Atlas Copco ER S-1 User manual

Atlas Copco
Energy Recovery Stand Alone Kit
Instruction book

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Instruction manual
1. General Information
Energy Recovery Stand Alone Kit
Document Number : 9845 0512 02
Concerning : GA 11-315 kW
Preliminary Operations : –
Safety Instructions : General
Persons Required : 1
Special Tools : –
Consumables : –
2. Document Overview
This document covers the following subjects:
1. General Information .....................................................................................................................................................1
2. Document Overview.....................................................................................................................................................1
3. Preface.........................................................................................................................................................................4
4. Safety precautions .......................................................................................................................................................4
4.1. Safety precautions during installation......................................................................................................................4
General precautions...........................................................................................................................................................4
Precautions during installation...........................................................................................................................................4
4.2. Safety precautions during operation........................................................................................................................5
General precautions...........................................................................................................................................................5
Precautions during operation.............................................................................................................................................5
4.3. Safety precautions during maintenance or repair....................................................................................................6
General precautions...........................................................................................................................................................6
Precautions during maintenance or repair .........................................................................................................................6
5. Energy Recovery (ER).................................................................................................................................................8
5.1. Description...............................................................................................................................................................8
5.2. Components ............................................................................................................................................................8
5.3. Labels......................................................................................................................................................................8
5.4. Main parts of the Energy Recovery unit.................................................................................................................10
5.5. Typical flow............................................................................................................................................................11
5.6. Mechanical modifications & installation .................................................................................................................12
Internal modifications.......................................................................................................................................................12
External modifications......................................................................................................................................................15
5.7. Electrical modifications & installation.....................................................................................................................17
5.8. Remarks................................................................................................................................................................18
6. Applications for the energy recovery system..............................................................................................................19
6.1. General..................................................................................................................................................................19

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6.2. Low temperature rise/High water flow....................................................................................................................19
6.3. High temperature rise/low water flow.....................................................................................................................19
6.4. Recovery water flow ..............................................................................................................................................19
6.5. Recovery water requirements for closed water circuits..........................................................................................19
6.6. Recovery water requirements for open water circuits............................................................................................20
7. Operation...................................................................................................................................................................21
7.1. Thermostatic bypass valve....................................................................................................................................21
Heat exchanger bypass valve (of ER unit) with lever.......................................................................................................21
Main oil cooler bypass valve of oil filter pipe....................................................................................................................21
Thermostatic valve instructions........................................................................................................................................21
7.2. Energy recovery system is turned on.....................................................................................................................22
Compressor start-up ........................................................................................................................................................22
Maximum energy recovery...............................................................................................................................................22
Low consumption of recovered energy ............................................................................................................................22
Recovery water flow too high or water inlet temperature too low.....................................................................................22
7.3. Energy recovery system is turned off.....................................................................................................................23
7.4. Commissioning the energy recovery system.........................................................................................................23
For fixed speed compressors...........................................................................................................................................23
For VSD compressors......................................................................................................................................................23
7.5. Stopping the ER unit for a longer period................................................................................................................23
8. Maintenance...............................................................................................................................................................24
8.1. Compressor oil.......................................................................................................................................................24
Before installation.............................................................................................................................................................24
Oil filling instructions ........................................................................................................................................................24
Oil drain instructions.........................................................................................................................................................24
Volumes...........................................................................................................................................................................25
Length flexibles................................................................................................................................................................25
8.2. Thermostatic bypass valves...................................................................................................................................25
8.3. Heat exchanger.....................................................................................................................................................25
8.4. Maintenance schedule...........................................................................................................................................25
9. Energy recovery data.................................................................................................................................................26
9.1. Reference conditions.............................................................................................................................................26
9.2. Effective operating pressure..................................................................................................................................26
9.3. Maximum operating pressure ................................................................................................................................26
9.4. Reading settings....................................................................................................................................................26
9.5. Modifying settings..................................................................................................................................................26
9.6. Recoverable energy...............................................................................................................................................27
Formula:...........................................................................................................................................................................27
9.7. Data for low temperature rise/high water flow systems..........................................................................................27
11+-30 kW range & VSD (ER S-1) ...................................................................................................................................27
30+-45 kW range (ER S-2)...............................................................................................................................................27
37+-75 kW & VSD range (ER S-2) ...................................................................................................................................27
55+-90 kW & VSD range (ER S-3) ...................................................................................................................................28
90+-180 kW & VSD range (ER S-4)..................................................................................................................................28

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180+-315 kW range (ER S-5)...........................................................................................................................................28
9.8. Data for high temperature rise/low water flow systems..........................................................................................28
11+-30 kW range & VSD (ER S-1) ...................................................................................................................................28
30+-45 kW range (ER S-2)...............................................................................................................................................29
37+-75 kW & VSD range (ER S-2) ...................................................................................................................................29
55+-90 kW & VSD range (ER S-3) ...................................................................................................................................29
90+-180 kW & VSD range (ER S-4)..................................................................................................................................29
180+-315 kW range (ER S-5)...........................................................................................................................................29
9.9. Pressure drop heat exchangers.............................................................................................................................30
Formulas..........................................................................................................................................................................30
9.10. Dimension drawings ..............................................................................................................................................31
9.11. Installation proposal...............................................................................................................................................34
9.12. Conversion list of metric units into imperial units...................................................................................................34
10. Circuit diagrams (9845 1800 00)................................................................................................................................35
10.1. ER + Mk 4 Elektronikon.........................................................................................................................................35
10.2. ER + Mk 5 Elektronikon.........................................................................................................................................36

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3. Preface
This manual details and illustrates the main components and the functional working principle of the energy recovery unit
stand alone version for use on 11 to 315 kW oil injected compressors.
For the sake of convenience, the terms “energy recovery” and “energy recovery unit” may be abbreviated as “ER” and “ER
unit”.
4. Safety precautions
These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence some statements may not apply to
your machine.
All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal
caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed
by the manufacturer.
4.1. Safety precautions during installation
General precautions
1. The operator must employ safe working practices and observe all related work safety requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised
personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the
compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the
emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating switch
must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to
clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye
protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall be replaced if
unsuitable for safe operation.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose
or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a
lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety helmet when working in
the area of overhead or lifting equipment.
2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never
obstruct the air inlet. Care must be taken to minimise the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn hoses.
Distribution pipes and connections must be of the correct size and suitable for the working pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead to internal
fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it
is not in contact with or close to flammable materials.
8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is remotely controlled
and may start without warning.

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The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any
maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate
precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the start equipment.
10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the
exhausted air does not re-circulate to the compressor air inlet or cooling air inlet.
11. The electrical connections must correspond to the applicable codes. The machines must be earthed and protected
against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is activated, a sign
stating "This machine may start without warning" must be affixed near the instrument panel.
13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return valves (check
valves) must not be relied upon for isolating pressure systems.
14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or
auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure-
relieving device or devices as required.
15. Pipework or other parts with a temperature in excess of 80°C (176°F) and which may be accidentally touched by
personnel in normal operation must be guarded or insulated. Other high-temperature pipework must be clearly marked.
16. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety
device with set pressure according to the maximum cooling water inlet pressure.
17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
4.2. Safety precautions during operation
General precautions
1. The operator must employ safe working practices and observe all related work safety requirements and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised
personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the
compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the
emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating switch
must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to
clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye
protection.
Precautions during operation
1. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line,
ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully
depressurized before disconnecting it.
2. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
3. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or particles.
4. Never operate the machine below or in excess of its limit ratings.
5. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out
routine checks. Wear ear protectors when opening a door.
6. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear
protectors.
7. Periodically check that:
•All guards are in place and securely fastened
•All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
•There are no leaks
•All fasteners are tight

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•All electrical leads are secure and in good order
•Safety valves and other pressure-relief devices are not obstructed by dirt or paint
•Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or
abuse
8. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions
against air pollution and possible contamination of the breathing air.
9. Do not remove any of, or tamper with, the sound-damping material.
10. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or
auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure-
relieving device or devices as required.
4.3. Safety precautions during maintenance or repair
General precautions
1. The operator must employ safe working practices and observe all related local work safety requirements and
regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised
personnel.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the
compressed air must be adequately purified according to local legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the
emergency stop button, switch off the voltage and depressurise the compressor. In addition, the power isolating switch
must be opened and locked.
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to
clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye
protection.
Precautions during maintenance or repair
1. Always wear safety glasses.
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
7. Close the compressor air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve
the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours
of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed
openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by
steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be
stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of
spontaneous ignition of the oil vapour when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not
be put out of action.

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16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures, temperatures and
time settings are correct. Check that all control and shut-down devices are fitted and that they function correctly. If
removed, check that the coupling guard of the compressor drive shaft has been reinstalled.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel for
carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g.
when steam-cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork and in the
air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by genuine material from the
manufacturer to prevent the sound pressure level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. The following safety precautions are stressed when handling refrigerant:
•Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use breathing
protection.
•Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant
contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the
clothing until all refrigerant is flushed away; then seek medical first aid.
22. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.

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5. Energy Recovery (ER)
5.1. Description
The energy required in any compression process is mainly transformed into heat. In oil-injected screw compressors, most of
this compression heat is dissipated through the oil system. The Energy Recovery stand alone kit is designed to recover most
of this heat by transforming it into warm/hot water without adversely affecting compressor performance. The water can be
used for various applications.
5.2. Components
The stand alone energy recovery system comprises:
•Completely stainless steel oil/water heat exchanger.
•Thermostatic bypass valve with on/off lever.
•Temperature sensors for water inlet and outlet control.
•Necessary bolts, pipes, hose assemblies, etc.
•The Energy Recovery system also includes thermostats for both the bypass valve of the Energy Recovery unit and the
main bypass valve of the oil filter pipe.
•Flexibles to connect the kit to the main compressor
•Tap flange (except for GA 11-30 kW range)
5 versions are available:
•2230 0060 90 for 11+- 30 kW
•2230 0060 91 for 30+- 55 kW
•2230 0060 92 for 55+- 90 kW
•2230 0060 93 for 90+- 180 (VSD) kW
•2230 0060 94 for 180+- 315 kW
5.3. Labels
Part Number Picture Description
1079 9902 55 Warning label – hot surface
1622 5529 00 System operation remark
1079 9913 79 Water in
1079 9913 69 Water out