will be installed before the air is released into the
atmosphere, keeping he air around the compressor oil/oil fumes free

3.15. Monitoring Capabilities – The compressor package shall have the appropriate displays, controls, and
indicators to monitor operation as specified below:

Status Indicators
• Stopped/Running • Week Timer

• Compressor Status • Active Protection Functions

• Machine Control Mode • Service

• Automatic Restart • Main Screen

Machine Control Mode

• Local Start / Stop • Network Control
• Remote Start / Stop

Week Timer
• Week Action Schemes • Status
• Week Cycle • Remaining Running Time
 Compressor Specification
Two-Stage, Water-Cooled
Variable-Speed, Oil-Free Rotary Screw

Active Protection Functions

• Emergency Stop • Warning
• Shutdown

Service
• Overview • Next Service • Service Plan • History

Counters
• Running Hours • Fast Starts
• Loaded Hours • Fan Starts
• Motor Starts • Module Hours
• Load Relay • Emergency Stops

Regulation
• Unloading Pressure 1 • Loading pressure 2

• Loading Pressure 1 • Pressure Band Used

• Unloading Pressure 2 • Digital Pressure Band Selection

Inputs
• General • Main Motor
• Elements • Network
• Dryer • Cooler
• Drains • Oil Circuit
 Compressor Specification
Two-Stage, Water-Cooled
Variable-Speed, Oil-Free Rotary Screw

Outputs
• General • Drains
• Dryer • Main Motor

SP (Shock Pulse Method)

• Motor, Drive End • High Pressure Stage, Drive End

• Motor, Non-drive End • High Pressure Stage, Non-drive End

• Low Pressure Stage, Drive End • Gearbox

• Low Pressure Stage, Non-drive End

4. Shipment and Delivery Preparation

4.1. Plastic foil to protect against rain
4.2. Wooden pallet
4.3. VCI paper to protect against corrosion due to moisture in the environment

5. General Installation Requirements

5.1. Upon placement on a level surface and connection to essential utilities, the unit shall be provided
available for immediate operation.
5.2. The compressor does not require bolting to the floor.