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.
OLD
NEW
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 KW 90 KW 500 KW 500 KW
315 KW 315 KW
GA 315-500
Twin-Element
200 KW 200 KW
GA 315 VSD
GA 200-315
Twin-Element
180 KW 180 KW
GA90-160
GA132 - 180 VSD
160 KW 160 KW
New GA 90
+
-160
+
New GA 132-160 VSD
April 2008 April 2008
2009 2009
New GA 90
+
-160
+
& GA 132-160 VSD
Concept
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
GA90+
GA110
GA110+
GA132
GA132+
GA160
GA160+ Integrated in GA160+ - 315+ to be released during 2009
GA132VSD
GA160VSD
Release Feb 2008 Not Available
Models kW
Pressure variants 50Hz
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 60Hz
75 psi 100 psi 125 psi 150 psi 200 psi
GA90+
GA110
GA110+
GA132
GA132+
GA160
GA160+ Integrated in GA160+ - 315+ to be released during 2009
GA132VSD
GA160VSD
Release Feb 2008 Not Available
Models KW
Pressure variants 60Hz
Available
New GA units
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
Canopy
Frame (Modular)
Aircooled Watercooled
Pack Pack
Pack - VSD or FF
FF - VSD
Pack or FF
VSD
Canopy
Doors with hinges instead of take out doors
OLD
NEW
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)
OLD
NEW
IN
Canopy
All drain, water connections on same front side in the frame
instead on different locations in the stays
OLD
NEW
Canopy
Compressed air outlet
Pack (Water) FF (Air)
OLD
NEW
Located in the roof
Flow diagram Aircooled unit
Unloader
HD Air filter
Element
Heavy duty oil filter
OSV + CV
Oil separator
Oil cooler
Aftercooler
VSD driven fans
Water separator
ID
By pass valve
New GA units
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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
OLD
NEW
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)
OLD NEW
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
OLD
NEW
New GA units
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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
OLD
NEW
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
OLD
NEW
Vessel
TABEL
Vessel
Entrance in the vessel below the Oil Separator
No shield
Lower oil carry over
Connection with vitaulic coupling
OLD
NEW
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
OLD
NEW
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
Setting Compressor 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
OLD NEW
Minimum Pressure valve (MPV)
Less pressure drop over the valve
due to integrated design in the
cover
9 bar max. 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
Setting Compressor type GA
After cooler (Air cooled)
2 sizes
Integrated Water separator drain
OLD NEW
Aftercooler
2 sizes
Separate Water separator drain
Aftercooler (Water cooled)
Tube & shell cooler Plate cooler
Stainless Steel tube stack Copper brazed stainless steel plates
OLD
NEW
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
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
Oil circuit (Air cooled)
Oil cooler
Cooler placed horizontally at the
bottom
2 sizes
Special omega profile (better
resistance against thermal stress)
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
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
OLD NEW
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
OLD NEW
Combined After- and Oilcooler
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 bar 88C
6.9 7.5 8.5 8.6 bar 83C
5.2 5.5 bar 75C
Pressure Thermostat
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
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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 OC Valve
New GA units
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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
OLD NEW
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
Gearbox
Drive 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
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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)
OLD NEW
DD-filter (Full Feature Version)
Only with the option Integrated Dryer
New GA units
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
Lifting tool- Basic lifting tool set
2908 0049 80
Used for general lifting
applications
+ dedicated applications with
use 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
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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
Product range
Bodywork
AIR Circuit
AIR-OIL Circuit
Oil Circuit
Cooling circuit
Drive Train
Electrical
Dryer
Service Tools
Service Actions
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Service Teleconference New GA01a

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