Atlas Copco Intercooler Kit for Oil-Free Compresso Replacement – 2906014500

Atlas Copco 2906014500 – Intercooler Kit for Oil-Free Compressors

The Atlas Copco 2906014500 (2906-0145-00) is an Intercooler Kit designed for compatible Atlas Copco ZR oil-free compressors.

The intercooler is an important component in a multi-stage compression system. Its primary function is to reduce the temperature of compressed air between compression stages. By removing heat from the air after the first compression stage, the intercooler helps improve the efficiency of the subsequent compression stage and assists in controlling compressor operating temperatures.

The official Atlas Copco catalog lists the kit weight as approximately 2.93 kg and identifies it for stationary oil-free compressors/ZR applications, with use up to 8,000 hours.

Working Process:

During operation, atmospheric air enters the first compression stage of the ZR oil-free compressor.

The first compression stage increases the pressure of the incoming air. As the air is compressed, its temperature also rises significantly.

The hot compressed air then flows into the intercooler.

Inside the intercooler, heat is transferred from the compressed air to the cooling medium. This reduces the temperature of the air before it enters the next compression stage.

Cooling the air between stages reduces the work required for subsequent compression and helps maintain suitable operating temperatures.

The cooled air then enters the second compression stage, where it is compressed further to achieve the required final pressure.

The intercooler therefore operates continuously whenever the compressor is producing compressed air.

Main Functions:

• Cools compressed air between compression stages.
• Reduces interstage air temperature.
• Improves the efficiency of multi-stage compression.
• Helps control compressor operating temperatures.
• Protects downstream compression components from excessive heat.
• Supports stable compressor performance.
• Helps maintain reliable oil-free compressed-air production.
• Provides a complete service package for intercooler maintenance.

Kit Components:

Atlas Copco’s official catalog lists multiple sealing and fastening components in the 2906014500 Intercooler Kit, including:

• Gaskets
• Seal washers
• Lock washers
• O-rings
• Seals
• Dowty seal washers
• Gasket 13 × 20 × 1.5
• Gasket 33 × 39 × 2

The official listing specifies quantities for the individual components and gives the complete kit weight as 2.93 kg.

Intercooler Operating Cycle:

1. Air Intake: Atmospheric air enters the first compression stage.
2. First-Stage Compression: The air is compressed and its temperature increases.
3. Hot-Air Transfer: The hot compressed air enters the intercooler.
4. Heat Transfer: Heat moves from the compressed air to the cooling medium.
5. Air Cooling: The temperature of the compressed air decreases.
6. Second-Stage Entry: The cooled air enters the next compression stage.
7. Final Compression: The air is compressed to the required final pressure.
8. Compressed-Air Delivery: The final compressed air proceeds to the downstream system.

Importance of the Intercooler:

Interstage cooling is important because compression naturally increases air temperature.

If the intercooler does not remove sufficient heat, the temperature entering the second compression stage can become excessive.

This can result in:

• Increased compressor temperature.
• Reduced compression efficiency.
• Increased thermal stress.
• Increased load on downstream components.
• Reduced compressor reliability.
• Possible high-temperature alarms or shutdowns.

A properly functioning intercooler helps maintain the intended temperature and efficiency of the compression process.

Importance of the Sealing Components:

The intercooler assembly contains multiple connections and sealing interfaces.

The gaskets, O-rings, seals and seal washers supplied in the 2906014500 kit maintain leak-tight connections.

Over time, sealing components can experience:

• Hardening
• Compression set
• Thermal ageing
• Cracking
• Surface damage
• Contamination
• Loss of elasticity

A deteriorated seal can allow compressed air or cooling medium to escape.

Replacing the sealing components during intercooler service helps restore the integrity of the assembly.

Possible Failure Conditions:

Potential intercooler-related problems include:

• Air leakage.
• Cooling-medium leakage.
• Restricted heat transfer.
• Fouling or contamination.
• Damaged sealing surfaces.
• Deteriorated gaskets.
• Damaged O-rings.
• Loose or damaged connections.
• Excessive interstage temperature.

Possible compressor symptoms may include:

• Increased interstage temperature.
• Reduced compressor efficiency.
• Abnormal temperature readings.
• Reduced air delivery.
• Air leakage around intercooler connections.
• Cooling-medium leakage.
• Increased operating temperature.
• High-temperature alarms.

These symptoms should be diagnosed carefully because temperature and leakage problems may also originate from other components in the cooling or compression system.

Maintenance Procedure:

Before servicing the intercooler, stop the compressor and isolate the electrical and pneumatic energy sources according to the applicable Atlas Copco safety procedure.

Completely depressurize the compressor and allow hot components to cool to a safe working temperature.

Inspect the intercooler for:

• Leakage
• Corrosion
• Contamination
• Damaged connections
• Damaged sealing surfaces
• Worn gaskets
• Worn O-rings
• Damaged washers
• Signs of overheating

Remove the applicable old sealing and service components.

Clean the mating and sealing surfaces.

Install the replacement gaskets, O-rings, seals, washers and other components supplied with the 2906014500 Intercooler Kit.

During installation:

• Ensure all O-rings are correctly seated.
• Do not twist or damage sealing rings.
• Ensure gaskets are correctly positioned.
• Install seal washers in their correct locations.
• Check all mating surfaces for damage.
• Correctly secure the applicable fasteners.
• Keep the intercooler circuit free from foreign material.

After assembly, perform the applicable pressure and leakage checks.

Restart the compressor according to the manufacturer’s operating procedure.

Monitor:

• Interstage temperature
• Discharge temperature
• Air pressure
• Airflow
• Cooling performance
• Leakage
• Abnormal vibration
• Abnormal noise

The intercooler should provide stable temperature reduction during normal compressor operation.

Service Benefits:

Using the Atlas Copco 2906014500 Intercooler Kit during appropriate maintenance helps:

• Restore intercooler sealing.
• Reduce air and cooling-medium leakage.
• Maintain effective interstage cooling.
• Support compressor efficiency.
• Reduce thermal stress.
• Protect downstream compression components.
• Maintain reliable oil-free compressor operation.
• Reduce the risk of unexpected downtime.

Part Number: 2906014500
Alternative Number: 2906-0145-00 / 2906 0145 00
Brand: Atlas Copco
Official Description: Intercooler Kit for Oil-Free Compressors
Application: Stationary oil-free compressors / ZR
Service Use: Up to approximately 8,000 operating hours
Official Listed Weight: 2.93 kg
Component Type: Intercooler service kit
Primary Function: Supports interstage cooling and intercooler servicing
Main Components: Gaskets, seals, O-rings, seal washers, Dowty washers and lock washers
Operating Function: Maintains leak-tight intercooler connections while supporting effective heat removal between compression stages
Main Benefits: Reliable interstage cooling, restored sealing, reduced leakage, improved compressor efficiency and dependable compressor operation.

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