service teleconference new ga01a

Videoconference New GA 90+-160+

New GA units

Technical service course 2008

New GA

Focus on differences

To highlight the new service related items.

OLDNEW


New GA units

Product range Bodywork AIR Circuit AIR-OIL Circuit Oil Circuit Cooling circuit Drive Train Electrical Dryer Service Tools Service Actions Production, Delivery and GBP information


GA 90 Product portfolio

90 KW90 KW 500 KW500 KW315 KW315 KW

GA 315-500

Twin-Element

200 KW200 KW

GA 315 VSD

GA 200-315

Twin-Element

180 KW180 KW

GA90-160

GA132 - 180 VSD

160 KW160 KW

New GA 90+-160+

New GA 132-160 VSD

April 2008April 2008 20092009


New GA 90+-160+ & GA 132-160 VSDConcept

Dual offer product strategy (eg GA 110 GA 110+) New Best in performance screw elements

+46C / 115 F ambient temperature design

HAT up to +55C / 131 F

Good oil separation < 3ppm

Modular concept (eg Z units) 5.5 barg and 14 barg variants (75 psi / 200psi)


Available models 50Hz

Premium Models GA+ pack & FF +46C max ambient temp

Standard Models GA pack & FF GA Pack +46C max ambient temp. / GA FF +40C max ambient temp.

GA VSD pack & FF +46C max ambient temp.

Old GA : 40C max ambient temp.

5,5 bar 7,5 bar 8,5 barg 10 bar 14 bar G A90+

G A110

G A110+

G A132

G A132+

G A160

G A160+ Integrated in G A160+ - 315+ to be released during 2009

G A132VSD

G A160VSD

R elease Feb 2008 N ot Availab le

M odels kW Pressure variants 50H z

Available


Premium Models GA+ pack & FF +115F max ambient temp.

Standard Models GA pack & FF GA Pack +115F max ambient temp. / GA FF +104F max ambient temp.

GA VSD pack & FF +115F max ambient temp.

Old GA : 104F max ambient temp.

Available models 60Hz75 psi 100 psi 125 psi 150 psi 200 psi

G A90+

G A110

G A110+

G A132

G A132+

G A160

G A160+ Integrated in G A160+ - 315+ to be released during 2009

G A132VSD

G A160VSD

R elease Feb 2008 N ot Availab le

M odels K W Pressure variants 60H z

Available


New GA units



Canopy


Frame (Modular)Aircooled Watercooled

PackPack

Pack - VSD or FF

FF - VSD

Pack or FF

VSD


Canopy Doors with hinges instead of take out doors

OLDNEW


Canopy Air-cooled units : Cooling Air inlet in front of back side of the unit

instead on the roof (except for inlet grating of dryer)

IN (dryer)

OUT

IN (motor)IN (air filter)

OLDNEW IN


Canopy All drain, water connections on same front side in the frame

instead on different locations in the stays

OLDNEW


Canopy Compressed air outlet

Pack (Water) FF (Air)

OLDNEW

Located in the roof


Flow diagram Aircooled unit

Unloader

HD Air filter

Element

Heavy duty oil filter

OSV + CVOil separator

Oil cooler

Aftercooler

VSD driven fans

Water separator

ID

By pass valve


New GA units



Elements used

C146 C190

2 different elements : C146 element (as in GA75-90) C190 element (New size 2)

As function of power and pressure variant


Elements used


Elements used GA 132-160 VSD

Used element C190 Direct drive No gearbox


Air filter

Heavy duty air filter as standard

Double lifetime

Dp sensor has a warning/protection function to protect the compressor element Service warning : -0.050 mbar Shut-down warning : -0.080 bar - New Shut down : -0.085 bar - New

OLDNEW


Unloader

Vacuum unloader (cfr AII units and Size 3) No spring

2 models : For C146 element : identical to GA75-90 AII units For C190 element : new larger unloader (similar design as for C146 element)

OLDNEW


Unloader (C146)

Blow off valve and solenoid valve located on the canopy because of vibration reasons.


Unloader (for C190)

Working principle similar as for the unloader of the C146 element

No Quad ring in this unloader : This will result that the valve of the

unloader can go open during stand still.

During start up the unloader valve will be open for a second and close immediately

Groove is foreseen to place a Quad ring (if problems occur in the future)


Air inlet connection VSD units

No unloader as in old design

OLDNEW


New GA units



Check Valve

The Check Valve (CV) and Oil Stop Valve (OSV) are integrated in one housing for both elements C146 and C190.

Internal components of CV and OSV similar as old design Vulcanised Check valve

OLD

OLDNEW


Vessel

Welded vessel (4 versions) Casted vessel (2 versions) Same diameter 3 heights Same diameter 2 heights

Largest vessel exists with and without inside reinforcements

OLDNEW


Vessel

TABEL


Vessel

Entrance in the vessel below the Oil Separator No shield Lower oil carry over

Connection with vitaulic coupling

OLDNEW


Vessel

Special nipple for easy oil sampling in running conditions

Vitaulic coupling

Filling of the unit through a pipe connected with the vessel.Plug without pressure relief hole.

Extra pressure relief valve is foreseen on top of the vessel.

Level gauge


Vessel

Pressure relief nipple: To check if the vessel is not under

pressure. Located before the blow-off hose

In the previous design GA 99 the pressure relief nipple was foreseen in

the filling plug

OLDNEW


Vessel

Oil temperature measurement in the vessel (Oil separator temp): No protection function Sensor direct contact with oil

Drain hose

Temperature switch: Hardware protection Shutdown at 130C


Vessel

Lifting device for the cover of the vessel: On the vessel two positions are

foreseen Depending of aircooled or

watercooled version

Safety valve : Herose Settings

218 psig max. working pressure of 75 ,100 ,125 ,150 or 200psi

15 bar (e)max. working pressure of 5.2 , 6.9 , 8.6 ,10.4 or 13.8 bar

15 bar (e)max. working pressure of 8.5, 10 or 14 bar

11 bar (e)max. working pressure of 5.5 or 7.5 bar

SettingCompressor type GA


Vessel

Oil Separator Element (OSE) Improved OSE Material

Three sizes : Difference in height Same diameter See ASL for details


Minimum Pressure valve (MPV)

New MPV integrated in the cover of the vessel 3 springs possible depending pressure variant

3.5 bar 6 bar 9 bar

1 spring : 4 bar

OLDNEW


Minimum Pressure valve (MPV)

Less pressure drop over the valve due to integrated design in the cover

9 barmax. working pressure of 13.8or 14 bar or 200 psi

6 bar max. working pressure of 10 or 10.4 bar or 150psi

3.5 bar max. working pressure of 5.5 , 7.5 , 8.5 or 8.6 bar or 75 ,100 ,125psi

SettingCompressor type GA


After cooler (Air cooled)

2 sizes

Integrated Water separator drain

OLDNEW

Aftercooler 2 sizes

Separate Water separator drain


Aftercooler (Water cooled)

Tube & shell cooler Plate cooler

Stainless Steel tube stack Copper brazed stainless steel plates

OLDNEW


Electronic Water Separator Drain

Integraded water separation in the Aircooled Aftercooler

Reduced pressure drop

New Electronic water Drain (Atlas Copco Design)

Regulated by MkIV

Level sensor

Solenoid


New GA units



Oil circuit (Air cooled) Oil cooler

Cooler placed horizontally at the bottom

2 sizes Special omega profile (better

resistance against thermal stress)


Oil circuit (Air cooled)

Oil coolers Coolers are placed on a skid Possible to take out the oil cooler out of the unit and lift it up Cooler is foreseen with gas spring Better draining Better cleaning


Oil circuit (Air cooled) Bypass valve in the oil cooler

With low pressure the valve is open (during start up) to avoid temperature peaks.

Pressure regulated on outlet oil cooler pressure

During unload the cooler will be partly by-passed



Oil filter housing Connection from oil cooler to oil filter housing with fix piping connected with

Vitaulic couplings Two heavy duty glass fibre oil filters

Hex. Key SW17

OLDNEW



Oil Nozzle for C146 element

Nozzle with diameter 10,5 mm

Placed at the outlet of the oil filter housing

No nozzle on C190



Extra oil injection Valve Extra oil is injected to the element

to reduce the element outlet temperature

The valve is regulated with the vessel temperature and fan speed (it will goes open at a temperature of 94C)

The fan speed need to reach a certain speed

Delay time At 110C the valve goes open

immediately


Oil circuit (Water cooled)

Oil cooler Coolers placed horizontally in the bottom Tube & Shell coolers 1 bigger oil cooler : GA90+ - GA110 2 oil coolers: GA132 GA160

OLDNEW

Combined After- and Oilcooler


Oil circuit (Water cooled) Combined Thermostatic and bypass

valve in one housing Not for 14 bar unit Units without Energy Recovery Thermostat valve in function of pressure Bypass valve (similar function as for air

cooled units)

10 10.4 bar88C

6.9 7.5 8.5 8.6 bar83C

5.2 5.5 bar75C

PressureThermostat


Oil circuit (Water cooled) Electronic Bypass Valve

Bypass and temperature regulation function

Only used on 14 bar units VSD units Units equipped with Energy Recovery

Regulation of the valve done with 4 -20 mA

MK IV control : Regulation done in function of the

condensation temperature in the vessel. The condensation temperature calculated in

function of: Working pressure Ambient temperature


New GA units



Cooling Air flow circuit

Standard VSD Fan(s) on all Air cooled units

Fan converter : Siemens Micromaster 420/440 located in the control cubicle

Fan(s) speed depending on setting mode and running conditions Lowest Dew point mode ( for FF

version) 50C oil injection regulation

Normal mode 90C vessel temperature regulation

Load/unload Cooling temperature


Cooling Air flow circuit

Radial fan design Lower noise

4 Fan combinations 1 x 3kW 1 x 4kW 2 x 3kW 2 x 4kW


Cooling Water flow circuit

Cooling water connections (water in and water out) placed in the frame.

Cooling water flow circuit : Fix pipes Connections with vitaulic couplings

Regulation valve at the inlet of the cooling water

Option: automatic water shut off valve


Cooling Water flow circuit

AC OC OCValve


New GA units



Drive train


Motors ABB make

Exception : 60 Hz CSA / UL Approval : WEG motors

Re-greasing instruction : See instruction book See the data plate on the motor

WEG motors : Use Roto-Glide Blue

ABB motors : Use Roto-Glide Amber


Voltages

GA 90+-160+

50 Hz IEC Approval 380V 400V 500V 525V 550V

60 Hz IEC Approval 380V 440V

60 Hz CSA / UL Approval 460V 575V

GA 132160 VSD 50 Hz IEC Approval

380V 400V 500V 525V

60 Hz IEC Approval 380V 440V

60 Hz CSA / UL Approval 460V 575V


Coupling

Spider coupling

2 sizes and qualities Small size coupling :

Red color : GA90+ - GA160 Blue color : GA132VSD GA160VSD

Big size coupling : Red color : GA160+

Lifetime 24.000 hrs

OLDNEW

Sure flex coupling

1 size

Lifetime 16.000 hrs


Gearbox

3 different gearboxes: C-190 element : 2 types C-146 element : 1 type

1 coupling housing: C-190 element : only for VSD units

C190-142.5 C190-190 C146-160


Elements used positions

C190 element

Bearing position for C190-190

Bearing position for C190-142.5


GearboxDrive shaft bearing : two types used Double row angular contact ball bearing Double row barrel roller bearing


Gearbox

Overhaul at 40.000 hrs

Drive shaft seal similar concept as old design

Gears for life

Overhaul instructions will be published on GBP.


New GA units



Electrical cubicle Power cable connections

Selection cables sizes: see instruction book

The selection of the cables is done in function of the worst acceptable conditions a unit can run in.

Cables need to be connected directly on the contactors

Electrical cubicle is split up in two parts The power part with main

contactors The control part with relays, fuses,

etc

Control cubicle has similar design as on Industrial Air units: Use of modular block(s) Use of plugs


VSD Drives

ABB VSD Drive Main drive : ASC800 Fan drive : ASC550/800 Dryer drive : ASC550/800

Extra cooling fan standard


New GA units



Heat exchanger Dryer (Full Feature Version)


Different dryers possible to choose:

ID310+ ID440 ID525

Bypass piping and valves of the dryer needs to be placed by the customer himself.

Dryer Pressure Dew Point : measurement of the lowest air temperature in the compressed air flow in the heat exchanger

Refrigerant : measurement of the refrigerant temperature in the heat exchanger (see LAT measurement in present GA units)

Refrigerant R404A




OLD

Thermostatic expansion valve with HGB valve MK IV controlled Solenoid valve in line with HGB

Constant pressure expansion valve (ID 340) - Setting of expansion valve Thermostatic expansion valve with HGB valve (ID 470)

OLDNEW


DD-filter (Full Feature Version)

Only with the option Integrated Dryer


New GA units



Lifting tool- Basic lifting tool set 2908 0049 80

Used for general liftingapplications

+ dedicated applications withuse of extensions


Lifting tool- Motor lifting set 2908 0055 80

Possibility to use the present motor lifting tool but for some

frames (water cooled units) and some motors an adaptation of the

tool is necessary


Lip Seal & Main Shaft Bushing tool 2908 0150 80


Coupling tool

New tool will be designed to remove the coupling of the motor and element


Mounting Tool for the Check valve of the Minimum Pressure Valve 2908 0152 00

Tool can be used with extra modified plate (under development)


New GA units



Overview service actions Oil change :

Roto Inject Fluid (RIF) : 4.000 hrs Roto XTend Duty Fluid (RXD) : 8.000 hrs

Regreasing drive motor : 4.000 6.000 hrs (See AIB or data plate motor) Fan motors are greased for the lifetime of the bearings Air filter : 8.000 hrs (in normal conditions) or when Dp : -0.050 bar Oil filters : 8.000 hrs (in normal conditions) Oil separator : 8.000 hrs (in normal conditions) Overhaul unloader, CV, OSV, MPV, EWD solenoid valve, bypass valve :

8.000 hrs Coupling : 24.000 hrs Rebearing fan motor(s) (for Aircooled units) : 24.000 hrs General overhaul unit (element, motor, gearbox) : 40.000 hrs All data in IQ in W22.


Spare Part availibility

Example: new GA 160

ASC has orderred the requested spare parts 1621 7376 99 Airfilter 100 parts in stock 1621 7378 90 oilfilter 200 parts in stock 1623 0514 99 oilseparartor 50 parts in stock

List critical parts has been defined and will be stocked before W22

Kits are released and will be stocked before W22


New GA units



We are committed to your superior productivity throughinteraction and innovation.

service teleconference new ga01a

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