Atlas Copco Compressor Cooler ZR250

1. Product Overview

Atlas Copco (Atlas Copco), as a global leader in air compressor manufacturing, offers the ZR250 series oil-free screw air compressor cooler as a core component in industrial compressed air systems. The ZR250 cooler utilizes multi-stage compression and efficient heat exchange technology to rapidly dissipate heat generated during compression, ensuring stable operation in constant temperature environments. This cooler is designed to be compatible with multiple models in the ZR250 series, including standard models, variable speed models (VSD), and different pressure versions (such as 8.6bar and 10bar), meeting operational requirements for exhaust volumes of 40-50.46m³/min.

Core Functional Positioning

• Heat Load Capacity: Designed for the 250kW motor power of ZR250 models, the cooler achieves heat exchange for over 40m³ of compressed air per minute, controlling outlet air temperature within 15°C above ambient temperature.
• Environmental Protection & Energy Efficiency: Features dual water/air cooling modes with oil-free compression technology, eliminating lubrication oil leakage risks and meeting clean air standards for pharmaceutical and food industries.
• System Integration: Works with compressor main units, dryers, and filters to form a complete compressed air post-treatment system, ensuring end-use air quality compliance.

2. Technical Features & Data Specifications

1. Structural Design Parameters

• Cooling Methods:
  • Water-Cooled: For environments ≥35°C or high-altitude areas, requiring cooling water flow ≥15L/min with inlet water temperature ≤32°C.
  • Air-Cooled: Uses axial fan forced convection with air volume ≥8000m³/h, noise ≤75dB(A), suitable for industrial environments with dust concentration ≤50mg/m³.
• Heat Exchange Efficiency:
  • High-efficiency copper tube fin heat exchanger with heat transfer coefficient ≥200W/(m²·K), 30% more efficient than traditional aluminum heat exchangers.
  • Water-cooled models reduce compressed air temperature from 120°C to ≤40°C with an 80°C temperature gradient.
• Materials & Manufacturing:
  • Heat exchange tubes made of TP304 stainless steel with corrosion resistance meeting ASTM A249 standards, service life ≥10 years.
  • 2.5mm fin spacing with hydrophilic aluminum foil coating improves anti-scaling performance by 40%.

2. Performance Data Indicators

Parameter	Value Range	Test Conditions
Rated Exhaust Volume	40-50.46m³/min (8.6-10bar)	ISO 1217 Standard Conditions (20°C, 1bar)
Cooling Water Flow (Water-Cooled)	15-25L/min	Inlet Water 32°C, Outlet ≤40°C
Fan Power (Air-Cooled)	3-5.5kW	Ambient Temperature 40°C
Pressure Drop	≤0.03MPa	Full Load Operation
Protection Rating	IP55	Compliant with IEC 60529 Standard

3. Innovative Technology Applications

• Intelligent Temperature Control: Integrated DTC control panel monitors cooling water temperature, flow rate, and heat exchanger surface temperature in real-time, automatically adjusting fan speed or water valve opening to reduce energy consumption by 15%.
• Modular Design: Flange connection between cooler and compressor main unit allows online replacement, reducing maintenance time to under 2 hours.
• Freeze Protection: Water-cooled models feature electric heating strips and temperature sensors that activate freeze protection when ambient temperature ≤5°C, preventing heat exchange tube cracking.

3. Application Scenarios & Case Studies

1. Industry Applications

• Electronics Manufacturing: Provides ≤-40°C dew point air for wafer dicing and PCB printing processes, preventing electrostatic discharge risks.
• Pharmaceutical Industry: A vaccine manufacturer using ZR250VSD variable speed models maintains compressed air oil content below 0.003mg/m³, meeting GMP certification requirements.
• Aerospace: Aircraft brake system testing requires 0.8MPa high-pressure air supply, with the cooler supporting ZR250-7 models for 72-hour continuous stable air supply with pressure fluctuation ≤±0.02MPa.
• Chemical Industry: During polyethylene reactor pressurization, the cooler withstands 150°C high-temperature gas impact while optimizing fin structure to reduce thermal stress below 120MPa.

2. Detailed Case Analysis

• Case 1: Semiconductor Packaging Plant
  • Problem: Oil-injected screw compressors caused chip yield to drop to 85% due to oil content.
  • Solution: Upgraded to ZR250VSD with water-cooled cooler reduced oil content to 0.001mg/m³, increasing yield to 98% with annual cleaning cost savings of ¥2 million.
  • Data: Cooler outlet temperature decreased from 95°C to 38°C with 22% energy reduction.
• Case 2: New Energy Vehicle Battery Plant
  • Problem: Electrode coating required stable -60°C dew point air, but original equipment's 0.08MPa pressure drop caused uneven coating thickness.
  • Solution: ZR250 cooler + adsorption dryer combination optimized pressure drop to 0.02MPa with ±2°C dew point stability, improving battery capacity consistency by 15%.

4. Maintenance Strategies

1. Routine Maintenance

• Cooling Water Quality Management:
  • Hardness ≤150ppm, pH 6.5-8.5, tested monthly.
  • Corrosion inhibitors (e.g., molybdate) maintained at 50-100ppm concentration.
• Filter Replacement Cycles:
  • Air Filters: Replace every 2000 hours or when pressure difference reaches 0.05MPa.
  • Cooling Water Strainers: Clean every 500 hours, replace every 3000 hours.

2. Comprehensive Maintenance Plan

Maintenance Level	Interval	Key Procedures	Material Cost
Level 1	8000 hours	Clean heat exchanger scale, inspect fan bearing clearance	¥8,000
Level 2	16000 hours	Replace seals, measure heat exchange tube wall thickness	¥15,000
Overhaul	40000 hours	Replace fin assemblies, test heat exchange efficiency	¥35,000

3. Troubleshooting & Repair

• Common Issue 1: High Outlet Temperature
  • Causes: Scale buildup, fan failure, insufficient cooling water flow.
  • Solutions:
    1. Chemical cleaning with EDTA tetrasodium (5% concentration, 60°C, 4-hour circulation).
    2. Replace faulty fans (recommended: EBM-PAPST model 4826N).
• Common Issue 2: Cooler Leakage
  • Detection: Charge with nitrogen to 0.5MPa, maintain pressure for 24 hours - acceptable if pressure drop ≤0.01MPa.
  • Repair: Mechanical tube expansion + high-frequency brazing composite process, post-repair pressure test must withstand 1.5x working pressure.

5. Conclusion

The Atlas Copco ZR250 cooler delivers an efficient, reliable, low-maintenance industrial cooling solution through multi-stage compression heat management, modular design, and intelligent control systems. Its dual water/air cooling modes adapt to various conditions while oil-free operation meets high cleanliness requirements in electronics, pharmaceuticals, aerospace and other advanced manufacturing sectors. With proper maintenance, the equipment achieves ≥15-year service life and 30% lower lifecycle costs than conventional models. As industries pursue carbon neutrality goals, the ZR250 cooler's energy efficiency makes it the premier choice for compressed air system upgrades.