Service Teleconference New GA01a
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Transcript of Service Teleconference New GA01a
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Videoconference New GA 90+-160+
New GA units
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Technical service course 2008
New GA
Focus on differences
To highlight the new service related items.
OLDNEW
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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)
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Canopy
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Technical service course 2008
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Technical service course 2008
Frame (Modular)Aircooled Watercooled
PackPack
Pack - VSD or FF
FF - VSD
Pack or FF
VSD
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Technical service course 2008
Canopy Doors with hinges instead of take out doors
OLDNEW
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Technical service course 2008
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
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Technical service course 2008
Canopy All drain, water connections on same front side in the frame
instead on different locations in the stays
OLDNEW
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Technical service course 2008
Canopy Compressed air outlet
Pack (Water) FF (Air)
OLDNEW
Located in the roof
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Elements used
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Technical service course 2008
Elements used GA 132-160 VSD
Used element C190 Direct drive No gearbox
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Unloader (C146)
Blow off valve and solenoid valve located on the canopy because of vibration reasons.
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Technical service course 2008
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)
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Technical service course 2008
Air inlet connection VSD units
No unloader as in old design
OLDNEW
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Vessel
TABEL
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Technical service course 2008
Vessel
Entrance in the vessel below the Oil Separator No shield Lower oil carry over
Connection with vitaulic coupling
OLDNEW
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Vessel
Oil Separator Element (OSE) Improved OSE Material
Three sizes : Difference in height Same diameter See ASL for details
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
After cooler (Air cooled)
2 sizes
Integrated Water separator drain
OLDNEW
Aftercooler 2 sizes
Separate Water separator drain
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Technical service course 2008
Aftercooler (Water cooled)
Tube & shell cooler Plate cooler
Stainless Steel tube stack Copper brazed stainless steel plates
OLDNEW
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Oil circuit (Air cooled) Oil cooler
Cooler placed horizontally at the bottom
2 sizes Special omega profile (better
resistance against thermal stress)
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Technical service course 2008
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
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Technical service course 2008
Oil circuit (Air cooled)
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Technical service course 2008
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
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Technical service course 2008
Oil circuit (Air cooled)
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
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Technical service course 2008
Oil circuit (Air cooled)
Oil Nozzle for C146 element
Nozzle with diameter 10,5 mm
Placed at the outlet of the oil filter housing
No nozzle on C190
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Technical service course 2008
Oil circuit (Air cooled)
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Cooling Air flow circuit
Radial fan design Lower noise
4 Fan combinations 1 x 3kW 1 x 4kW 2 x 3kW 2 x 4kW
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Technical service course 2008
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
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Technical service course 2008
Cooling Water flow circuit
AC OC OCValve
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Technical service course 2008
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
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Technical service course 2008
Drive train
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
Elements used positions
C190 element
Bearing position for C190-190
Bearing position for C190-142.5
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Technical service course 2008
GearboxDrive shaft bearing : two types used Double row angular contact ball bearing Double row barrel roller bearing
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Technical service course 2008
Gearbox
Overhaul at 40.000 hrs
Drive shaft seal similar concept as old design
Gears for life
Overhaul instructions will be published on GBP.
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Technical service course 2008
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
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Technical service course 2008
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
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Technical service course 2008
VSD Drives
ABB VSD Drive Main drive : ASC800 Fan drive : ASC550/800 Dryer drive : ASC550/800
Extra cooling fan standard
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Technical service course 2008
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
-
Technical service course 2008
Heat exchanger Dryer (Full Feature Version)
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Technical service course 2008
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
Heat exchanger Dryer (Full Feature Version)
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Technical service course 2008
Heat exchanger Dryer (Full Feature Version)
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
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Technical service course 2008
DD-filter (Full Feature Version)
Only with the option Integrated Dryer
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Technical service course 2008
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
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Technical service course 2008
Lifting tool- Basic lifting tool set 2908 0049 80
Used for general liftingapplications
+ dedicated applications withuse of extensions
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Technical service course 2008
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
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Technical service course 2008
Lip Seal & Main Shaft Bushing tool 2908 0150 80
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Technical service course 2008
Coupling tool
New tool will be designed to remove the coupling of the motor and element
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Technical service course 2008
Mounting Tool for the Check valve of the Minimum Pressure Valve 2908 0152 00
Tool can be used with extra modified plate (under development)
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Technical service course 2008
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
-
Technical service course 2008
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.
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Technical service course 2008
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
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Technical service course 2008
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
-
Technical service course 2008
We are committed to your superior productivity throughinteraction and innovation.
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Technical service course 2008