compressed air

s o l u t i o n s
Issue 1: 2002
Atlas Copco integrates wireless communications in
key service products to better serve customers

In this issue:
The automotive
industry

Compressor
rental

Energy savings
– FREE CD
The face of innovation

THE ENERGY SAVER CD

How to cut your compressed air costs.
Everything you Variable Speed Drive
Compressors
wanted to know
Electronic controllers
about energy
Leak detection
saving, compressors
Air management
and compressed air surveys

Preventative maintenance
systems - on one programmes
FREE CD.
 The face of commitment
What’s
Welcome to the third edition of Compressed Air Solutions. Customer event
Foreword by Geert Follens, Managing Director, Atlas Copco Compressors Limited
in the North West
Atlas Copco Compressors will be
Focussing on opportunities Investing in future growth holding a three-day exhibition of
It is a good time, in this first edition of During 2002 we will continue to develop new its latest products at Oulton Park
Compressed Air Solutions in 2002, to look back at products. You will see some of the developments we
racetrack in Cheshire in the week
2001. Atlas Copco had a good year in GB and in made last year inside this edition - and there is
of 27th May.
the rest of the world. Growth slowed down much more to come. To be able to keep up the
somewhat, but this is not a surprise if we look at speed of new developments and to assure the On display will be our range of
the current economic climate. It does not happen quality of the products, Atlas Copco has invested in compressors, ancillary equipment and
very often that the US, Asia and Europe are in a new labs in the main manufacturing site in Belgium. survey software, plus we will be running a
recession at the same time. This is a clear commitment to the business we are programme of seminars on topical
in and, of course, to you. compressed air issues. Visitors will also
The most concerning parameter is the manu-
facturing output in GB. The decline in 2001 was very We will also put more focus on service during this get the chance to test their driving skills
sharp, and this is a sector that was already hit very year. There is a need for companies to have one after viewing the exhibits. We will be
badly in the previous years. It almost looks like the partner looking after their complete air net, from inviting key local customers, but anyone
GB economy is becoming a service economy. generation to point of use. We already have interested in viewing our products should
contracts where we take this responsibility and we contact us.
Another important point that received a lot of
will certainly extend the offer. Our service engineers
attention in 2001 was care for the environment. The
will give you peace of mind so that you can focus on
Kyoto agreements were signed and, closer to home
your core business. In this edition, you can read
for us, we had the Climate Change Levy. It is good to
about the latest web and radio technologies that are
see that on an international, but also on a national
level, people are starting to care about the world in
enabling them to provide an ever more accurate
and rapid service – an illustration of our
Contents
which we live.
commitment to being at the forefront in meeting 2 Foreword by Geert Follens
Reducing manufacturing costs modern business requirements.
It is in these difficult times that Atlas Copco can 3 What's new:
Geert Follens Distributor news
help you to reduce the costs of the products you
manufacture and at the same time take care of the Investment in new labs
environment. It is now more than ever that our New CEO
Variable Speed Drive compressors can reduce your
energy bill. But it is not only the VSD machines; we 4-5 Saving energy
have many other products and services that can Free CD reader offer
help you in saving energy and in creating a cleaner
world. The offer inside this magazine gives you the 6 Foam manufacturer
opportunity to get a free CD-Rom explaining all the
saves energy
features and benefits of these.
7 Industrial compressor rental
Another important product we offer, a flexible
finance package, can help you to realise the 8-9 Focus on the automotive
investments in the equipment you need to save industry
energy. In many cases, the savings on the energy
bill are higher than the monthly payments for the 10-11 New products
new products. We are very flexible in our finance
packages and can certainly offer you a deal that
suits you.
12-13 Total service - now and into
the future

14 Honda uses centrifugals

Compressed Air Solutions Atlas Copco Compressors Limited
Editor: Joanna Canton Swallowdale Lane, Hemel Hempstead, Herts, HP2 7HA 15 Finance options for equipment
Telephone: 01442 222279 Telephone: 01442 261201 Fax: 01442 234791
Email: [email protected] email: [email protected]
16 Compressed air in rail link
www.atlascopco.co.uk
Freephone: 0800 181 085
2
FREEPHONE 0800 181 085
New
Distributor scoops Investment in new tested at every stage of their development. It has
always been Atlas Copco's procedure to expose
environmental award test labs all compressors to a comprehensive test
Atlas Copco distributor, Control Gear Ltd, In the fourth quarter of 2001, Atlas Copco programme before market launch, to safeguard
has won an award for best practice in invested 13 million Euro (£8 m) in new that customers receive a product of the highest
environmental performance amongst laboratory and test facilities at its quality. The new facilities provide more capacity
businesses in Wales. manufacturing plant, Atlas Copco and speed up and enable better control of the
The accolade was presented at the ARENA Airpower, in Antwerp, Belgium. test process, bringing products to market in a
Network Wales Environment Awards 2001, which This significant investment is speeding up the shorter timeframe.
showcased the most outstanding examples of development and time to market of new products. Atlas Copco Airpower is the world's largest
Welsh companies who put the environment at the It also signifies a strong commitment to growing compressor manufacturing plant. Its new test
centre of their operations. Atlas Copco's compressor business, to product laboratories are the latest in a line of state-of-the
Overall winner of the 2001 Awards was the development and enhanced customer value. art investments over recent years, including
Control Gear Group of Treforest, a long-standing The new 2400m building houses a preparation
2
research and development capabilities to support
distributor of Atlas Copco industrial compressors, and assembly area and twelve state-of-the-art innovation, high performance machine tools and
ancillary equipment and tools. Control Gear was test cells where compressors can be thoroughly modern logistics systems.
credited for its approach to training, waste
management, recycling, transport and
compressor energy efficiency initiatives.
Mel Fortune, Control Gear’s Quality &
Environmental Manager, stated that winning the
award was a tremendous achievement for the
whole team. “Everyone has worked extremely
hard and there has been a huge change in our
culture and working practices in order to protect
our environment.” He added, “We have worked
with a number of major companies during the last
year, helping them to identify areas of energy
efficiency. The use of the Atlas Copco
compressed air Measurement Box has been
extremely useful during these exercises.”
The ARENA Network event is a leading
Website competition
environmental competition, which aims to
position Wales as the “clean, green place to do As part of our ongoing website New CEO for the
business”, where companies’ actions to protect development, Atlas Copco has launched
a new competition on the website,
Atlas Copco Group
the environment also give them sound
commercial advantages. It has already where prizes such as power tools or Gunnar Brock has been nominated
contributed towards measurable reductions in meals for two are awarded to winners.
President and CEO of the Atlas Copco
environmental impact in Wales. Take a look at www.atlascopco.co.uk,
in the News section, and try your luck! Group. Giulio Mazzalupi, Atlas Copco's

current CEO, who retires after 31 years of

Distributors of the year service, will be handing over the reins to
We are pleased to announce that Martlets Air
Power, based in Winchester, has been named Mr Brock on July 1st. Prior to joining
Atlas Copco Compressors Ltd’s Distributor of the
Atlas Copco, Mr Brock headed Alfa Laval,
Year 2001, due to outstanding performance in
increasing overall sales and market share the Tetra Pak Group and, currently, Thule.
throughout the year. Anglian Compressors & He will be only the 10th CEO since the
Equipment of Peterborough has won the award
Group was founded in 1873.
for Quality Air Distributor of the year for highest
sales of ancillary equipment in 2001.

3
[email protected]
Avoiding energy penalties
Atlas Copco How are companies affected by
the CCL?
has a number of Certain industries have a target to hit for
reducing their energy consumption. They are
energy-saving affected by the CCL in two ways: firstly in a levy of
a certain amount per kWh of electricity and gas
suggestions to used; and secondly, an additional penalty is
minimise incurred if their target level is exceeded.
Therefore, the two most obvious ways to avoid the
companies' penalties are to stay within the allocated level, and
to reduce energy consumption further, thus
penalties under reducing the levy that must be paid. But how to do Describe Atlas Copco's
these things is not so obvious. VSD compressor range
the Climate Atlas Copco has the widest range of VSD
How can Atlas Copco help
Change Levy reduce the impact of the CCL?
compressors on the market - 37 to 900 kW -
including Full Feature variants with integrated air
Our main thrust is energy savings derived from a
(CCL). In a more efficient usage of compressed air equipment.
quality equipment, and oil-free versions, meaning
that there is a VSD to suit the needs of the vast
nutshell, our Compared to these, Enhanced Capital Allowances
are just an added bonus. The benefit of an ECA is
majority of installations. To help protect operators'
end-product quality as well as their production
philosophy is that you take the full capital allowance on the
cost bottom line, Atlas Copco introduced last year
value of the motor and the inverter in the first year,
that the best way which is useful for improving your cashflow in that
a range of VSD compressors designed to deliver
100% oil-free air.
year, then the allowance reduces in subsequent
to avoid the years. However, with energy representing over What other ways are there to
reduce energy consumption?
energy penalties 70% of the total lifecycle cost of a standard
compressor, VSD-derived energy savings and good If you take into account all of the below

is to use less housekeeping in the installation can see methods, you could save at least 35% on your total
electricity costs for producing compressed air:
equipment payback realised within one- to two-
energy. years and savings are ongoing. Compressor control systems
Installing a multi-compressor controller system
How do VSD compressors is a way of reducing energy by an average of 10%.
save money? A controller will ensure that the most efficient
Installing a typical VSD combination of compressors is running at all times.
compressor saves an average of Atlas Copco's latest generation of ES controllers
35% of compressor energy, look at the air demand in the system compared to
which can be a significant what is available from the existing compressors,
amount as compressors are then they only run the ones needed to meet that
often the biggest users of demand, whilst allowing for back-up.
electricity on a plant. A VSD compressor saves
energy by matching its output as closely as
possible to the system's demand, which will vary
throughout the day in the majority of cases. The
saw-tooth effect of a load/no-load compressor is
smoothed with a VSD and there is no overshoot in
pressure, both of which save energy and,
consequently, money. To put VSD derived annual
energy savings into perspective, 100 VSD
compressors would save the equivalent of the
typical power consumption of an average town of
some 40,000 inhabitants.

4
FREEPHONE 0800 181 085
 Potential savings
of minimum 35%
If you take into consideration all the
areas in which energy is potentially
wasted on a site, it adds up to a large
amount of electricity. The potential
savings on a compressed air electricity
bill are therefore enormous -
a minimum of 35% if all of the remedial
actions indicated on the previous page
Energy recovery Alex Grant, Product Marketing Supervisor at Atlas Copco were taken.
Another effective method is through energy Compressors, presented the energy-saving benefits of VSD As an example, recovering this 35%
recovery. All compressors generate a great deal of compressors at the Energy Efficiency Best Practice
could save you £70,000 per year on a
Programme Seminar in Manchester. The next seminar
heat when they run loaded, up to 90% of takes place in St Neots, Cambridgeshire on 500 kW compressor running on 3 shifts
which can be recovered rather than March 27. Contact us for details of this and (24 hours/day) taking electricity at 5
wasted. For example, heat is other energy efficiency seminars that pence per kWh.
Atlas Copco will be attending.
taken out of a water-cooled
compressor via the water,
so this could be used for
handwashing purposes in
the factory. In the case of
an air-cooled compressor,
the hot air can be recovered
for local space heating in the
MPRESSE
colder months, thus cutting
O D o w o n t he F REE
At
heating bills. It is even possible to
C kn la
s
The face of innovation

control the temperature either via a o C

t AI
CUT YOUR

thermostat or manually.
ed

op

Best practice
ne

co

Further energy savings can be made simply

RC
THE ENERGY SAVER CD
En
’ll

through good housekeeping ideas, which cost

How to cut your compressed air costs.
r y th i ng y o u

erg

relatively little to implement. For example, leak

detection surveys can pinpoint any air leaks in Everything you wanted
Variable Speed Drive
OSTS
y S aver CD

Compressors
the system; auto drain traps in the air receivers to know about energy Electronic controllers

and pipework should be checked to ensure they saving compressors

Leak detection

are operating correctly; be sure to install the and compressed air

Air management
surveys
appropriate size of pipework to keep pressure Preventative maintenance
Eve

systems - on one FREE CD. programmes

drops down to a minimum, and consider the
correct pipeline velocity, the materials, bends
and installation; reduce the discharge pressure
ST

of the compressor to an absolute minimum;

select all ancillary equipment carefully to avoid
O
CO

CD
A

pressure drops. R N
Bear in mind that an extra 7% of electricity is
T
N

SA GY
E

needed to overcome each one bar of pressure

TA VIN E
drop. For example, an extra 7% for a 500 kW CT G ENER F R
compressor equals 35 kW. Over a 24 hour US R
operation at 5 pence/kWh, this amounts to £14,000 FO R YO U
spent unnecessarily on electricity per year.

5
[email protected]
VSD compressor
saves energy for foam manufacturer
As part of its group-wide energy efficiency programme, Kay-Metzeler
has installed an Atlas Copco Variable Speed Drive (VSD) compressor
at its foam manufacturing site at Bollington in Cheshire, resulting in a
saving of thousands of pounds per year off its electricity bill.
The GA75 VSD compressor was installed example, in the block foam area, compressed air is
Kay-Metzeler is a division of the British
by Atlas Copco's local distributor, Pneumatic used to pressurise many vessels full of polyols,
Vita Group, a world leader in specialist
Services Ltd, to supply compressed air to the silicones and amines, which feed the metering
polymer technology. Compressed air has
whole factory. As the air demand is very pumps. These vessels need to be pressurised before
many applications throughout Kay-
cyclic, a variable speed drive compressor production starts up, causing a high air demand early Metzeler's production line, which makes
was the ideal solution to meet the on in the day. The VSD copes easily with this peak, 20,000 parts for transport seats and
fluctuations in the most energy-efficient way. whereas a fixed-speed compressor would have to be furniture per week. For example, in
tailored to meet the maximum demand and run pneumatic controls, conveyors to move
Substantial energy savings offload the rest of the time, wasting around 30% of the foam moulds along the production line,
Initially, Pneumatic Services used Atlas Copco's energy it uses. mixers and pumps, foam trimming tools,
compressed air Measurement Box to survey the air air knives, and spray guns for applying
Air throughout the process release agent to the moulds to release the
consumption on site. The results showed that Kay-
foam easily. Another application on site is
Metzeler would save £6,000 per year in electricity by As the compressed air comes directly into
pneumatically controlling the conveying of
operating a VSD instead of a fixed-speed contact with the chemicals during the pressurisation
large blocks of raw polyurethane foam on
compressor. Adding the predicted maintenance and of the vessels, the air must be clean, dry and
to a racking system, where they must be
overhaul costs to these energy savings, showed an contaminant free. For this reason, Kay-Metzeler left overnight to cool, prior to being
overall payback of under three years for the VSD. uses an Atlas Copco refrigerant dryer and filters transported by truck to other sites within
Said Tom Anderson, Divisional Project Engineer, at with its compressor. All are housed in a purpose- the British Vita Group for further
Kay-Metzeler, "Because the VSD compressor saves built building. At only 70 dB(A) the GA75 VSD runs so processing.
on our electricity bill, it also gives us the possibility quietly that it does not disturb anyone, even when Overall the Bollington site produces in
of reduced Enhanced Capital Allowances on our the building doors are open. excess of 1500 blocks of foam per week,
Climate Change Levy liability." which, in volume terms, is a huge
Although Kay-Metzeler has an average Comprehensive service amount. All pieces of waste foam are
granulated and processed for recycling by
compressed air consumption over a 24 hour shift of Alongside the proven energy savings, reliability
Kay-Metzeler. Here also, compressed air
275 cfm (130 l/s), the demand varies throughout each and aftersales service were contributing factors in
has a part to play, operating the shutters
shift from 180 cfm (85 l/s) to 360 cfm (170 l/s). For the choice of an Atlas Copco compressor. As there
on the silos and blasting the silo filters to
is no standby unit, maximum compressor uptime is clear them several times a day.
crucial to Kay-Metzeler's production. To guarantee
this, Pneumatic Services covers the VSD with a
five-year total responsibility service contract. The
price is fixed, giving an added advantage of being
able to budget, with no unforeseen bills. As the
compressor runs for 116 hours per week, Pneumatic
Services schedules routine maintenance around
Kay-Metzeler's shift pattern and offers a 24 hour
call-out service in case of emergencies.
"We have had a long and successful history of
using the Atlas Copco brand, " said Tom Anderson.
"This previous experience, combined with the good
Large blocks of foam on a conveyor,
Spraying a mould release agent on to service and flexible maintenance offered by which uses pneumatic cylinders to
the foam blocks with an air gun to Pneumatic Services, makes us confident that the control the movement of the blocks
ensure that the foam does not stick Atlas Copco compressed air equipment will not let along the conveyor.
inside the mould. us down," he confirmed.
6
FREEPHONE 0800 181 085
Keep your air on
with Atlas Copco's industrial rental compressors
❖ Specia
Atlas Copco has been well known for many years as o ffer lo
al f
Atlas Copco

fe
a key supplier of air compressors, but it is less well

ec

r❖
fer ❖ Sp
Industrial Rental is

Special offe
offering reduced rental rates
known that we are also in the business of hiring to readers of Compressed Air
Solutions. Please call us on

f
compressors through Atlas Copco Industrial Rental.

ial o
0800 169 6611 for a quotation

c
or to place an order.

pe

r
❖
Whether your need is to cover a planned compressors, which have no oil within the compression S Sp
compressor overhaul, allow for temporary element, guaranteeing that oil cannot contaminate your ial offer ❖ ec
increased capacity, to fill in for a breakdown in a pipework or end product. Our oil-free compressors come
hurry, or to have the reassurance of a standby in both air-cooled electric-driven or diesel-driven
unit, Atlas Copco Industrial Rental can provide versions, stationary or mobile, in accordance with
you with the right quantity and quality of your requirements.
compressed air, all day every day, to ensure you Furthermore, Atlas Copco's portable, diesel-driven
maintain continuity of production. rental compressors are spillage-free and incorporate
Our rental fleet includes both electric and diesel- refinery and rig equipment, such as spark arrestors and
driven compressors, weatherproofed and mobile, chalwyn valves, meaning that they are safe, environment-
meaning that they can be used indoors, outdoors and in friendly and ideal for offshore applications.
semi-permanent industrial installations. The range goes
from 55 cfm (26 l/s) to 1534 cfm (724 l/s), and we offer You never know when you
pressures up to 20 bar (290 psi). might need us!
Because we know that compressed air is vital to so
The right quality of air many operations, Atlas Copco Industrial Rental operates 100 generators
When your application demands clean and dry air, we
can provide a range of ancillary equipment, including
a 24 hour call out number, every day of the year, to
ensure that the wait for a hired compressed air supply is
bought for hire
dryers, filters and aftercoolers, which are matched to the always a short one. We also offer rapid, nationwide 100 Atlas Copco generators have
compressor. Air receivers, hoses and fuel bowsers service and installation support, using the resources of been purchased by Generator Power
complete the package, all from one convenient source. our eight, long-established service branches around Ltd, a specialist in the rental of
For particularly sensitive applications such as food and Great Britain. generating sets, to meet its growing
drinks, pharmaceuticals and electronics, Atlas Copco So if you find yourself needing extra compressed air or business demands.
Industrial Rental's fleet also offers 100% oil-free "Z" have to act fast to keep your production running in an
The order comprises a mixture of
compressors and the oil-free, wheel-mounted “PT” QAS18 (17kVA) and QAS38 (34kVA)
emergency - rest assured that Atlas Copco Industrial
generating sets. "Our business is
Rental can help you keep your air on!
growing rapidly, with orders coming in
from a variety of industries, such as
telecomms, construction, quarrying
and manufacturing," said Steve
Cardwell, Managing Director of GP.
"This latest investment in Atlas Copco
generators will help us fulfil the strict
demands of our clients in these areas."
The new 100 units swell GP's fleet
size to over 300, available for hire
across the country 24 hours a day,
seven days a week. "Our customers
like the Atlas Copco generators
because they are very substantial
machines, specially designed to stand
up to rough on-site applications and
have low noise levels," explained Steve
Cardwell.
7
[email protected]
Atlas Copco gears up
to fulfil th
In the automotive The sophistication of the compressed air user in this
market has increased over recent years. The
introduction of more modern paints and sprayguns,
industry, compressed etc, has forced the market to look at higher volumes
of air, and better quality of the air supply. Also
air is needed at environmental legislation has become an increasingly
big issue. For example, the onus is on the customer to
many different levels deal responsibly with oil/water condensate. What's
more, larger users in the bodyshop/automotive market
to suit the diverse have started to become extremely cost conscious.

needs of users in More air, cleaner air and air

tyre outlets, MOT for less energy
And at the same time as needing more, cleaner and cheaper air,
bays, sprayshops, customers are also looking for compressors that are physically no
bigger. We believe that our recently introduced GX compressor

and general range has the versatility to suit this demanding market. With its
launch, all eventualities of air flow, pressure and quality are covered.

bodyshops. For example, spraybooth manufacturers need a very high quality of

air to ensure that sprayguns and paint are not affected by impurities.
In this case a compressor with air treatment equipment is the

Atlas Copco solution, such as the Full Feature version of the GX, which contains
dryer, filters and oil/water separator within the compressor canopy,

Compressors can giving high quality air from one compact machine. So far, around 90%
of the GXs sold have been receiver-mounted and over 60% were Full
Feature versions.
now confidently say Many garages are mislead into believing that they need
compressed air at 10 bar for all applications, but in reality most air
that it is in a position tools and other equipment in a standard workshop only need 7 bar.
Sprayshops in fact, mainly need only 4-5 bar. If this is the case, a
to provide both the smaller compressor would fit the bill, which in turn reduces the
purchase price. Bear in mind that the higher the operating pressure,
right products and the less air is delivered from a compressor - and vice versa.
There are of course outfits that do require air at a higher pressure,
the levels of say 10 bar (145psi), such as commercial vehicle workshops, large
tyre outfits and others operating specialised equipment. For these
dedicated support to parts of the business, piston compressors have long been the
workhorse. They operate at 10 bar, are very hardy machines and, as
meet these differing the quality of the air is not the major issue, are cost effective to buy.
Atlas Copco supplies a full range of piston compressors, called the L
needs. range, with capacities from 2.2 to 50.6 cfm (1.02 to 23.9 l/s).
Atlas Copco Compressors is also the world's leading supplier of
variable speed drive (VSD) compressors, which are helping
customers in industries from printing to pet food to reduce their
energy bills by an average of 35%. In the automotive industry too,
VSDs are starting to find their place. Larger bodyshops who consume
a variable amount of air when they run different tools throughout the
day, are ideal candidates for benefiting from a VSD compressor.
These days the VSD range includes 18, 22 and 30kW models, which
are the right size to run a larger bodyshop.

8
FREEPHONE 0800 181 085
he needs of the automotive industry
product and service knowledge from these dealers
and has the confidence to choose an Atlas Copco GX workshop and
product from them. Currently Atlas Copco is running a
training programme for automotive dealers on all
automotive compressor
aspects of our air compressors and ancillary range extended
equipment related to the automotive industry.
Atlas Copco's GX range of compact, value-
To support this dealer network, and prove our for-money compressors is now available from
commitment to this key market, Atlas Copco has 2 kW up to 22 kW, ideal for providing quality
recently put into place a dedicated Automotive Team, compressed air to automotive applications, such
headed up by Keith Barron, GX/Automotive Sales as workshops and bodyshops, tyre and exhaust
bays, as well as for joinery and carpentry, iron
Manager, pictured below. The team provides just one
and steel, textile and clothing industries.
point of contact in each area: sales, service, training,
The smallest model in the range - the GX2 - delivers
logistics/order processing, and technical support.
4.8 l/s (10.2 cfm) at 7.5 bar. With a noise level of only
62 dB(A), it can be placed next to the point of use
without disturbing operators. The largest model, the
Good housekeeping GX22 produces 61.9 l/s (131.2 cfm) at 7.5 bar. 10 and
13 bar versions are also available.
General good housekeeping of compressed air
Two different variants are offered: the Pack and the
equipment is as crucial in the automotive industry as
Full Feature. The Pack is more basic, whereas the Full
in any other, although awareness levels of this tend to Feature includes a refrigerant dryer, filters, aftercooler
be lower. For instance, to keep a compressor running and oil separator integrated within the compressor's
most effectively and cost-efficiently, it has to be canopy. The integrated design guarantees dry and
serviced regularly. The filters must be changed at clean air to protect downstream equipment and end
regular intervals so that they do not become saturated products, and reduces installation time and operating
expenditure.
and pass oil, moisture and dirt through them. If routine
The GX can be either receiver-mounted or floor-
filter maintenance is not carried out, the risk to the air
mounted. The GX2-4 models have a 200 litre air
supply and the air tools is very real, which could
receiver and the GX 15-22 models have a 500 litre air
amount to a costly experience in a sprayshop, for receiver. Their footprints are only 0.5m2 and just over
example. Furthermore, it should be remembered that 1m2 respectively, ideal for small premises where space
certain items of compressed air equipment must be is at a premium or for placing next to the point of use.
tested to meet Health and Safety legislations. The first GX 2-4's in the world were sold by
Breathing air has to comply to COSHH L5 distributor, Pneumatic Services Ltd. One is in use in a
regulations. Making sure that it meets the required garage, whilst the other is in a high-tech laboratory,
showing just how versatile these new compressors are.
purity levels is vital in protecting operators' health and
avoids companies facing fines or prosecution. Atlas
GX Roadshow
During February and March our GX range hits the
Copco can provide quick and efficient breathing air
road in a purpose-designed exhibition vehicle. Three
monitoring tests to a predetermined schedule, to
machines are being driven around the country and
check for carbon dioxide, carbon monoxide, oil and
introduced to dealers and end customers by members
water in the air supply. This procedure is carried out
of our automotive team.
on each individual breathing air inlet without having to
shut down the supply compressor.

A strong automotive team

Atlas Copco's focus is to offer a purpose-designed
compressor product combined with a dealer network,
in order to provide end users in the automotive
industry with a total package of confidence, quality
and service.
Our automotive compressor range is sold via a
nationwide network of dealers. It is extremely
important that the end user receives the right level of

9
[email protected]
New Products
New low The new ZE/ZA 3-6 series of oil-free
screw compressors has been launched to

pressure provide compressed air at low pressure

for many production processes. It is a
compressors highly efficient all-in-one package in
terms of energy, cost and floor space.
Low pressure air is vital in many industrial
processes, such as powder and bulk handling,
mixing, aeration, air separation, fermentation,
and cooling and drying processes. In most of
these applications, product contamination,
pulsation or performance degradation can be
detrimental to a profitable and efficient
operation. Thanks to its oil-free screw
compressor technology, Atlas Copco's ZE/ZA range
totally eliminates those risks.
The new ZE/ZA compressors are available both in air-cooled (ZE)
and water-cooled (ZA) versions. Pressure ranges from 1 to 3.5 bar(e)
(15 to 50 psi), while flow rates go from 272 to 4360 cfm (128 to 2058 l/s.)
The ZE/ZA 3-6 compressors come as a silenced, ready-to-use
package with a long list of components fitted as standard.
The range has also been designed to easily integrate additional
components to suit particular needs. Options include an integrated
stainless steel aftercooler, which does not require additional floor
space. When dry air is needed, the ZE/ZA can be linked to an Atlas
Copco refrigerant or adsorption air dryer, depending on the
requirements of the application.

... and high The new GR110-200 two-stage, oil-injected

rotary screw compressor series offers an

pressure efficient and complete package for high-

pressure air applications.
compressors Using rotary screw technology, the GR110 and
GR200 air-cooled variants and the GR110W,
GR132W, GR160W and GR200W water-cooled
variants are designed for applications that require
high-pressure air from 13 up to 20 bar. Their
capacity ranges from 255-442 l/s (541-937 cfm) for
the 13 bar version, and 211-385 l/s (447-816 cfm)
for the 20 bar version.
Full integration of a refrigeration dryer module
with bypass, plus an optional integrated filter on the
13 bar variants, results in a complete, all-in-one compressed air
system that provides high quality air to the application point.
Compared to existing single-stage machines of the same size, the
new two-stage GR series has improved capacity and efficiency,
with reduced sound pressure levels, eliminating the need for
additional baffling.
What is more, the design of the new GR series package allows easy
access to components for fast routine service.

10
FREEPHONE 0800 181 085
 VSD dryers Atlas Copco is pleased to introduce another
unique innovation in the compressed air industry -
The FD VSD dryer’s capacity is 750 l/s (1589 cfm) and the
effective working pressure of a FD750 VSD is from 4 to 14.5
the first ever variable speed drive (VSD) dryers. bar(g). The dryer can operate in three different modes:
save energy This innovative concept has been applied both to lowest dewpoint of +30C; at a dewpoint of 200C below
refrigerant dryers (designated FD) and adsorption dryers ambient temperature; and at a dewpoint of 120C below
(MD). The FD dryer is designed to be used with Atlas ambient. The two watercooled versions of the MD VSD -
Copco’s oil-injected GA and ZT VSD compressors, whereas MD400W and MD800W - cope with air flows of 412 l/s
the MD VSD is used alongside oil-free Z VSD compressors, (873 cfm) and 815 l/s (1726 cfm) respectively, and have a
adding up to even greater energy savings for the customer. pressure dewpoint of -150C to -400C.
Atlas Copco’s dryers have always been an effective
solution to the problem of moisture in the air, which is
known to damage the compressed air system or
contaminate products. Now, with the introduction of the VSD
versions, drying efficiency has reached new heights. Thanks
to the variable speed drive, the dryer’s power consumption
is immediately reduced as soon as air flow or load
decreases, in the same way as with a VSD compressor. The
result is the lowest possible running cost – offering savings
of between 25% and 50% compared to other dryers.
The frequency converter that powers the dryers is
integrated within the dryer package. An LCD display
communicates all relevant parameters to the operator in a
clear and concise manner, such as dewpoint, energy saving
percentage, warnings of failures.

Four-wheelers Atlas Copco's range of four-wheel compressors

has been redesigned to be compliant with the
have been inserted along the length of the compressor canopy on
both sides, as well as inside the roof, to reduce the noise emitted

meet latest Exhaust Emission Standard 97/68/EC and the

Outdoor Noise Directive 2000/14/EC, which came
from the units to the required 102 dB(A) level.
Benefiting from the latest innovations in electronic engines
regulations into effect in January 2002.
The reengineered units - called XAMS, XAHS, XRHS and XRVS
from Mercedes Benz, the compressors are able to meet the
exhaust emissions requirements, and guarantee increased
compressor - are the most technologically advanced portable reliability, safety and fuel economy. Furthermore, the
compressors on the market. Internal sound dampening panels compressor's electronic controls are linked to the engine
management system for unsurpassed performance and
efficiency. The user interface allows customers to easily check
the operating status of the compressor and to quickly diagnose
any problems, thus reducing downtime.
The range was also designed to reduce the cost of ownership
for the customer. Their sturdy build and reliable operation allow
the compressors to withstand the harshest of applications and
climates. A totally new design concept has greatly improved the
environmental aspects of the compressor. The engine and
compression element components lie completely within a spillage
containment frame, so that oil cannot be leaked into the ground.
Service access was another key issue in the redesign of the
units and is an area where cost of ownership has been reduced.
A full range of standard options, including aftercooler, water
separator, filters, spark arrestor and road signalisation, is
available to suit the requirements of the application.

11
[email protected]
A service second to none
Colin Newton, Aftermarket Service Manager, explains current

Atlas Copco Compressors offers a portfolio of service pipework on a site with a small, purpose-designed sonic gun.
packages, because we recognise that regular compressor The gun can measure the amount of air leakage and from there
maintenance not only keeps production running at top can calculate the value of the wasted air.
efficiency, but is also an opportunity to reduce running
costs. Add to this new technologies in the pipeline, and Service contracts tailored to your needs
Atlas Copco is changing the future of compressor survicing. We believe that prevention is better than cure. This is why
Atlas Copco Compressors is the only manufacturer in its field we developed the unique Atlas Copco Serviceplan scheme,
with a dedicated service operation. We have eight regional which is designed to keep your equipment operating at
service branches around Great Britain and a team of around 75 maximum efficiency 365 days a year, anywhere in the country.
service engineers directly employed by Atlas Copco. We believe Available on any compressor, generator or associated
in the "one-to-one" concept, whereby one unit sold equals one equipment, including non-Atlas Copco models, our fixed price
unit supported. This is to make sure that our products are Serviceplan schemes give optimum performance, maximum
maintained on a regular basis by Atlas Copco trained engineers. productivity and financial security.
And the regional branches mean that technical support or spare There are three Serviceplan schemes to suit every production
parts are just a phone call away, and service engineers never requirement. No matter which you choose, the costs are fixed
have far to travel to ensure the continuous operation of your from the outset, eliminating any hidden surprises.
production processes. The first of these packages is called the Total Responsibility
Plan. This is the most comprehensive fixed price maintenance
Regular servicing saves money and repair system available today. We take full responsibility for
A major portion of the lifetime costs of a compressor - around the equipment and, except for daily maintenance, keep it fully
72% - is down to electricity, whereas servicing is only 9% operational to a predetermined timetable to fit in with your
(installation is 2% and investment is 17%). Regular servicing will operating needs.
reduce the energy running costs of a compressor significantly, The second is called Maintenance Plan. This planned,
so the potential gains are enormous. preventative maintenance scheme provides scheduled service
One area where regular servicing will reduce running costs is and diagnostic checks.
ancillary equipment. For instance, if a filter is clogged up or you And finally, we have the Inspection Plan. This flexible scheme
are using an inefficient dryer, it will lead to a pressure drop in is designed to complement your own maintenance facility. Our
the compressed air system. And for every 0.5 bar drop, you need engineer identifies the actions needed to keep your plant
an extra 3% of electrical power (based on a 250kW operating effectively and efficiently, meaning that you can
compressor). concentrate on your core activities.
Or you may have air leaks in your system, which means that
the compressor has to run for longer than is needed. To A range of on-site surveys
illustrate this, surveys on energy wastage carried out in the US On request, we can also build energy consumption surveys
and Europe; both concluded that around 20% of compressed air and air quality tests into our standard service packages. Leak
is wasted (around £2.50 per hour, based on a 250kW compressor detection is one way of reducing air consumption, as mentioned
and 0.05p/kWh). Therefore repairing leaks is one way of above. Another is the Atlas Copco Measurement Box - a crucial
instantly saving money. tool in evaluating air management in a particular application. It
With our new leak detection surveys, it is easy to spot the gives a true picture of the site's compressed air usage and from
leaks in a compressed air system. Our engineer surveys all the this can determine the most energy efficient solution for the site.
Our air quality tests check for carbon monoxide, carbon
dioxide, oil and water in the air supply. This is crucial especially
where breathing air is used, to ensure that it complies with
COSHH L5 regulations. Insurance inspections are another
service that we offer, whereby our engineer will carry out a
visual inspection of the air receivers in conjunction with the
statutory insurance company visit, meaning that the equipment
need only be taken offline once to check that it meets legal
requirements.
Furthermore, we offer “site responsibility” - which includes
taking responsibility for all compressors on site. Our engineers
are trained to carry out site surveys, then put forward a
recommendation for improved site management. It tends to be
larger companies who are looking for this kind of turn-key
solution, with the expectation of seeing either a cost saving, or
receiving a better quality of compressed air.
12
FREEPHONE 0800 181 085
and future service products and how maintenance saves money

An emphasis on training air consumption over a period

On average, Atlas Copco of time, the corresponding energy
Compressors provides 22 weeks costs and the efficiency of the
of service training each year, factory.
aimed at our own engineers, In conjunction with this is the
distributor engineers and launch of the latest generation of
sometimes our customers. Every successful participant is issued our compressor controller, which
with a "passport" to prove his competence in that area. This links compressors - Atlas Copco or
passport gives confidence to the customer that his compressed even other brands - via a modem,
air equipment is in the best possible hands. and makes the compressor room a
Currently, we are working with Rycote Wood College in lot more efficient and smarter-
Thame to come up with a compressed air qualification equal to running. More about this will
NVQ level 3 and endorsed by the British Compressed Air follow in the next issue of
Society. This should be in place before the middle of the year. Compressed Air Solutions.

Realtime service software

Atlas Copco is currently testing in some European countries a
new service software that will allow engineers to remotely
access our central computer system whilst out on the road or
on a customer's site. Using a small handheld computer fitted
with an instant radio link, they will be able to check the
availability of spare parts on the spot, thus increasing response
time to the customer. Another functionality will be a realtime
planning board, so that if the engineer needs to rearrange
appointments, colleagues back at base are kept informed of his
new schedule.
Furthermore, soon Atlas Copco will have one master record
of each product variant available on its Intranet in pdf format,
for any of its sales companies around the world to download.
This eliminates the need for regularly reprinting updates of
instruction books and operators manuals.
Another part of the package calls up drawings of all
New vans offer better flexibility compressor components on screen, with their part numbers, for
We are not only investing in our service people, but also in quick and easy cross-referencing. When the required part is
their vehicles. Based on valuable input from our engineers, we located, it can be dragged and dropped into the shopping
have recently standardised on mid-sized vans. These allow side basket. This e-commerce facility is currently only available to
loading on both sides, which gives a better weight distribution, Atlas Copco and its distributors.
and the vans are higher, providing a larger carrying capacity.
Each van is also equipped with a sink, so that engineers can
wash up in remote locations.

Exciting new technology for the future

With the advent of the Internet, many new possibilities have
opened up to us in the compressor servicing business, and Atlas
Copco is at the forefront in developing and introducing them to
the market.
For example, this year we will see the launch of the
Compressor Room Concept (CRC). This facility allows an Atlas
Copco service engineer or a customer to monitor the operating
status - pressure, temperature, air flow, etc. - of a compressor in
realtime over the Internet. The programme gathers performance All of these emerging technologies complement our existing
data or highlights any problem areas without the need for a service capabilities. Through them, Atlas Copco is proving its
physical visit, which is of great benefit particularly in the case of drive to offer ever more accurate information and even faster
isolated compressor installations, such as offshore locations. response times to customers, whilst still focusing on our ultimate
The CRC can also build financial reports, including data such as aim of keeping production running in the most efficient way.
13
[email protected]
Oil-free air for Honda
Oil-free Honda of the UK Manufacturing Ltd is using an
oil-free Atlas Copco ZH7000 compressor and a ZH6
should any problems arise,” said Dale Smith, Senior Staff
Engineer, Facilities, at Honda of the UK Manufacturing Ltd. A

centrifugal compressor to provide the air required throughout

its recently opened second car manufacturing plant
positive past experience of Atlas Copco oil-free compressors on
other parts of the site plus the benefits of a local service branch

compressors in Swindon, Wiltshire.

The ZH7000 and ZH6 run in a duty/standby arrangement at the
also contributed to the decision.
Compressed air is used throughout the plant, starting in the
drive Honda plant, which produces the Civic 5-door model. The plant has a
constant demand for around 6000 m3/hour (5400 cfm) of
press facility, where flat metal sheets go through four different
presses to become panels. Then they are transferred to the
Civic compressed air at 8.5 bar. Having a back-up capacity is essential welding area, where pneumatically controlled welding robots
to avoid stopping the production line when routine maintenance perform approximately 100 spot welds in a few seconds, resulting
production is performed on the main compressor. in the formation of the car’s basic body shell.
Honda was the first company in the world to buy an Atlas From here, the body shell goes into the paint shop, which is
Copco ZH7000 three-stage oil-free centrifugal compressor. The the major user of compressed air on site. Guaranteed oil-free air
ZH7000 is the latest in our growing range of oil-free 2-stage and is critical to Honda, particularly in the paint process, as even the
3-stage centrifugal compressors, which will cover flowrates from slightest trace of oil would cause the paint finish to blister and
4,400 m3/hr (2,500 cfm) to 15,000 m3/hr (8,800 cfm) by the end of pit. Whilst some manufacturing industries can use oil-injected
2002. The ZH compressor package is fully wired and compressors plus filtration, this type of application
equipped with all interconnecting pipework and cannot afford to risk using anything but a
fittings. Within the noise-attenuated canopy, compressor with absolutely no oil in its air
the gearbox, compression stages, electric compression element.
motor, coolers and regulation system are The first paint process is the pre-
Honda’s manufacturing
mounted on a single baseframe, requiring treatment and electro coat area, which
plant in Swindon
minimal space and installation. ellerremoves any dust or grease from the car
A ZH40

The ZH7000 has a unique oil seal, whose body and gives an anti-corrosive coating.
imp

design does not require any buffer air, even Here the car bodies are submerged into the
00-

various treatment tanks. The next process is

in

during stand-by and unload operations. This

70

0
an
0

is of major importance to Honda as it ensures st

ain le the application of sealer to the joints of the car
ard
less
the compressors will start unaided even in the steel, back w body to prevent water ingress, followed by a colour
event of a major site power failure. coat and a clear coat of paint. In total, each car receives
“The Atlas Copco compressors met our requirements for air four coats of paint. The facility is capable of changing paint
capacity, air quality and reliability, whilst also presenting the best colour in just 3.2 seconds.
package in terms of cost and back-up, which is essential to us From the paint shop, the body shell is moved to the frame
assembly line where it is transformed into the finished product.
Various air tools are used on the assembly line, for example in
fitting the instrument panels, bumpers, engines, wheels and
windscreens. A further application of compressed air is in the
engine assembly plant on the neighbouring site, which runs six
Atlas Copco oil-free Z range compressors.
Honda’s other car assembly plant, situated next door to the
new plant, produces 3-door Civics, CRV and Accord models.
There is a link pipe from plant two to plant one, which also
operates two Atlas Copco oil-free Z range compressors plus MD
dryers, to supplement its production where necessary.
In total, Honda’s manufacturing plant in Swindon employs
over 4000 people. The new £130 million facility was the first
green-field car manufacturing plant to be built in Great Britain
in the last eight years.
The new plant is a world class car manufacturing facility
which complements Honda’s existing Swindon plant to become a
key element in the company’s Global Supply Network. The twin
plants have a combined capacity of 250,000 units per annum -
and will together account for 8% of Honda’s global needs.

14
FREEPHONE 0800 181 085
Air on a shoestring?
Air compressors are almost certainly the
largest electricity consumer on an industrial
site and, with the Climate Change Levy upon us,
it is even more important to ensure they are
providing a cost-effective supply of compressed
air. But what if you find that you need to make a
substantial investment to achieve the most
energy efficient compressed air operation, but
have no budget for it in that financial year? Total Air: This is a flexible operational United Utilities Energy Saving
Atlas Copco’s flexible range of finance lease, whereby the customer leases Partnership: Atlas Copco is working with
options softens the blow in such a scenario. equipment, including service, for a pre- United Utilities to offer the unique Energy
By paying for compressed air equipment agreed period of either three, five or seven Saving Partnership - a scheme that enables
through a finance deal, you can take years. At the end of the term, the customer customers to reduce energy costs immediately.
advantage of the energy savings now and has the choice of either renewing the Atlas Copco/United Utilities will identify and
pay for the equipment over a longer period contract at a reduced price, or evaluate the areas of business where savings
to suit you. On top of the energy savings, you upgrading/downgrading the equipment to can be made and then meet the costs of
will reap all the benefits of a more reliable suit the current demand. installing the equipment, e.g. compressed air
air supply, the latest technology, and Lease Purchase: This is available equipment, needed to realise these savings.
guaranteed availability through a service with or without service included. Payments The investment is recovered by claiming a
contract included in the deal. are spread over a pre-agreed period of percentage of the savings over an agreed
There are various products on offer from three, five or seven years. At the end of the period. It's a win-win situation - at the end of
Atlas Copco to satisfy individual needs: term the customer owns the equipment. the contract the customer is left with new
energy efficient compressors, the benefit of
the full savings on energy costs and
documented evidence for Climate Change
Levy. United Utilities already has more than 150
of these schemes in place throughout the UK.
Contract Air: Under this system, Atlas
Copco takes full responsibility for installing
and running the compressed air equipment
and supplying air at a fixed price per unit. The
customer need only provide the space and an
electricity source. Air is supplied on demand,
with no worries to the customer of downtime
or organising routine maintenance. Another
benefit of this system is that the installation
can be easily resized should the air demand
increase or decrease in the future.

As an example, you could lease an

11kW compressor (40 cfm) from
£30 per week over 5 years, including
service and breakdown maintenance,
under our Total Air package.

In summary, if your company requires the

latest, most energy-efficient compressed air
technology today, but does not have the
capital to invest right now, the various finance
schemes available from Atlas Copco
Compressors can provide the perfect solution.

15
[email protected]
Compressed air
plays a role in Channel Tunnel Rail Link
Two containerised Atlas
Copco compressors,
sold to Ceresola
Tunnelbautechnik AG
by distributor Motivair
Compressors Ltd, are
helping contractors to
see the light at the end
in a precast concrete segment plant. A prerequisite At their workshops in Brownhills, Motivair
of the Channel Tunnel when Ceresola put together their specification for a constructed a purpose-built container to house the
compressed air system was a quiet source of reliable, compressed air system in, and installed all
Rail Link project. dry and clean air. Said Natascha C. Wiesenthal, associated pipework, lights and ventilation. The
Project Manager at Ceresola, "We were looking for a container keeps the noise of the compressors down
The new high-speed railway line, the Channel permanent set-up for the compressor system, to comply with the 55dB(A) limit of the work site, thus
Tunnel Rail Link (CTRL), between the Channel including two compressors that could operate avoiding disturbance to the local residents. At the
Tunnel in Folkestone and St Pancras station in independently from one another, with associated end of the project, the whole container can be
London, is the first major railway line to be built in ancillary equipment, and additional option of mounting moved to another segment plant, if required for the
Britain since the railway age of the nineteenth frame or container housing. We also needed the same next tunnelling project.
century, and is currently the most important supplier to be able to install the compressed air After a rapid completion by Motivair, the container
infrastructure project in the country. The 109 km pipework inside the segment factory." was transported to the CTRL construction site in
long route is being constructed in two phases. The Stratford, east London, where it will be used to
second construction section includes a 19.8 km Purpose-built provide air to the segment plant for approximately
long, two-track tunnel beneath the Thames and two years. The segment plant produces the concrete
London's northern suburbs. containerised solution segments which make up the tunnel lining.
Ceresola Tunnelbautechnik AG is a Swiss The solution from Motivair not only matched Specifically, the compressed air is used in the plant's
engineering contractor who specialises in precast Ceresola's requirements, but was also the best offer compacting station to lift up and support the steel
concrete segment production plants for tunnelling in terms of price, quality, innovation and technology. moulds as they are vibrated, to ensure compaction of
projects. They are one of the companies awarded the The package comprised two Atlas Copco GA37 Full concrete for the segment production. Air is also used
contract for delivery of the manufacturing plant for Feature compressors, running in a duty-standby in the cleaning of the moulds and for opening and
production of the concrete segments used in the arrangement, and using a common 4000 litre air closing them.
tunnel lining for CTRL on behalf of Union Railways receiver. Because an Atlas Copco Full Feature Section two of the Channel Tunnel Rail Link
(North) Ltd, a subsidiary of London and Continental compressor includes a dryer, filters, aftercooler and construction will be completed by the end of 2006,
Railways Ltd, who is responsible for the construction oil/water separator inside its canopy, the end result is reducing the journey from London St Pancras
of Section Two of the new railway into central London. a source of air free from dirt and oil, with a International to Paris Gare du Nord to around 2
Compressed air is necessary for many applications conveniently small footprint. hours 15 minutes.

Atlas Copco Compressors Limited

Swallowdale Lane, Hemel Hempstead, Herts, HP2 7HA
Telephone: 01442 261201 Fax: 01442 234791
email: [email protected] web: www.atlascopco.co.uk
Freephone: 0800 181 085