Atlas Copco ZR 90 (FF) Oil-Free Rotary Screw Air Compressor

Description

The Atlas Copco ZR 90 is the 90 kW water-cooled machine of the ZR/ZT 55-90 oil-free family, a fixed-speed compressor built for industries where the purity of the air decides the quality of the product. The compression chambers run completely free of oil, the package carries the ISO 8573-1 CLASS 0 (2010) certification verified by TÜV, and the Full Feature build integrates the IMD adsorption dryer inside the same frame. Three pressure versions at 50 Hz and three at 60 Hz cover free air delivery from 214.6 to 268.1 l/s.

Where the ZR 90 Sits in the Oil-Free Range

The ZR/ZT 55-90 family closes the gap between the smaller oil-free packages and the ZR/ZT 110-275 class, and the ZR 90 tops this family with 90 kW of installed motor power. The letter Z marks the oil-free architecture: the precision-cut rotors never touch, so no lubrication is needed inside the compression chamber and no oil can reach the air stream. Plants that run fluctuating demand pair this fixed-speed machine with the ZR 90 VSD of the same name, which adjusts its speed continuously instead of loading and unloading.

Atlas Copco pioneered oil-free air technology over sixty years and became the first manufacturer awarded CLASS 0 certification. The ZR 90 carries that standard into the 90 kW class, and the package arrives as a complete all-in-one installation: place it on a flat floor, connect the power line and the air outlet, and push the start button.

Water Cooling and the Full Feature Concept

Two names describe the branches of the ZR 90, and each adds one fact:

• Standard — the compressor package delivers oil-free air for networks with external air treatment downstream, with the water-cooled design rejecting the heat of compression into the plant cooling circuit.
• FF — Full Feature: the package integrates the IMD adsorption dryer, so dry air leaves the machine directly with no external energy spent on regeneration.

The ZR 90 is offered as the ZR 90 – 7.5, – 8.6 and – 10 bar versions at 50 Hz, and as the ZR 90 – 7.25, – 9 and – 10.4 bar versions at 60 Hz. Every version combines with both branches, so a plant picks the pressure band first and the depth of air treatment second.

Technical Specifications of the ZR 90

The table below condenses the ZR 90 into its headline figures:

Rated Data at 50 Hz

Unit performance is measured according to ISO 1217, annex C, edition 4 (2009). The 7.5 bar version is measured at 7 bar, the 8.6 bar version at 8 bar and the 10 bar version at 9 bar:

The 7.5 bar version leads the series at 241.4 l/s (511 cfm), and moving to the 10 bar band trades flow for pressure at 214.6 l/s (455 cfm). The installed motor power stays at 90 kW across all versions, and the sound pressure level holds at 74 dB(A) at the work station.

Rated Data at 60 Hz

The 60 Hz versions cover three bands from 7.25 to 10.4 bar(e), with the motor rated at 120 hp. The measurement pressures follow the same rule: the 7.25 bar version reads at 7 bar, the 9 bar version at 8 bar and the 10.4 bar version at 9 bar:

The 7.25 bar version tops the whole series at 268.1 l/s (568 cfm). The noise level is the A-weighted emission sound pressure level at the work station, measured according to ISO 2151: 2004 using ISO 9614/2, with a total uncertainty value of 3 dB(A).

Dimensions and Weight

The ZR 90 keeps one footprint across all versions and both branches, which makes floor planning a one-line exercise:

The Full Feature build adds 250 kg over the Standard package without taking any additional floor space, because the IMD dryer fits inside the same length, width and height. No foundations are required, and the package installs directly on the flat floor of the compressor room.

Class 0 Air Purity, Verified by TÜV

The ZR 90 belongs to the first compressor range in the industry certified oil-free according to ISO 8573-1 CLASS 0 (2010). TÜV type-tested the range with the most rigorous methodologies available, measuring all possible oil forms across a range of temperatures and pressures, and found no traces of oil at all in the output air stream. 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.

That certification is what makes the ZR 90 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, petrochemical operations in extreme heat and humidity, and pharmaceutical production from tablet coating to bottling.

The Water-Cooled Design

Water cooling defines the ZR branch of the family. The cooler is built from corrosion-resistant stainless steel tubing with robot welding, which removes the risk of leaks, and an aluminium star insert increases the heat transfer of every tube. Downstream of the cooler, a labyrinth-design water separator efficiently removes the condensate from the compressed air, so low moisture carry-over protects the downstream equipment and extends the lifetime of the high-pressure element.

Full Feature: The Integrated IMD Adsorption Dryer

In the ZR 90 Full Feature, the IMD adsorption dryer eliminates the moisture before it enters the air net. The dryer uses the heat of the compressor for regeneration, so no external energy is needed to dry the air, and the savings against a conventional dryer are large. The pressure drop through the dryer is minimal, which cuts the operating cost again, and the whole drying function lives inside the compressor package instead of beside it.

Energy Recovery Up to 90 Percent

The integrated energy recovery system of the ZR 90 recovers up to 90 percent of the power input as hot air or hot water. The recovered energy feeds preheated boiler feed water, space heating through radiators, showers and industrial processes such as textile dyeing and absorption chillers. For plants with a thermal load, the recovery turns the heat of compression into a measurable return on investment instead of a cost of running the cooling tower.

Control and Monitoring

The Elektronikon unit controller runs the compressor and the integrated dryer from one control system. The high-resolution color display shows the running conditions with clear icons and intuitive navigation, monitors the maintenance status, and raises pro-active service indications, alarms for malfunctions and safety shutdowns. The display supports 31 different languages, and built-in remote control and notification functions come as standard with ethernet-based communication.

SMARTLINK and Options

The option list of the ZR 90 tailors the package to the plant:

• Monitoring and protection bundle — anti-condensation heaters, SPM bearing monitoring and PT 1000 sensors in the windings and bearings.
• SMARTLINK — online data monitoring of the compressed air system with warning indications and maintenance scheduling.
• Energy recovery and water shut-off valve — the water-cooled branch accepts both options for plants with a thermal load.
• PDP sensor and low load kit — Full Feature options for dew point verification and stable part-load running.
• Anchor pads, wooden case packaging, material certificates, test certificate and witnessed performance test — for controlled installation and documented acceptance.
• Teflon-free elements — for applications where even the coating material is specified.

Applications of the ZR 90

Food and beverage plants run the ZR 90 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 petrochemical 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 profile fluctuates heavily, the plant adds the ZR 90 VSD of the same rating next to this fixed-speed machine, and growing networks step up to the ZR/ZT 110-275 class above.

Service and Support Around the ZR 90

The ZR 90 is built for long overhaul intervals, few service interventions and minimal maintenance cost, 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, and genuine Atlas Copco parts keep the package at its rated performance.

Seadweer supplies genuine Atlas Copco spare parts and service kits for the ZR 90 and its Full Feature branch. Send us the compressor model together with the parts you need, and the correct items are confirmed with the quotation in one pass.

FAQ

What does the ZR 90 deliver at 8.6 bar?

The 8.6 bar version delivers 227.6 l/s at 50 Hz, which equals 13.7 m³/min or 482 cfm, measured at 8 bar according to ISO 1217 annex C, edition 4 (2009). At 60 Hz the 9 bar version reads 240.9 l/s (510 cfm).

Is the ZR 90 a water-cooled machine?

Yes. The ZR letter marks the water-cooled branch of the ZR/ZT family: the cooler uses corrosion-resistant stainless steel tubing with robot welding and an aluminium star insert for heat transfer. The air-cooled equivalent is the ZT 90.

How oil-free is the air?

The ZR 90 carries the ISO 8573-1 CLASS 0 (2010) certification verified by TÜV, the most stringent class of the standard. TÜV testing found no traces of oil at all in the output air stream across the tested range.

What does the Full Feature build add?

FF integrates the IMD adsorption dryer inside the compressor package. The dryer regenerates with the heat of the compressor, so no external energy is needed, and the weight rises from 1,925 kg to 2,175 kg without any change to the 2,180 × 1,450 × 2,184 mm footprint.

How much energy can the ZR 90 recover?

The integrated energy recovery system recovers up to 90 percent of the power input as hot air or hot water. Typical uses are boiler feed water preheating, space heating and industrial processes such as textile dyeing.

How loud is the ZR 90?

The sound pressure level at the work station reads 74 dB(A) on every version at both frequencies. The value follows ISO 2151: 2004 with the ISO 9614/2 method and carries a total uncertainty value of 3 dB(A).