Oil-free VSD compressor offers up to 10% more output, 15% lower energy consumption

Atlas Copco has launched the ZR 90-160 VSD+, a new range of oil-free rotary screw air compressors with motor variants of 90, 110, 132, 145 and 160kW.

They offer up to 10% more flow and up to 15% less energy consumption compared with other VSD compressors, as well as a 25% reduction in floor-space.



Ideal for applications in the food and beverage, electronics, automotive, textile and pharmaceutical industries, which require oil-free air to guarantee product integrity and quality, the water-cooled ZR 90-160 VSD+ is housed in a soundproof, enclosed canopy and equipped with two high-efficiency permanent magnet motors, plus a new state-of-the-art compressor element and cooler design.

Two permanent magnet motors

The ZR 90-160 VSD+ compressor incorporates two permanent magnet motors, each independently driving the low and high pressure compression elements.

The speed of the elements is controlled using Atlas Copco’s NEOS Variable Speed Drive (VSD) technology.

NEOS optimises the speed of both elements throughout the entire operational speed range of the compressor to maximise unit efficiency.

The NEOS drive and motors are designed and manufactured by Atlas Copco to ensure a perfect match and optimal performance.

The reliable IP66 water-cooled permanent magnet motors contain oil-lubricated bearings to ensure a long maintenance-free lifetime. Moreover, all service parts are grouped together for ease of access for a minimal service time.

Mark Ranger, Business Line Manager for Oil-Free Air at Atlas Copco UK commented: “Following years of intensive R&D we’re proud to unveil our latest leap forward in oil-free compressor technology.

“Not only does the innovative dual-motor concept enhance energy efficiency and output by up to 15 and 10 per cent respectively, but there is the optional benefit of having an integrated, guaranteed -40oC pressure dew-point dryer that offers almost zero energy consumption.”

Remote monitoring

This remote monitoring system provides analysis of the whole compressed air system, advises users on how they can reduce energy costs and can predict preventive maintenance interventions to avoid potential downtime.

To illustrate the potential of the technology, Atlas Copco recently performed live field tests with a number of customers.

This included leading Italian-beer brand Peroni, who trialled a ZR 160 kW VSD+ oil-free compressor for over 6000 running hours at its production site in Padova, Italy.

As this video highlights, they were highly impressed with its reliability, guaranteed oil-free air quality and the level of support from Atlas Copco.

As an added benefit, the re-designed cooler incorporates a highly efficient water separator.

Parallel water flow optimises cooling of the motor, element and the cooler itself.

Meanwhile, enlarged stainless steel surface coolers improve cooling efficiency and ensure optimum performance over a long lifetime.

Furthermore, all components in the compressor element, such as the rotor profiles, smart inlet and rotor coating have been enhanced for maximum efficiency and durability, and ensure a guaranteed supply of Class 0 oil-free air.

The ZR 90-160 VSD+ can be offered with an Atlas Copco Total Responsibility Service Plan, which takes care of all compressor maintenance, upgrades, repairs and possible breakdowns throughout the life of the compressor.

The compressor savings of 10% increased flow and 15% reduced energy consumption are achievable when comparing a new ZR 160 kW VSD+ compressor against a previous generation 160 kW VSD compressor.

The 25% reduction in floor-space is achievable when switching from using an oil-free compressor installed with a conventional, adjacently located, heated twin-tower desiccant dryer (taking up a combined floor-space of 7.5 m2) against a full-feature version of the ZR 160 VSD+ compressor, which includes an integrated MD or MDG 450 dryer and takes up a floor-space of 5.6 m2.