Atlas Copco ZR4 Intercooler Kit Replacement – 2906011000

The Atlas Copco 2906011000 is a ZR4 Intercooler Kit designed for applicable oil-free ZR/ZT compressors. The intercooler is part of the multi-stage compression system and reduces the temperature of air between compression stages.

Intercooling is important because compressing air increases its temperature. By cooling the air between stages, the compressor can perform the next compression stage more efficiently and maintain suitable operating temperatures.

Working Process

1. First-Stage Compression – Atmospheric air enters the first compression stage and is compressed.
2. Temperature Increase – Compression raises the air temperature.
3. Intercooler Entry – The hot compressed air flows through the intercooler.
4. Heat Transfer – Heat is transferred from the compressed air to the cooling medium.
5. Air Cooling – The temperature of the compressed air is reduced.
6. Second-Stage Compression – The cooled air enters the next compression stage.
7. Efficient Compression – Cooling between stages reduces the thermal load on the subsequent compression stage.
8. Continuous Cycle – The intercooling process continues while the compressor is operating.

Main Functions

• Services the ZR4 intercooler assembly.
• Maintains reliable sealing of intercooler connections.
• Helps maintain efficient heat transfer.
• Reduces interstage compressed-air temperature.
• Supports efficient multi-stage compression.
• Helps prevent air or cooling-medium leakage.
• Supports stable compressor operating temperatures.
• Helps maintain compressor reliability.

Official Kit Components

Atlas Copco’s official product listing gives the following components:

The official catalog lists the kit weight as 620.06 g.

Role of the Sealing Components

The washers and sealing washers supplied with the kit maintain leak-tight connections around the intercooler assembly.

A deteriorated sealing component can cause:

• Compressed-air leakage
• Cooling-medium leakage
• Pressure loss
• Reduced cooling efficiency
• Contamination around connections

Replacing the service components during scheduled maintenance helps restore the sealing condition.

Possible Failure Symptoms

An intercooler or its seals may deteriorate because of:

• Thermal cycling
• Vibration
• Corrosion
• Contamination
• High operating temperature
• Pressure fluctuations
• Ageing of sealing components
• Incorrect installation

Possible symptoms include:

• Increased interstage temperature.
• Reduced compressor efficiency.
• High discharge temperature.
• Air leakage.
• Cooling-medium leakage.
• Increased energy consumption.
• Temperature alarms.
• Compressor shutdown.

Maintenance Procedure

1. Shut down the compressor according to the applicable Atlas Copco service procedure.
2. Isolate the electrical supply.
3. Fully depressurize the compressor.
4. Allow the intercooler and surrounding components to cool.
5. Isolate the applicable cooling circuit.
6. Remove the intercooler connections.
7. Inspect the intercooler and mating surfaces.
8. Remove worn sealing washers and related components.
9. Clean the mating surfaces.
10. Install the replacement components from 2906011000.
11. Ensure sealing washers are correctly positioned.
12. Reassemble the intercooler according to the applicable service procedure.
13. Restore the air and cooling circuits.
14. Restart the compressor.
15. Check for air/cooling-medium leakage.
16. Monitor interstage and discharge temperatures.

Service Benefits

Using the 2906011000 ZR4 Intercooler Kit during appropriate maintenance helps:

• Restore intercooler sealing.
• Maintain effective interstage cooling.
• Support efficient multi-stage compression.
• Reduce leakage.
• Control compressor operating temperature.
• Improve compressor reliability.
• Reduce maintenance-related downtime.

Technical Summary

Recommended catalog title: Atlas Copco 2906011000 – ZR4 Intercooler Kit for ZR/ZT Oil-Free Compressors, 2906-0110-00.

The official Atlas Copco listing confirms the ZR4 Intercooler Kit, application, weight and service duration.