Atlas Copco Cooler Cleaning Kit for Oil-Free Compressors Replacement – 2906039600

Atlas Copco 2906039600 – Cooler Cleaning Kit for Oil-Free Compressors

The Atlas Copco 2906039600 (2906-0396-00) is a Cooler Cleaning Kit designed for compatible stationary oil-free ZR compressors.

The kit is used during scheduled cooler servicing to restore the sealing condition and service condition of the compressor cooling system. Atlas Copco specifies that this kit can be used for service up to 16,000 operating hours and lists an approximate kit weight of 1 kg.

The cooler system is responsible for removing heat generated during the compression process. Maintaining clean heat-transfer surfaces and properly sealed cooler connections is essential for maintaining efficient compressor cooling.

Working Process:

During normal operation, atmospheric air enters the oil-free compressor and passes through the compression stages.

Compression increases the temperature of the air. In a multi-stage oil-free compressor, the compressed air passes through intercoolers between compression stages and through an aftercooler after the final compression stage.

The coolers transfer heat from the compressed air to the cooling medium.

Over time, dirt, dust and other contaminants can accumulate on cooler surfaces. This contamination can restrict heat transfer and reduce cooling efficiency.

During scheduled maintenance, the 2906039600 Cooler Cleaning Kit is used to service the applicable cooler assembly and replace associated sealing components.

The cooler is cleaned to remove accumulated contamination and restore heat-transfer efficiency.

The O-rings, gaskets, plugs and Dowty sealing washers supplied with the kit help restore leak-tight connections during reassembly.

After servicing, the cooler can transfer heat more effectively, helping maintain the compressor within its required operating-temperature range.

Main Functions:

• Supports scheduled cooler maintenance.
• Helps restore cooler heat-transfer performance.
• Removes accumulated contamination from the cooler system.
• Replaces applicable O-rings and sealing components.
• Helps prevent compressed-air or cooling-medium leakage.
• Supports proper intercooling and aftercooling.
• Helps maintain compressor operating temperature.
• Supports reliable oil-free compressor operation.
• Helps reduce the risk of overheating and thermal shutdown.

Official Kit Components:

Atlas Copco’s official catalog lists the following components in the kit:

• O-ring 39.2 × 3 – 4 pcs
• O-ring 50 × 3.5 – 6 pcs
• O-ring – 1 pc
• O-ring 54.5 × 3 – 1 pc
• O-ring – 1 pc
• O-ring 64.5 × 3 – 1 pc
• O-ring – 2 pcs
• Plug 1/4 A A – 2 pcs
• O-ring – 1 pc
• O-ring – 1 pc
• O-ring – 1 pc
• O-ring 59.5 × 3 – 1 pc
• Gasket – 1 pc
• Aftercooler Kit – 1 pc
• Dowty Seal Washer 1/4 – 6 pcs
• O-ring – 1 pc

Atlas Copco lists the complete kit weight as approximately 1 kg.

Cooler Operating Cycle:

1. Air Intake: Atmospheric air enters the oil-free compressor.
2. First-Stage Compression: Air is compressed and its temperature rises.
3. Intercooling: Hot compressed air passes through an intercooler.
4. Heat Transfer: Heat is transferred from the compressed air to the cooling medium.
5. Temperature Reduction: The compressed-air temperature decreases.
6. Next Compression Stage: The cooled air enters the next compression stage.
7. Final Compression: Air is compressed to the required final pressure.
8. Aftercooling: The final hot compressed air passes through the aftercooler.
9. Final Heat Removal: Additional heat is removed before the compressed air enters the downstream system.
10. Continuous Operation: The cooling cycle continues while the compressor is running.

Importance of Cooler Cleaning:

Cooler surfaces must remain sufficiently clean for efficient heat transfer.

Dust and contamination can form a layer on heat-transfer surfaces. This layer acts as an insulating barrier and reduces the ability of the cooler to remove heat.

A contaminated cooler may result in:

• Higher interstage temperature.
• Higher final discharge temperature.
• Reduced cooling efficiency.
• Increased energy consumption.
• Increased thermal stress.
• High-temperature alarms.
• Compressor shutdown.
• Reduced compressor reliability.

Regular cooler cleaning helps maintain effective heat transfer.

Role of the Sealing Components:

The O-rings and gaskets supplied in the kit provide sealing at the applicable cooler connections.

During cooler maintenance, existing seals may become hardened, compressed or damaged.

Replacing them helps:

• Prevent air leakage.
• Prevent cooling-medium leakage.
• Maintain pressure integrity.
• Maintain proper cooler operation.
• Reduce the risk of repeated leakage after service.

The 1/4-inch plugs close applicable openings, while the Dowty seal washers provide sealing at the relevant threaded connections.

Role of the Aftercooler Kit:

The included Aftercooler Kit supports servicing of the final cooling stage.

After final compression, compressed air remains hot. The aftercooler removes additional heat before the air is delivered to the downstream compressed-air system.

Effective aftercooling helps reduce the temperature of delivered compressed air and supports downstream equipment.

Possible Failure Conditions:

Cooler performance can deteriorate due to:

• Dust accumulation.
• Dirt contamination.
• Restricted airflow.
• Fouling of heat-transfer surfaces.
• Corrosion.
• Mechanical damage.
• Damaged O-rings.
• Deteriorated gaskets.
• Leakage.
• Reduced cooling-medium flow.

Possible symptoms include:

• High discharge temperature.
• High interstage temperature.
• High-temperature alarms.
• Reduced compressor efficiency.
• Increased energy consumption.
• Compressor thermal shutdown.
• Air or cooling-medium leakage.
• Reduced aftercooling performance.

Similar symptoms can also be caused by fans, cooling-water systems, temperature sensors, airflow restrictions or other components, so proper diagnosis is required.

Cooler Cleaning & Maintenance Procedure:

Before maintenance, stop the compressor using the normal shutdown procedure.

Isolate the electrical supply and applicable cooling/pneumatic energy sources.

Depressurize the relevant systems and allow hot components to cool to a safe working temperature.

Inspect the cooler assembly for:

• Dust and dirt accumulation.
• Blocked passages.
• Corrosion.
• Mechanical damage.
• Leakage.
• Damaged seals.
• Restricted cooling airflow.
• Contaminated heat-transfer surfaces.

Clean the cooler according to the applicable Atlas Copco maintenance procedure.

Remove old O-rings, gaskets, plugs and sealing washers where required.

Clean all mating and sealing surfaces.

Install the replacement components supplied with the 2906039600 Cooler Cleaning Kit.

During assembly:

• Ensure O-rings are correctly seated.
• Do not twist or cut O-rings.
• Install gaskets in the correct position.
• Install Dowty washers correctly.
• Install plugs in their designated locations.
• Ensure the aftercooler components are correctly assembled.
• Verify that cooling passages are unobstructed.
• Secure all applicable connections correctly.

After reassembly, perform the required leak and functional checks.

Restart the compressor and allow it to reach normal operating conditions.

Monitor:

• Interstage temperature.
• Final discharge temperature.
• Cooling performance.
• Cooling-medium flow.
• Airflow.
• Compressor pressure.
• Leakage.
• Abnormal noise.
• Overall compressor stability.

Service Benefits:

Using the Atlas Copco 2906039600 Cooler Cleaning Kit during appropriate scheduled maintenance helps:

• Restore cooler heat-transfer efficiency.
• Maintain proper compressor temperatures.
• Improve intercooling and aftercooling performance.
• Reduce overheating risk.
• Reduce thermal stress.
• Restore cooler sealing.
• Reduce air/cooling-medium leakage.
• Support compressor efficiency.
• Improve operating reliability.
• Reduce unplanned downtime.

Part Number: 2906039600
Alternative Number: 2906-0396-00 / 2906 0396 00
Brand: Atlas Copco
Official Description: Cooler Cleaning Kit for Oil-Free Compressors
Application: Stationary oil-free compressors / ZR
Service Capability: Up to 16,000 operating hours
Official Listed Weight: 1 kg
Component Type: Cooler cleaning and service kit
Primary Function: Supports cleaning and servicing of compressor coolers
Main Components: O-rings, gasket, aftercooler kit, plugs and Dowty seal washers
Main Benefits: Improved heat transfer, reliable cooling, reduced leakage, controlled compressor temperature and dependable oil-free compressor operation.

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