Atlas Copco ZR110–145 Intercooler Kit Replacement – 2906073200

Atlas Copco 2906073200 – ZR110–145 Intercooler Kit

The Atlas Copco 2906073200 (2906-0732-00) is an Intercooler Kit designed for compatible ZR110–145 oil-free compressors.

The intercooler is an essential part of 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 next compression stage and assists in maintaining suitable compressor operating temperatures.

The kit is primarily a service and sealing kit containing replacement O-rings, plugs and Dowty seal washers required for servicing the intercooler assembly. Atlas Copco’s official catalog lists the kit weight as approximately 475 g.

Working Process:

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

The first-stage compression increases both the pressure and temperature of the air.

The hot compressed air then passes through 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 the following compression stage and helps control the thermal load on the compressor.

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

The intercooler operates continuously while the compressor is running.

The sealing components contained in 2906073200 maintain leak-tight connections around the intercooler. Over time, O-rings and sealing washers can deteriorate due to temperature cycling, pressure fluctuations and ageing.

During service, these components are replaced to restore the sealing integrity of the intercooler assembly.

Main Functions:

• Supports servicing of the ZR110–145 intercooler.
• Maintains leak-tight intercooler connections.
• Replaces worn or deteriorated O-rings.
• Replaces applicable plugs.
• Replaces Dowty sealing washers.
• Helps prevent compressed-air leakage.
• Helps prevent leakage at intercooler connections.
• Supports effective interstage cooling.
• Helps maintain reliable compressor performance.

Official Kit Components:

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

• O-ring – 1 pc
• O-ring – 1 pc
• O-ring – 1 pc
• O-ring – 1 pc
• Plug 1/4 A A – 2 pcs
• O-ring – 1 pc
• O-ring – 2 pcs
• O-ring – 1 pc
• Dowty Seal Washer 1/4 – 2 pcs

The official listed kit weight is approximately 475 g.

Intercooler Operating Cycle:

1. Air Intake: Atmospheric air enters the compressor.
2. First-Stage Compression: The first-stage element compresses the air.
3. Temperature Increase: Compression causes the air temperature to rise.
4. Intercooler Entry: Hot compressed air enters the intercooler.
5. Heat Transfer: Heat is transferred from the compressed air to the cooling medium.
6. Air Cooling: The compressed-air temperature is reduced.
7. Second-Stage Entry: The cooled air moves to the next compression stage.
8. Final Compression: The air is compressed to the required pressure.
9. Compressed-Air Delivery: The final compressed air continues to the downstream system.

Role of the 2906073200 Service Components:

The intercooler contains several connection points and sealing interfaces.

The O-rings provide sealing between mating components and prevent air or cooling-medium leakage.

The 1/4-inch plugs close or service the applicable openings in the intercooler assembly.

The Dowty seal washers provide reliable sealing around applicable threaded connections.

Together, these components help maintain the pressure integrity of the intercooler system.

Importance of Intercooler Sealing:

The intercooler operates under pressure, making effective sealing essential.

A damaged or hardened O-ring can allow compressed air or cooling medium to escape.

Potential consequences include:

• Reduced compressor efficiency.
• Loss of compressed air.
• Cooling-medium leakage.
• Increased interstage temperature.
• Reduced intercooling performance.
• Increased thermal load.
• Unstable compressor operation.

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

Possible Failure Conditions:

The service components can deteriorate because of:

• Temperature cycling
• Pressure fluctuations
• Ageing
• Compression set
• Contamination
• Improper installation
• Mechanical damage
• Damaged sealing surfaces

Possible symptoms include:

• Air leakage around intercooler connections.
• Cooling-medium leakage.
• Increased interstage temperature.
• Reduced compressor efficiency.
• Abnormal pressure behavior.
• Visible contamination around connection points.
• Repeated leakage after previous service.

Leakage should be diagnosed carefully because nearby fittings, tubing, gaskets or other components may produce similar symptoms.

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 assembly for:

• Damaged O-rings
• Worn sealing surfaces
• Damaged plugs
• Damaged Dowty washers
• Corrosion
• Contamination
• Air leakage
• Cooling-medium leakage

Remove the old service components carefully.

Clean all relevant mating and sealing surfaces.

Install the replacement O-rings, plugs and Dowty seal washers supplied in the 2906073200 Intercooler Kit.

During installation:

• Ensure O-rings are correctly seated.
• Do not twist or cut O-rings.
• Check that sealing surfaces are clean.
• Install plugs in their correct locations.
• Install Dowty washers correctly.
• Secure all applicable connections properly.
• Keep the intercooler circuit free from foreign material.

After reassembly, perform the applicable pressure and leak checks.

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

Monitor:

• Interstage temperature
• Discharge temperature
• Air pressure
• Airflow
• Cooling performance
• Air leakage
• Cooling-medium leakage
• Abnormal vibration
• Abnormal noise

A properly serviced intercooler should provide stable temperature reduction and maintain leak-tight connections during normal compressor operation.

Service Benefits:

Using the Atlas Copco 2906073200 Intercooler Kit during appropriate maintenance helps:

• Restore intercooler sealing.
• Reduce compressed-air leakage.
• Reduce 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: 2906073200
Alternative Number: 2906-0732-00 / 2906 0732 00
Brand: Atlas Copco
Official Description: Intercooler Kit for ZR/ZT Oil-Free Compressors
Application: ZR110–145 oil-free compressors
Component Type: Intercooler service/sealing kit
Official Listed Weight: 475 g
Primary Function: Supports servicing and sealing of the intercooler assembly
Main Components: O-rings, 1/4-inch plugs and Dowty seal 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 and dependable compressor performance.

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