Compresor de aire de tornillo rotativo sin aceite Atlas Copco ZT 90 VSD

Descripción

El Atlas Copco ZT 90 VSD es el modelo con variador de velocidad y refrigeración por aire que encabeza la gama de compresores sin aceite ZT 55-90. Comprime el aire hasta alcanzar una calidad 100 % libre de aceite a través de dos etapas sin aceite, y su variante «Full Feature» incorpora un secador de adsorción IMD integrado, de modo que el conjunto suministra aire seco desde una única unidad. Las versiones cubren dos rangos de presión en 50 Hz y 60 Hz, y todas las variantes cuentan con la certificación ISO 8573-1 Clase 0 (2010).

Un paquete refrigerado por aire de la gama Z sin aceite

La gama de compresores de tornillo sin aceite por debajo de los 100 kW se articula en torno a la plataforma ZT 55-90, y el modelo ZT 90 VSD constituye el modelo de mayor potencia, con 90 kW / 120 hp. La letra ZT identifica la versión refrigerada por aire de la plataforma, mientras que la ZR, del mismo bastidor, es la versión refrigerada por agua, y ambas comparten el sistema de dos etapas elemento sin aceite y el enfoque técnico de la plataforma. La refrigeración se lleva a cabo a través de la amplia sección de refrigeración situada en el interior del equipo, por lo que la máquina no necesita ningún circuito externo de agua de refrigeración en las instalaciones.

VSD y VSD FF: qué abarca cada término

Hay dos nombres que describen las ramas del ZT 90 VSD, y cada uno aporta un dato:

• VSD (variador de velocidad): el variador ajusta la velocidad del motor principal en función de la demanda de aire, lo que mantiene estable el rango de presión y reduce el consumo energético a carga parcial.
• VSD FF — Características completas: el paquete integra un secador por adsorción IMD, por lo que el secado se produce dentro del compresor en lugar de junto a él, sin necesidad de aire de instrumentación externo.

Cada modelo se fabrica en dos versiones de presión, el ZT 90 VSD – 8,6 y el ZT 90 VSD – 10,4, y toda la gama está disponible tanto en 50 Hz como en 60 Hz.

Especificaciones técnicas del ZT 90 VSD

La tabla siguiente resume las principales características del ZT 90 VSD:

Datos nominales a 50 Hz y 60 Hz

Cada versión de presión del ZT 90 VSD se presenta con tres ajustes, y el intervalo de FAD dentro de cada fila abarca todo el rango de velocidades del VSD en ese ajuste. Las cifras proceden de las fichas técnicas de 50 Hz:

The 60 Hz data sheets for the ZT 90 VSD list the same working pressures, FAD spans and sound levels as the 50 Hz sheets, so the table above reads the same for both frequencies.

The 8.6 bar(e) version peaks at 293.9 l/s (622.7 cfm) on its minimum setting, and the 10.4 bar(e) version peaks at 289.5 l/s (613.4 cfm). Within one version, moving from the minimum to the maximum pressure setting costs about 39 l/s of peak flow. The installed motor power stays at 90 kW / 120 hp across all settings and both frequencies.

Datos nominales de la versión VSD+

The VSD+ build extends the ZT 90 VSD in the 10.4 bar class with dual NEOS drives and a permanent magnet motor. The dual drive system regulates the machine from 28 to 100 percent of load without unloaded operation, and the unit performance follows the same ISO 1217 measurement basis:

The sound pressure level of the VSD+ build reads 72 dB(A) at the work station. In the Full Feature build with the integrated dryer, the rated data reads 79 to 292 l/s (168 to 618 cfm) at the minimum setting, 79 to 277 l/s at 7 bar, 78 to 246 l/s at 9 bar and 76 to 223 l/s (161 to 473 cfm) at 10.4 bar, with a sound level of 74 dB(A).

Dimensiones y peso

The footprint of the ZT 90 VSD depends on the branch, and the integrated dryer of the Full Feature version adds length to the package:

The Full Feature package is 685 mm longer than the Pack because the adsorption drum of the dryer rides inside the same canopy. Width and height are shared at 1,650 mm and 2,150 mm, so floor planning comes down to the length difference between the two branches.

Detalles del diseño de refrigeración por aire

The ZT carries the cooling duty inside the package. Cooling jackets around the compression stages hold the temperatures of both stages under control in different ambient conditions, and the ample cooler section keeps pressure drops low while holding a low air approach temperature. The result is a complete oil-free package that installs without a cooling-water circuit and runs continuously in severe ambient conditions.

Filtración de admisión y gestión del condensado

Air enters through a two-stage dust removal system that captures 99.9 percent of particles at 3 micron, which protects the compression stages and keeps intake losses low. After compression, a water separator removes the condensate from the air stream, and the low moisture carry-over protects downstream equipment. The drive motor is an IP55 TEFC unit that protects against dust, chemicals and humidity, and the mechanical interlock of the inlet and blow-off valve handles load and unload regulation without an external air supply.

Tecnología VSD y eficiencia energética

Energy dominates the cost of compressed air: over 80 percent of a compressor’s lifecycle cost is the energy it consumes, and air generation can account for more than 40 percent of a plant’s electricity bill. The ZT 90 VSD attacks that share directly. Its drive follows the air demand by adjusting the motor speed, which brings energy savings of up to 35 percent and cuts the average lifecycle cost of the compressor by 22 percent.

Estabilidad de la presión y rango de regulación

The integrated design holds the net pressure band within 0.10 bar (1.5 psi), and the compressor carries no speed windows that would jeopardize the savings or the stable net pressure. Turndown is maximized to 70-75 percent, so the package keeps regulating deep into low demand instead of unloading early.

The motor is an IE3 premium efficiency unit combined with an in-house designed frequency converter, and the converter is rated for stable operation in ambient temperatures up to 50°C / 122°F. and the whole drive train is EMC tested and certified so compressor operation does not influence external sources and vice versa. Mechanical enhancements keep every component below critical vibration levels throughout the entire compressor speed range.

Flujo de aire a través del conjunto

The path of the air through the ZT 90 VSD runs in four steps, and the Full Feature branch extends the third of them into the integrated dryer:

• Filtration and first compression — the inlet filter cleans the air, the throttle valve with its integrated blow-off valve takes care of the load regulation, and the first stage raises the pressure to an intermediate level.
• Cooling and second compression — the intercooler lowers the temperature, a moisture separation system prepares the air, and the high-pressure stage brings it to the final pressure.
• Cooling and drying — the after-cooler condenses moisture out of one part of the air, while a second part flows directly into the regeneration area of the heat-of-compression MD dryer.
• Oil flow — a separate oil pump feeds cool, filtered oil to the bearings and the gears and returns it to the sump, so the oil circuit never meets the compressed air.

Cómo se regenera el secador por calor de compresión

In the regeneration area, the hot air from the high-pressure stage regenerates the adsorption drum and then passes through the regeneration cooler, where it is cooled down and its moisture is separated and evacuated. The cold regeneration air is mixed with the air from the after-cooler in the nozzle-ejector system, and the combined stream passes through the drying section of the adsorption drum, where the remaining moisture is removed. Dry air leaves the ZT 90 VSD FF through the outlet connection flanges, and the whole process runs on compression heat without external instrument air.

The separation between the air path and the oil path is the mechanical basis of the Class 0 certificate. The compressed air touches only oil-free surfaces from inlet to outlet, which is why the ZT 90 VSD appears in plants where a trace of oil would stop production.

Supervisión y control

The Elektronikon MK5 Touch controller runs the ZT 90 VSD and its integrated converter from one full-color touch display. Clear icons and intuitive navigation give fast access to all of the important settings and data, the controller monitors the running conditions and the maintenance status, and the built-in remote control and notification functions come with a simple integrated webpage as standard. Support covers 31 different languages, including character-based languages.

SMARTLINK y funciones de control de carga

SMARTLINK monitors the compressed air installation over the ethernet: customized reports track the energy efficiency of the compressor room, components are replaced on time to keep uptime high, and early warnings avoid breakdowns and production loss. Around that, the control algorithms trim the load profile of the ZT 90 VSD in three ways:

• Dual set-point and automatic stop — the controller switches between two setpoints manually or automatically, and the sophisticated algorithm runs the drive motor only when needed.
• Delayed Second Stop — the controller takes the running conditions into account and allows the machine to stop when no frequent motor starts preceded, which generates major savings against a fixed unload timer.
• Timer functions and dual pressure band — the machine stops when no air is needed, and lower pressure settings during nights and weekends cut the energy draw further.

Installations with three or more machines add the Optimizer 4.0 central controller. It regulates pressure, capacity and speed across the group, prevents higher pressures than required and excess unloaded running, and compensates automatically for pressure drops caused by filters, piping and dryers.

Calidad del aire y aplicaciones

Atlas Copco was the first compressor manufacturer to receive the ISO 8573-1 CLASS 0 certification, with TÜV as the certifying body, and the ZT 90 VSD carries that certification on the air at the outlet flange. The certification followed type testing in which all possible oil forms were measured across a range of temperatures and pressures, and no traces of oil were found in the output air stream. For the buyer, the class removes interpretation work, because the oil limit behind Class 0 is zero.

The applications cluster where air purity decides product quality. Food and beverage plants run the ZT 90 VSD for fermentation, packaging, aeration, transportation, filling and capping, cleaning and instrument air. Textile mills use certified oil-free air for spinning, weaving, dyeing, texturizing, winding and coning, and pharmaceutical production depends on strict moisture control that clean, dry air supports.

Power plants and oil and gas installations form the second cluster. In power generation the ZT 90 VSD supplies flue gas desulphurization, oxidation air and fluidized beds around the clock, and in oil and gas fields it covers control air, instrument air and buffer air. In each case the air-cooled design removes the need for a cooling-water circuit at the installation site.

Elegir entre las versiones 8.6 y 10.4

The ZT 90 VSD – 8.6 covers the general plant band up to 8.6 bar(e) / 125 psig and holds the highest peak flow of the family at 293.9 l/s. The ZT 90 VSD – 10.4 reaches 10.4 bar(e) / 150 psig for higher-pressure processes and still peaks at 289.5 l/s. Matching the version to the real process pressure keeps the operating point where the data sheets put it.

Servicio técnico y asistencia para el ZT 90 VSD

Service parts are grouped together for ease of access, which keeps service time minimal, and all components are designed for serviceability and a long-lasting lifetime. Optional service plans extend the warranty, and the silenced canopy keeps the working conditions around the package comfortable for everyone in the immediate environment. The Elektronikon records support the inspection conversation with warning indications, maintenance scheduling and online visualization of the machine’s condition.

Seadweer supplies genuine Atlas Copco spare parts and service kits for the installed base of the ZT 90 VSD and its Full Feature branches. 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

¿Qué significa «ZT» en el modelo ZT 90 VSD?

The letter marks the cooling type of the package. The ZT 90 VSD is the air-cooled oil-free compressor, and the ZR of the same platform is the water-cooled counterpart.

¿Qué aporta el FF al ZT 90 VSD?

FF stands for Full Feature: the package integrates an IMD adsorption dryer that regenerates with compression heat. The branch adds 685 mm of package length and 400 kg of weight, and it needs no external instrument air.

¿Hasta qué profundidad puede llegar el ZT 90 VSD?

Turndown is maximized to 70-75 percent, with no speed windows in the operating range. The net pressure band stays within 0.10 bar across the whole speed range. The VSD+ build of the platform regulates from 28 to 100 percent of load on dual NEOS drives.

¿Existe el ZT 90 VSD en 60 Hz?

Yes. The ZT 90 VSD is built in 50 Hz and 60 Hz, and the 60 Hz data sheets list the same working pressures, FAD spans and sound levels as the 50 Hz sheets.

¿Qué nivel de ruido tiene el ZT 90 VSD?

The ZT 90 VSD – 8.6 is rated at 78 dB(A) at the work station, and the ZT 90 VSD – 10.4 at 77 dB(A). The silenced canopy and the integrated pulsation damper hold the sound pressure level in that band.

¿En qué sectores se utiliza el ZT 90 VSD?

Food and beverage, textiles, pharmaceuticals, power plants and oil and gas are the main users. All of them specify certified oil-free air, and many of them pick the air-cooled package where no cooling water is available.