new ga 30 through 90 kw range 2005
DESCRIPTION
New GA 30 through 90 kW Range 2005. Briefing. Agenda. Brief sales team on new GA range Objectives for new range What’s new When will the range be available. What. Redesign of GA 30 through 90 kW Including VSDs in this range. GA 30-55C. GA 55-90C. GA 37-50VSD. GA 75-90VSD. When. - PowerPoint PPT PresentationTRANSCRIPT
New GA 30 through 90 kWRange 2005
Briefing
Agenda
Brief sales team on new GA range
Objectives for new range
What’s new
When will the range be available
What
Redesign of GA 30 through 90 kW
Including VSDs in this range
GA 30-55C
GA 37-50VSD
GA 55-90C
GA 75-90VSD
When
Two phase introduction for new range
GA 55-90C and GA 75-90VSD– Series production start June 2005
GA 30-55C and GA 37-50VSD– Series production start October 2005
Why - objectives
Maintain leadership position
Increase market share
Improve performance
New robust look
Introduce new innovations
Pirate proof consumables
Introduce modular design techniques
GA 30-90 kW 2005
What’s new in 2005...
GA Plus Series
Eliminate the “C” naming convention
Introduce GA+ concept
Premium performance model and Basic performance model at each kW size
Plus series
Indicating higher FAD
Lower SER
More value for money
At each kW size
GA75FF
(basic)
GA75+ FF
(premium)
New range split 2005 30-90 kW
kWkW
HpHp
3030 3737 4545 5555 7575 9090
5050 100100
GA 55GA 55++-75-75++-90-90
GA 75-90 VSDGA 75-90 VSDC146 C146 oisois
June 2005
GA 30GA 30++- 37- 37++-45-45++-55-75-55-75
GA 37-45-55 VSDGA 37-45-55 VSDC111 oisC111 ois October 2005
Range split 5 year plan
kW
Hp
75 90
100
GA 55GA 55++-75-75++-90-90
GA 75-90 VSDGA 75-90 VSDJune 2005
GA (30GA (30++)- 37)- 37++-45-45++-55-75-55-75
GA 37-45-55 VSDGA 37-45-55 VSDOctober 2005
45 5530 3718 2211 155.5 7.5
502510
GA 18GA 18++- 22- 22++-30-30++-37-37
GA 22-30-VSDGA 22-30-VSDJune 2006
GA 11GA 11++- 15- 15++-18-22-30-18-22-30
GA 15-18 VSDGA 15-18 VSD
GA 5.5- 7.5-11GA 5.5- 7.5-11
GA 11 VSDGA 11 VSD
June 2007
GA Plus Series
Customer benefit– More choice
− Flexibility
– Size− Two frame sizes to choose from
− Saves on installation cost and space
– Performance/cost− Basic performance
− Premium performance
GA 30-90 kW 2005
Improved performance
in 2005...
Improved performance
GA 55-90 kW
– Reduce SER 3%
– FAD is the best, so leave it as is
– Push 90 kW FAD up...to AIF 90 kW levels
GA 75-90 kW VSD
– Reduce SER 3%
– FAD pushed to industry leading at max speed
Improved performance
GA 30-75 kW
– Reduce SER 2 to 8%
– FAD increase 2 to 6%; industry leading
GA 37, 45, 55 kW VSD
– Reduce SER 4%
– FAD increased 6%; industry leading
New C111 compressor
element
Sound level
Across the board reduction of 1 dB(A)
64 through 69 dB(A)
GA 30-90 kW 2005
New “Look” in 2005...
GA 55GA 55++-75-75++-90-90
GA 75-90 VSDGA 75-90 VSD
June 2005
GA (30GA (30++)- 37)- 37++-45-45++-55-75-55-75
GA 37-45-55 VSDGA 37-45-55 VSD
October 2005
GA 18GA 18++- 22- 22++-30-30++-37-37
GA 22-30-VSDGA 22-30-VSD
June 2006
GA 11GA 11++- 15- 15++-18-22-30-18-22-30
GA GA 15-18 VSD VSD
June 2007
Robust – Industrial image
One frame size for fixed speed and VSD
New vs old size phase one 55-90 kW
GA range dimensions, lxwxhmm fixed speed fixed, FF VSD VSD, FF
55+ 1380 1500 n/a n/a75+ 1480 1600 1630 175090 1580 1700 1780 1900
55 fixed: 2055x1028x1949 1400 1550 n/a n/a75 1500 1650 1650 1800
90C VSD: 2542x1028x1949 1600 1750 1800 1950
weight, kg
new range 2005
existing range
2290x1080x1960
1% reduction in weight
Fixed speed 14% bigger footprint
VSD 5% smaller footprint
New vs old size phase two 30-75 kW
x% reduction in weight
Fixed speed 20% bigger footprint
GA range dimensions, lxwxhmm fixed speed fixed, FF VSD VSD, FF
30+ x x x x37+ x x x x45+ x x x x55 x x x x75 x x x x
30 fixed: 1713x903x1670 830 920 n/a n/a37 970 1080 1130 125545 970 1080 1130* 1255*
55C VSD: 2113x903x1670 1035 1150 n/a n/a
weight, kg
new range 2005
2040x970x1800
existing range
VSD 4% smaller footprint
*Indicates GA 50VSD
Focus on robust – quality look
Shadow zones– Between panels hides small misalignment
Self aligning door panels– Easy to remove and install
– Suspended from roof panel− Center of gravity below supporting line
Roof sunk into panels– Aesthetically pleasing
Strengthened support structure– Eliminates transpot damage
– “Beafier” image
Self aligning doors
Single point lock and support system
Mechanical - Electrical
Clear separation between cubicle and compressor
Clean layout
Same cubicle structure
GA GA VSD
Modular design concepts
Resulting in
– 20% fewer parts
− Saves on spares logistics
− Reduced weight
− Simplified
– 10% fewer connections
− Less potential for leaks
− Lower pressure drop
− Saves energy
– Common internal layout
− Easier to service
46° C ambient
New maximum ambient temperature for standard units– Fixed, VSD and Full Feature units
Maximum ambient 46°C
Allows greater flexibility in applications
No deration of machine required
No extra cost
GA 30-90 kW 2005
Plenty of new Innovations inside...
Innovation 2005
unloader
Integrated WSDs
New OIS
High efficiency – maintanance free
gearbox
New separator element
Integrated oil filter
No loss electronic drains standard
New optimally sized IDs
High efficiency gearboxExisting design New high efficiency design
Features of high efficiency gearbox design
– 35% fewer parts
− Saves on spares logistics
− Reduced weight
− Simplified
– 40% less weight
– 50% less space required
– No drive coupling− Less parts
– Motor DE bearing lubricated by compressor oil, lower temps:longer life
– Motor ODE bearing “greased for life” closed design
– Results in maintenance free drive train− No greasing of motor is required
High efficiency gearbox
New high efficiency design
Features of high efficiency gearbox design
– No risk of improper greasing− No over or under greasing
– Compact drive train− Less vibrations:longer life
− Easier service access to unit
– Drive gear mounted on motor shaft
– 2% more efficient− Decreasing SER
– Very low gearbox pressure− Reduces load on lip seal
− Longer life
− Less potential for leaks
High efficiency gearbox
Maintenance free!
Patent pending!
Air/oil separator
Integration of components results in 50% less parts– Safety valve, DP sensor, oil filter
housing and MPV
Less spares inventory– Lower service costs
Less potential for leaks
Lower pressure drops– Saving on SER
Oil fill
Oil drain
Thermostatic valve, temp rating on
cover
Integrated oil filter housing
50% less parts
New “Pirate proof” oil filter– No metal parts: environmentally friendly
– Better particulate capturing ability at same liftime
Integrated oil filter housing
Oil filter
by-pass valve
Thermostatic valve
To oil stop valve
Oil filter
New higher efficiency oil filter– New rating Beta 12:75
– Industry standard rating beta 30:75
– This means only 1 particle in 75 of more than 12 micron passes through the filter
Result– Extremely clean oil
– Less wear on components
– Longer life of components
Longer expected lifetime for compressor element, bearings and gears– Even in harsh environments
Aftercooler – integrated WSD
Aftercooler – integrated WSD
Integrated water separator device
– 50% less parts
– Maintenance free
– Less pressure drop
− 100 mbar less
– 100% water separation efficiency
− Less load on air treatment equipment
− 10% efficiency gain over today’s design
Electronic water drain standard
– No loss drains
− Saves energy
– Large discharge port diameter
− Does not clog as easily
– Failure feedback to Elektronikon display
− intelligence
Patent pending!
Aftercooler drain
Drain connection
Balance line conncetion
Aftercooler inlet
Aftercooler inlet pipe is extended so condensed water can’t drain back into vessel
Aftercooler inlet
integrated WSD
Integrated 100% efficient water separator
Electronic no loss drain
Also on the Integrated dryer heat exchanger
Patents pending!
aftercooler
Integrated dryer heat exchanger
Improved oil separation
17% less oil carryover than today
– Less than 2 ppm
Improved aerodynamics in vessel inlet– Separates more oil before it gets to the element
New oil separator element– Lower pressure drop
– Better efficiency
– New filter material
Customer benefit– Less energy consumption
– Lower oil carry over
– Lower maintenance costs
– Longer “up time”
Patent pending!
New unloader
Using vacuum forces to open and close unloader valve instead of a big spring
Optimized for pressure drop
Allows 8% more FAD at 90KW
Easy maintenance: – Modulating spring removed
– Today special precaution needed when opening the unloader
Increased reliability– Modulating force is pressure instead of spring =>
less mechanical wear
– Improved seal designs for increased reliability of the blow-off valve
Compact design
Customer benefit– More efficient; +FAD, -SER
– Reliable
– Virtually maintenance free
New unloader - function
load unload
Vessel pressure
At load a vaccuum exists below the valve and above the valve piston
Vessel pressure is blocked thru the load solenoid valve
At unload vessel pressure is directed under the valve piston
The valve seats against the housing unloading the unit
New vaccuum controlled unloader
Patented!
New IFDs
Optimized IFDs sized for each flow
Integrated WSD; 100% efficiency
No loss electronic drain
Thermo expansion valve
Hot gas by-pass valve
Suitable for 46°C ambient standard
HAV to 50°C ambient– Oversizing
– Not available on largest size
New IFDs
Easier slide in-out modules
New IFDs
HAV FF units
Standard Suitable for 46°C ambient standard
HAV version 50°C maximum ambient
– Oversizing of the ID
– Not available on largest ID size, ID285
50 Hz varaints 60 Hz variants
GA75+ 7,5 bar GA 90 100 psiGA90 8 bar GA90VSD 100 psiGA90 7,5 barGA90VSD 7,5 bar
HAV not possible on these units as they use the ID285
Siemens motor
IP 55, TEFC enclosure
Class F insulation; B rise
Eff 1 – 50 Hz; EPAct – 60 Hz
Greased for life– Maintenance free
– DE bearing is lubricated by compressor oil
– Keeps DE bearing running cooler and longer than previous designs
Siemens motor
Sell the benefit of high efficiency
50 Hz motors exceed eff1 requirements
60 Hz motors exceed NEMA EPAct requirements
kW Atlas Copco IEC eff1 4 pole IEC eff2 4 poleGA eff% eff% eff%
55 95,2 94,2 9375 95,1 94,7 93,690 95,6 95 93,9
Siemens motor
Sell the benefit of high efficiency
Consider the benefit for GA 90 vs an industry standard of eff2
Annual savings = hours x kW x €/kWhr x difference in efficiency
= 2000 x 90 x 0.10 x ((95.6-93.9)*.01)
= 306 €/year
Siemens motor
Sell the benefit of reliability
60% of all motor failures are a result of improper lubrication– New motors will are immune to improper
lubrication
– ODE bearing is sealed and is greased for life
– DE bearing is cooled and lubricated by the compressor oil− Result the DE bearing will run 50% cooler than
grease lubricated bearings− Which will help to insure longer life of the bearing
FOCUS on VSD
Siemens motor
New Siemens micromaster drive
New Elektronikon Features
Energy saving dewpoint mode
– On FF units the ID dryer only runs when needed
Enhanced VSD audit feature
VSD fan algorythm
– Improves condensation prevention at light loads
Energy saving dewpoint feature
Today: ID dryer continues to runs continuously in automatic operation– Result can be a waste of energy in lightly loaded units
– Especially units that run one shift or not at all on weekends
Solution: add a mode called energy saving dewpoint mode which siwtches the dryer off if the unit has been off for a long period of time
Modes are selectable through Elektronikon– Standard mode – same functionality as today (factory std.)
– ESDM – energy saving dewpoint mode
Energy saving dewpoint feature
An ambient temperature sensor is added to FF units
Algorythm will attempt to minimize dryer run time during compressor stopped time– ID starts and stops to keep LAT below condensation
temperature, RH 50%
Energy saving dewpoint feature
Once the dryer starts “normal” LAT is reached in 1 to 2 minutes
Energy savings of 2/3 the normal ID power consumption are typical for a lightly loaded compressor
Consider the ID 285 total power of 5.5 kW as an example running 2000 hrs per year at 0.10 €/kW hr– Savings: 726 €/year
– Can be used to fight competitors pushing cycling dryers
PDP vs Ambient
-10
-5
0
5
10
15
20
25
30
35
40
0 5 10 15 20 25 30 35 40
T ambient (°C)
PD
P (
°C)
100 % RH
50 % RH ID LAT or PDP
Energy saving dewpoint feature
Once the dryer starts “normal” LAT is reached in 1 to 2 minutes
GA VSD audit feature
What is it?– Data feature in all AII GA VSDs
– Displays energy and flow data, based on AML figures
– Compares VSD power consumption to load / no load and modulation regulation systems
0
10
20
30
40
50
60
70
80
90
100
0 12.5 25 40 50 60 75 80 100
FAD [%]
PC
[%
]
energy savings
TraditionalVSD
GA VSD audit feature
How can it be used?– as an energy audit feature
– justifes the investment in VSD over alternative regulation systems
– in Marketing campaigns to promote VSDs; i.e. “try and buy” program
New in 2005 GA– Displays total energy saved
– And displays total energy cost saved in your currency
VSD fan control
New fan control algorythm– Prevents condenstae forming in oil at light loads
Ambient temperature sensor is added
Condensation temperature is calculated– Ambient temperature
– Working pressure
Fan is then started/stopped to keep the element outlet temperature above this condensation temperature
0
10
20
30
40
50
60
70
80
90
100
110
120
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
T_ambient
T_S
et
Ts (4bar)
Ts (7,5bar)
Ts (10bar)
Ts (13bar)
Fan on:
Telement > ( 100°C OR T_set+10°C )
Fan off:
Telement < ( 40°C OR T_set )
VSD fan control
Options
130 Pa ducting 1) Phase sequence relayClass 1 filter (FF) Main power disconnectClass 2 filter (FF) Special paint colorDryer by pass (FF) Cooling water solenoidOSD Tropical thermostatOil containing frame AIRmonitorEnergy recovery NEMA 4 cubicle 1)Modulating control 1) NEMA 4X cubicle 1)Synthetic PAO oil NEMA premium motor 1)Food grade oil Package inlet pre-filter 1)Roto Extreme oil HAV to 55°C*
HD Roto fluid plus Russian GOST stampLifting device ES100 relay kitRain protection IT ancilliaries (VSD)Drive motor heaters Freeze protection (-10°C)Motor heaters + Thermistors Marine approvals
1) indicates available 6 months after start of series productionindicates a new option* FF HAV max is 50°C
Option Description