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EFFICIENCY
MATTERS
Atlas Copco Air Compressors
ZB VSD range
Variable speed direct drive centrifugal air compressors
for low pressure applications
guara nteed
10
0%oil-free
air
any contamination risk for 100% – and guaranteeing the
utmost reliability around the clock. And not just today, but
day after day, year after year, with minimal maintenance
cost, few service interventions and long overhaul intervals.
The shortest route to maximum profitability is to
minimize operational cost. The design of the Atlas Copco ZB
VSD compressors is focused on substantially saving energy,
ensuring product safety – only oil-free machines can exclude
Expertise
Since 1903, Atlas Copco’s philosophy has
been to continually improve our products
through intensive R&D, with the aim to
maximize the value for our customers.
Complete safety
Process, products and environment
free from contamination
Choice
Atlas Copco masters each compression
principle and offers the most energy
efficient technology for the application.
The right drive
Fixed speed machines are fine at full load
but when air demand fluctuates, a Variable
Speed Drive ensures substantial savings.
The integrated design
Internal piping, Variable Speed Drive,
100 % matched components... the only way
to ensure total reliability.
Trouble-free installation & commissioning
The ZB VSD centrifugal compressor is truly
plug-and-play. Put it on a flat floor, connect the
power line and the air outlet… and push the
start button.
The professional follow-up
Service Contracts will ensure you of the right
preventative maintenance, immediate response
and genuine spare parts… all over the globe.
Extending the limits in energy efficiency,
safety and reliability
Optimal use
Central control of a multi-compressor
installation can reduce the pressure
band and achieve the lowest overall
energy cost.
Energy
Safety
Reliability
Approvals and performances
EC directive 98/37/EC
Low voltage directive 73/23/EC
Pressure equipment directive 97/23/EC
Electromagnetic compatibility 89/336/EC
Noise level emission 67 dB(A), acc. ISO 9614 test code
UL approval
The Atlas Copco ZB VSD (Variable Speed Drive)
centrifugal air compressor is a completely innovative
approach to low pressure compressed air applications.
Because of the combination of revolutionary
technologies, the ZB VSD offers a range of features
and benefits that were previously impossible to combine
into one machine.
The centrifugal air compressor
of the new age
Standard
Air inlet system (incl. filters)
Sound enclosure
Outlet check valve
Blow-off valve (incl. silencer)
Electronic controller
Fully equipped electrical system
VSD - Variable Speed Drive system
Options
LAN or Internet control/monitoring
Aftercooler (water cooled)
Fine inlet filters 99% @ 1 µm
Complete
"all-in" package
Innovative design
brings numerous benefits
Unparalleled savings in life cycle cost
highest efficiency with VSD energy savings
lowest maintenance cost
reduced parts count for enhanced reliability
very low cooling water usage,
less energy to keep unit cool
low installation costs
Simple and safe "oil-less" design
no oil at all
no pumping system
no oil heater
no oil filter
no journal bearings
no speed increasing gears
Complete, compact size and low weight
weight 1200 kg
plug-and-play installation, no foundations
small footprint (mm)
Caring for the work environment
standard baffled sound enclosure
blow-off silencer
vibration-free operation
extremely low noise level < 67 dB(A)
totally oil-free, no oil-induced environmental issues
Contactless magnetic bearings
no contact means no wear, no vibration, no friction
no oil-lubricated journal or land bearings
magnetic bearings dynamically align the rotor shaft
on-board processor with real-time response
unsurpassed machine lifetime
dramatically reduced maintenance requirements
2080
14501520
1
2
3
For larger flow volumes, multiple ZB VSD units can
be connected in parallel. Two, three or more units offer
the advantages of a modular concept:
higher availabilityreliability through redundancywider operating range and efficiencyspace savingextremely low noise levelsexpandability
Modular electronics
The control cubicle houses theElektronikon® and the magneticbearing controller.The Variable Speed Drive (VSD)cubicle houses a state-of-the-artfast switching frequencyconverter and efficient power conditioning devices.
Advanced Elektronikon® monitoring & control
Operating modes: constant pressure mode (flow range: 50 - 100 %)constant flow moderemote 4-20 mA input (flow or pressure)
Functions:control– speed regulation– surge control– blow-off regulationsafetymonitoringself diagnosiscommunication– internal, with frequency converter and magnetic
bearing controller– external ( Modbus, Profibus )
Multiple compressor installation
In multiple compressor installations, the ES centralcontroller will ensure the optimal compressor mix. The total system can be monitored locally or remotely, via the network or from anywhere in the world.
Standalone or integrated solutions
Control
cubicle
VSD
cubicle
ZB 160 - 2ZB 160 - 2ZB 160 - 2
100%
100%
98%
96%
94%
100
90
85
80
75
Efficiency matters
2.5 %losses
losses
5 % 10 %
CONVENTIONAL SINGLE STAGE CENTRIFUGAL TECHNOLOGY
Drive
efficiency
83.4 %100 %
power
supply
oil-pump,
fans
motor gear and
bearings
1 % 3 % 1 %
ZB VSD DIRECT DRIVE CENTRIFUGAL TECHNOLOGY
Drive
efficiency
92.2 %
100 %
power
supply
pump,
fans
converter electric
filter
3 %
electric
motor
Broad operating range and no sacrifice of efficiency at partload conditions with Variable Speed Drive control.
ZB 160 - 2
Re
lati
ve
pre
ss
ure
ra
tio
(
)
0 0.5 1.0 1.5 2.0 l/s
100 %
Relative volume flow ( ) V
VA
P PA
VARIABLE SPEED PERFORMANCE CHARACTERISTICS
Relative speed ( ) Relative efficiency ( )n
na
N
NA
Direct drive technology
The ZB VSD is directly driven by a permanent magnetsynchronous motor, which is vastly superior to conventionaltypes. It reduces energy losses and cooling requirementsand offers a higher speed in a more compact design.A consistently high motor efficiency with low rotor losses ismaintained across the entire speed range... both at full loadand part load.Whereas conventional motors need power to excite amagnetic field in the rotor, the ZB VSD motor does not,thanks to the permanent magnets in the rotor.
Total absence of pump losses
With the impeller directly mounted onto the motor shaft andby absence of a gear box, the ZB VSD is totally oil-free,which excludes traditional oil-system losses.
Highest efficiency impeller
The unique stainless-steel backward lean impeller is a proprietary Atlas Copco design with labyrinth seals for highest efficiency with minimal air leakage.
9 %
energy savings with VSD
Process pressure
Pressure - standard load-unload
Pressure - turbo-modulating
Pressure - VSD
Why Variable Speed Drive (VSD) ?
Because a VSD compressor precisely follows the
varying air demand that is typical in most production
facilities, it dramatically reduces the energy bill and
provides many additional benefits. The result is a fast
payback of the investment and huge yearly savings long
after that.
Because energy constitutes the biggest portion of the
life cycle cost of a compressor, these savings have a
significant impact on the operational costs of your
compressed air system.
Predicting your savings
Call upon the expertise of Atlas Copco specialists and have an
assessment carried out in your factory.
A detailed report will show your current operation and the
achievable savings when adding a VSD solution to your
compressed air system.
Direct energy savings
Low load operation of a VSD compressor does not result
in energy losses or in blowing off compressed air to
the atmosphere.
The precise pressure control of the VSD compressor allows
a tighter and often lower discharge working pressure,
resulting in reduced energy consumption, less leak losses
and a more efficient and optimized process.
Tight control for superior process stability
The constant net pressure obtained by the VSD
compressor provides additional yearly savings:
– other base-load compressors will consume less
– leak losses – always present in compressed air
systems – are significantly reduced.
The stable pressure is highly beneficial to many processes,
avoiding expensive production interruptions, product loss
or quality issues.
STABLE NET PRESSURE
investment
maintenance
energy
0.1
bar
0
400
800
10 20
NO CURRENT PEAKS
Star Delta
DOL
Soft Starter
VSD
% F
ull
lo
ad
cu
rre
nt
Seconds
100 %
COMBINED MOTOR/CONVERTER EFFICIENCY
maximumminimum
Motor speed
integrated VSD
non-integrated VSD
Integrated VSD - The only way
The Elektronikon® system controls both thecompressor and the integrated converter; this ensures maximum machine safety andallows easy networking of the compressor.
All Atlas Copco VSD compressors are EMC tested and certified.External sources do not influence the compressor operation, nor does the compressor disturb other equipment via emissions or via the power supply line.
No current peaks during start-up
VSD compressors can be started and stopped
without limitation
frequent start-stops no longer lead to current
peak penalties
the electrical installation can often be rated for a
lower current, meaning savings in investment
Electrical filters
bar(e) psig
m3/h
cfm
ZB 160 VSD
ZB 120 VSD
ZB 80 VSD
0 1000 2000 3000 4000
589 1177 1766 2354
2.5
2.0
1.5
1.0
0.5
0
36.3
29.0
21.8
14.5
7.25
0
Volume flow
Pre
ss
ure
bar(e)
m3/h
cfm
ZB 100 VSD
0 2000 4000 6000
1177 2354 3531
1.2
1.0
0.8
0.6
0.4
0.2
0
psig
17.4
14.5
11.6
8.7
5.8
2.9
0
Volume flow
Pre
ss
ure
Single blower unit
Multiple ZB VSD in parallel
0 20 40 60 80 100 120
120
100
80
60
40
20
0
%
ZB VSD characteristics
The ZB VSD series offers a variety of pressure
ranges and flow cuts, to perfectly match the needs of
your application.
Multiple installation
For flow ranges beyond that of an individual ZB VSD
centrifugal compressor, multiple machines are easily
teamed up to meet the flow requirements. Because they
were designed to work in parallel, the overall system
efficiency remains high, regardless of the flow demands.
%
1st
1 & 2
1, 2 & 3
1, 2, 3 & 4
Sy
ste
m p
ow
er
System flow
1
SYSTEM EFFICIENCY
ZB 80 VSD
ZB 100 VSD
Atlas Copco offers a complete portfolio of
Aftermarket products, unrivaled in today’s 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.
These parts never carry a risk of incompatibility or
premature failure. Cost effective service kits are
available for periodic interventions based on
running hours.
Service Plans perfectly meet the needs of your
business and ensure a productivity at peak level.
Three levels are available: Total Responsibility Plan,
Preventative Maintenance Plan and Inspection Plan.
Fixed price repair is ideal for individual repairs; it is
streamlined to allow for a quick flow from quotation
to execution, without surprises.
The element exchange program offers the customer
the possibility of scheduled intervention rather than a
reaction to an element failure.
Consultancy services and on-site measurements help
to optimize the complete air net, minimize leak losses
and maximize energy savings. The following
packages can be included individually or combined:
in-depth system audits based on
actual measurements of the air
supply distribution system.
remote monitoring via the Internet;
negative trends can be detected
before any actual failure of the
equipment.
energy savings via system control
and management.
Global presence
Local service
2935 0
443 1
3 -
Pri
nte
d i
n B
elg
ium
- S
ubje
ct
to a
ltera
tion 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.
www.atlascopco.com
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 industry’s leadership
and the customer’s trust.
IISSOO 1144000011
Atlas Copco’s
Environmental Management
System forms an integral part
of each business process.
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