Compresor de aire de tornillo rotativo sin aceite Atlas Copco ZR 200 VSD (FF VSD⁺)

Descripción

The Atlas Copco ZR 200 VSD is the water-cooled entry of the ZR/ZT 200-355 VSD+ oil-free range, a 200 kW rotary screw compressor whose compression duty is split across two 100 kW modules. The compression chambers run completely free of oil, the package carries the ISO 8573-1 CLASS 0 (2010) certification, and the dual NEOS drives regulate the machine from 11 to 100 percent of load without ever running unloaded.

The single 10.4 bar(e) class covers free air delivery from 208 to 696 l/s across its minimum, effective and maximum settings. Water cooling carries the heat of compression out of the machine room through a closed circuit, which keeps the 72 dB(A) package compact and stable in hot environments. The Full Feature builds complete the picture, with the iMD or iMDG heat-of-compression dryer integrated inside the delivery.

Where the ZR 200 VSD Sits in the Oil-Free Range

The ZR/ZT 200-355 VSD+ range serves the plants whose oil-free demand has outgrown the 110-160 class and now runs continuously at industrial scale, and the ZR 200 VSD carries 200 kW of installed motor power at the entry of the range. The water-cooled machines of that previous line run the ZR 160 VSD. La letra Z indica que se trata de un sistema sin aceite: los elementos de compresión nunca inyectan aceite en el flujo de aire, por lo que no se produce ningún arrastre de aceite hacia el proceso.

Atlas Copco pioneered oil-free air technology over sixty years and became the first manufacturer awarded CLASS 0 certification. The ZR 200 VSD brings that standard into the 200 kW class through two identical compression modules that share the load, a design that keeps the elements small, the rotors efficient and the service items grouped. Plants that prefer air cooling instead of a water circuit run the ZT 200 VSD of the same rating.

Mínimo, efectivo y máximo

Cada valor de la clase de 10,4 bar(e) abarca un intervalo, y cada fila de las tablas oficiales aporta un dato:

• Mínimo: el ajuste de presión de trabajo más bajo, en el que la máquina ofrece su mayor caudal de aire libre para redes que funcionan en un amplio rango de presión.
• Efectivo: el ajuste nominal de la red, en el que los accionamientos duales equilibran el caudal y la presión para el perfil de carga diario.
• Máximo: la presión de trabajo máxima de su clase, en la que el sistema sigue proporcionando un caudal estable incluso en los puntos más exigentes de la planta.

Every setting combines with the standard Pack or with one of the two Full Feature builds that integrate a heat-of-compression dryer. The sections below present the rated data of each build in the printed 50 Hz and 60 Hz tables.

Technical Specifications of the ZR 200 VSD

The table below condenses the ZR 200 VSD into its headline figures:

Datos nominales del equipo VSD+

El rendimiento de la unidad se mide según la norma ISO 1217, anexo E, 4.ª edición (2009), con el caudal de aire libre referenciado a la presión de trabajo efectiva. La tabla para 50 Hz indica lo siguiente:

La tabla de 60 Hz muestra los mismos datos de la máquina en psig y cfm, con la potencia nominal del motor en hp:

The noise level is the A-weighted emission sound pressure level at the work station, measured according to ISO 2151:2008 using ISO 9614-2, with a total uncertainty value of 3 dB(A). The Pack carries the value 72 dB(A), and the two modules deliver the installed power of 200 kW at 50 Hz and 268 hp at 60 Hz.

Datos nominales de la versión iMD con todas las funciones

La versión «Full Feature», equipada con el secador por adsorción iMD, amplía el ajuste mínimo a 6 bar(e) y mantiene los ajustes efectivos y máximos propios de su clase. La tabla para 50 Hz indica lo siguiente:

A continuación se muestra la tabla de 60 Hz de la versión iMD:

Across the printed settings the iMD build delivers up to 689 l/s at its widest band, and the sound pressure level holds at 72 dB(A) at the work station.

Datos nominales del paquete iMDG Split

The iMDG build pairs the compressor package with the drum dryer as two coordinated units. The rated data of the compressor side reads as follows at 50 Hz:

At 60 Hz the iMDG table prints the minimum setting at 87 psig, the effective setting at 102 psig and the maximum at 151 psig, with free air delivery from 209 to 689 l/s (443 to 1459 cfm) across the band. The installed motor power reads 270 hp at 60 Hz.

Dimensiones y peso

Three configurations cover the delivery of the ZR 200 VSD, and the water-cooled design keeps every footprint compact:

The Pack fits a three-meter length, and the integrated iMD build stretches the frame to hold the dryer without widening the floor area. The iMDG configuration splits the weight between the compressor package and the dryer unit, which eases the rigging plan of plants that stage the installation in two steps.

Dos unidades NEOS sin pérdidas por descarga

The VSD+ concept of the ZR 200 VSD rests on two NEOS inverters that regulate the two compression modules together. The machine operates from 11 to 100 percent of load without wasting energy on unloaded running, the widest operating range on the market today, and the energy savings reach up to 35 percent during periods of low to medium air demand.

Another advantage of the dual NEOS drives is that the ZR 200 VSD always works at optimal efficiency at any pressure, where standard fixed speed and VSD machines hold a fixed gear ratio. The Permanent Magnet motor is water-cooled with oil lubricated bearings, and its rock-solid construction prevents dust and water from entering the windings. The two drives and the motor live inside the compressor frame as one engineered unit, which keeps the electrical installation to a single connection point.

La refrigeración por agua y el recorrido del aire en dos etapas

The air of the ZR 200 VSD passes two compression stages. It enters through the inlet filter, is compressed to an intermediate pressure, and flows through the pulsation dampener to the intercooler. After the intercooler, an automated moisture separation system removes the condensate before the air enters the high-pressure stage, where the pressure is brought to its final level.

The cooling water splits through the circuit in three directions. It flows to the intercooler and aftercooler that lower the temperature of the compressed air, and to the oil coolers that hold the oil temperature at its optimum. It also passes through the jackets of the motor and the elements, where it guarantees an optimal operating temperature.

The oil circuit pumps clean, cooled oil through a high efficiency filter to the gears for lubrication. The bypass valves protect the filter and keep the oil pressure stable across the load range.

Pureza del aire de clase 0 para procesos críticos

The ZR 200 VSD belongs to the oil-free range certified according to ISO 8573-1 CLASS 0 (2010). CLASS 0 is the most stringent class of the standard: the total oil concentration is as specified by the equipment user or supplier and more stringent than class 1. The unique Z seal design guarantees efficient and 100 percent certified oil-free air, because only oil-free machines exclude contamination risks 100 percent.

That certification is what makes the ZR 200 VSD the default choice where a single trace of oil costs a batch: food and beverage lines running fermentation, packaging and filling, electronics plants cleaning chips and boards, chemical and petrochemical operations in extreme heat and humidity, and pharmaceutical production from fermentation to bottling.

El secador integrado por calor de compresión

In the Full Feature builds, the dryer eliminates the moisture before the air enters the network. In the iMD build the whole drying function lives inside the compressor package, which saves installation space and removes the pressure drop of external piping.

In the iMDG build the drum dryer runs as the coordinated second unit: 60 percent of the main air flow is cooled in the precooler and aftercooler, while the remaining flow regenerates the adsorption drum with the heat of compression. No external energy is needed to dry the air in either build.

The cooled air leaving the regeneration section mixes with the flow from the aftercooler before it passes the drying section of the drum. Dry air with a guaranteed dew point leaves the compressor through the outlet connection flange, and zero loss drains clear all water and contamination from the circuit, so no compressed air is wasted at any drain point.

Control y supervisión

El controlador Elektronikon Mk5 Touch gestiona el compresor y el secador integrado desde una única pantalla táctil. El sistema ahorra energía gracias a la parada retardada, que detiene el compresor siempre que es posible; a la banda de presión dual, que reduce la presión de la red durante los fines de semana y por la noche; a los ajustes automáticos de la velocidad del motor principal, que se adaptan a la demanda de aire; y a la adaptación de la velocidad del secador en función de las necesidades reales.

SMARTLINK connects the ZR 200 VSD to the monitoring platform of the plant. Customized reports show the energy efficiency of the compressor room, early warnings avoid breakdowns and production loss, and all components are replaced on time to ensure maximum uptime.

Opciones y soluciones de ingeniería

The option list of the ZR 200 VSD tailors the package to the plant:

• Energy recovery — the heat of compression captured for heating or process water.
• Silicone-free rotor and high ambient temperature version — for specified processes and hot installations.
• Kit para la purga de aire seco durante las paradas: protege los componentes en condiciones de humedad o de funcionamiento intermitente.
• Almohadillas de anclaje, conectividad a la red informática, embalaje protector en caja de madera, certificado de pruebas y prueba de rendimiento presenciada: para una instalación controlada y una aceptación documentada.

Un equipo especializado en personalización diseña soluciones técnicas para temperaturas extremas y ubicaciones remotas, y antes de formalizar el pedido se comprueba la disponibilidad de todas las opciones en función de la configuración elegida.

Applications of the ZR 200 VSD

Food and beverage plants run the ZR 200 VSD for fermentation, aeration, transportation, filling and capping, where the CLASS 0 certification removes the contamination risk from the audit trail. Electronics manufacturers use the clean, dry air for removing microscopic debris from chip and board surfaces, and chemical sites value the machine’s ability to run in extreme temperatures and humidity conditions around the clock.

Pharmaceutical production completes the picture, from fermentation and tablet coating to packing and bottling, where 100 percent oil-free air protects both the process and the brand. Where the demand of the network grows beyond one machine, the plant adds a second ZR 200 VSD, and the Optimizer central controller regulates the group as one unit with the narrowest pressure band.

Service and Support Around the ZR 200 VSD

The ZR 200 VSD is built for long overhaul intervals, few service interventions and minimal maintenance cost. The hinged doors give easy access to all components, the service items are grouped together to minimize service time, and every machine is tested before delivery to ensure it meets the specifications. A global service operation with field service engineers across 160 countries backs the installed base.

Seadweer supplies genuine Atlas Copco spare parts and service kits for the ZR 200 VSD and its Full Feature builds. Send us the compressor model together with the parts you need, and the correct items are confirmed with the quotation in one pass.

Preguntas frecuentes

What does the ZR 200 VSD deliver at maximum pressure?

At the maximum setting of 10.4 bar(e) the Pack delivers 208 to 528 l/s, and across the full minimum-to-maximum band it covers 208 to 696 l/s. Free air delivery is referenced to the effective working pressure according to ISO 1217, Annex E, edition 4 (2009).

Is the ZR 200 VSD water-cooled?

Yes. The ZR letter marks the water-cooled branch of the ZR/ZT range: the cooling water carries the heat of compression out of the frame, the package holds 72 dB(A) at the work station, and the air-cooled equivalent is the ZT 200 VSD. Plants without a cooling water main run the ZT branch instead.

¿Hasta qué punto está libre de aceite el aire?

The ZR 200 VSD carries the ISO 8573-1 CLASS 0 (2010) certification, the most stringent class of the standard. The Z seal design and the oil-free compression chambers keep every form of oil out of the air stream, so no oil carry-over reaches the process.

¿Cuál es la diferencia entre iMD e iMDG?

Both Full Feature builds dry the air with the heat of compression. The iMD dryer lives inside the compressor package as one unit, while the iMDG build pairs the compressor with the drum dryer as two coordinated units with the weight split between them, and the rated data of both builds stays inside the same 10.4 bar(e) class.

¿Hasta qué punto puede bajar la máquina?

Los accionamientos duales NEOS regulan los dos módulos entre el 11 % y el 100 % de la carga sin funcionamiento en vacío, lo que supone el rango de funcionamiento más amplio del mercado. Dado que el diseño de accionamiento dual sustituye a la relación de transmisión fija, la máquina funciona con una eficiencia óptima a cualquier presión, y el ahorro energético alcanza hasta un 35 % en condiciones de demanda baja a media.

How loud is the ZR 200 VSD?

The sound pressure level at the work station reads 72 dB(A). The value follows ISO 2151:2008 with the ISO 9614-2 method and carries a total uncertainty value of 3 dB(A).