Installation guidelines

GA 90 160 A/W

Introduction:
Good product performance is dependent on a good installation. Poor installation can
affect machine performance. It can also create costly service problems.

Typical example for good compressor installation:

Storage instructions:
(Valid for 3 months)
Dont store the machine out in the air. Store the compressor, preferably indoors, in a
clean dry place.
Cover up the unit with tight fitting plastic or canvas, so as to avoid ingression of dust and
moisture.
Place the unit on a clean and level floor. The floor should be well ventilated. The floor
should be free from vibration or pulsation emanating from nearby machinery.
Make sure all coolant is drained and all connections closed off in water cooled units.
Avoid extreme ambient conditions (Temperature and moisture)
Min/Max ambient temperature during storage is 0 and 45 deg cel.
Once every two weeks, turn the motor/compressor coupling 10 turns by hand in order to
redistribute the oil (or grease) film on all moving parts.
Checking receipt of the compressor:
Check the crate for the sign of transport damages.
Check that no moisture penetrated the packaging. Check that contents not moved inside
the box.
Check that loose components (if any) are still properly wrapped and secured to the
bottom of the motor compartment.
If any transport damages observed, please report ACIL immediately.

Erection:
4 slotted hole (small) provided in compressor frame which can be used for horizontally
pulling compressor out of container.
Compressor can be moved by lift truck using the slots (big) in the frame and ensure that
the folks protrude from the other side of the frame.
Compressor can also be lifted after inserting beams in the slots and ensure that beams
cannot slide and that they protrude from frame equally.
The chains must be held parallel to the bodywork by chain spreaders in order not to
damage the compressor.
The lifting equipment must be placed in such a way that the compressor will be lifted
perpendicularly.
Weight of the compressor:
GA 90/110 (A) without dryer
GA 90/110 (A) with dryer
GA 90/110 (W) without dryer
GA 90/110 (W) with dryer
GA 132/160 (A) without dryer
GA 132/160 (A) with dryer
GA 132/160 (W) without dryer
GA 132/160 (W) with dryer

: Approx 2515 kg
: Approx 2825 kg
: Approx 2415 kg
: Approx 2685 kg
: Approx 3025 kg
: Approx 3355 kg
: Approx 2895 kg
: Approx 3175 kg

Foundation:
Foundation bed should be flat surface and should have sufficient bearing capacity.
For ventilation proposal, minimum distance between the top of the body work and the
ceiling is 1200 mm.
If more compressor (Air cooled) in one room, it is advisable to provide ducting even
distance between top of the compressor body work and ceiling is around 1200 mm.
Distance between two compressors should be minimum of 1600 mm and distance
between compressor & wall should be minimum of 1600 mm.
Ventilation:
Air cooled machines must be installed in such a way that an adequate flow of cooling air
is available and that the exhausted air doesnt recirculate to the compressor air inlet or
cooling air inlet.
Inlet grid (s) and ventilation fan should be installed in such a way that any recirculation
of cooling air to the compressor is avoided.
The air velocity to the grid (s) has to be limited to 5 m/s

For alt. 2, 3, 4 the maximum allowable pressure drop over cooling air duct is 30 Pa
For alt. 1, 3, required ventilation to limit the compressor room temperature can be
calculated from
Qv = 0.1 N/Delta T
Qv is the required ventilation capacity (m3/sec)
N is the shaft pf the compressor (kw)
Delta T is the compressor room temperature over the outdoor temperature
Ducting procedure:
Ducting should be individual and it should not be connected together between
compressors.
Compressor suction should not have any obstruction and if any suction duct provided,
Hot air exhaust ducting should not reduce from compressor grating. Poorly designed
ducting can lead to overheating of compressor.
Compressor room location:
Compressor room should be a dust free location.
If compressor located very near to generator or carbon/other dusty location, preventive
measure to be taken for healthy running of compressor.
Piping:
In system with a large distribution network it is preferable to have the compressor located
centrally in order to minimize piping between the compressor and the farthest work
station in the plant.
The compressor system should be arranged to minimize the number of valves, fittings
and flow obstruction in order to reduce pressure drops.
Isolation valve should be installed (Not in ACIL scope) in compressor discharge air
outlet line. It should be closed whenever compressor not in operation.
For water cooled compressor, shut off valves should be provided in water line (in and
out) pipes (Not in ACIL scope) and water drain valve should be provided in water in &
out pipe.

Delivery pipe:
Maximum length of pipe can be calculated from,
L = (Delta P * d5 * p) / 450 * (Qc power of 1.85)
Where,
L
: length of pipe in meter
Delta P
: max allowable pressure drop in bar (recommended is 0.1 bar)
d
: inner dia of pipe in mm
p
: absolute pressure at the compressor outlet in bar
Qc
: Compressed FAD in l/s

Pressure drop over the air outlet pipe can be calculated as follows

Dp
L
D
P
Qc

: Pressure drop (recommended maximum 0.1 bar)

: Length of outlet pipe in m
: inner diameter of outlet pipe in mm
: absolute pressure at the compressor outlet in bar (a)
: free air delivery of the compressor in l/s

It is recommended that the connection of the compressor air outlet pipe is made on top of
the main air net pipe to minimize carry over of possible remainder of condensate

When air receiver is placed after the compressor air outlet, the air receiver will act as
safety buffer which will prevent condensate from flowing back into the compressor.

Piping has to be aligned properly in the compressor. There should not be any stress on the
piping.

Discharge air pipe:

GA 90/110
: 2 or 2 - 8 NPT
GA 132/160 : G 3 or G 3 8 NPT
Water pipe size:
GA 90/110
:G1
GA 132/160 : G 1
Condensate drain pipings:
Condensate drain piping (manual and auto drain) should be separate pipe line and it
should not be connected together. Condensate drain (manual & auto) must hang free over
a receptacle which helps to have visual inspection at all times to ensure that condensate
drain systems are functional. Condensate drain should not be immersed in receptacle.

Provide a condensate drain valve in the lowest part of the pipe between the compressor
outlet valve and the air net.
Cooling water requirements:
Cooling water quality equipment must meet certain minimum requirements. The
following recommendation is general guidelines for acceptable coolant quality.
Detailed cooling water quality calculation can be obtained from compressor instruction
book.
Ph Greater than 6.8
TDS:
TDS is sum of all ions in the water.
For closed cooling system lesser than 3000 mg/l
For open cooling system lesser than 450 mg/l
Chlorides (CL-):
Chloride ion will create pitting corrosion on stainless steel. Their concentration should be
limited.
For closed cooling system lesser than 500 PPM
For open cooling system lesser than 150 PPM
If there is risk of boiler scale formation, then lower limit should be used.
Free chlorine (CL2):
Maximum allowable level 0.5 PPM on continuous basis.
For shock treatments, a maximum limit of 2 PPM for maximum 30 minutes/day applies.
Sulphates (SO4):
For closed cooling system lesser than 400 ppm
For open cooling system lesser than 150 ppm
Carbonate hardness:
For closed cooling system 50 to 1000 ppm CaCO3
For open cooling system 50 to 500 ppm CaCO3
Ammonia:
Maximum allowable concentration is lesser than 0.5 ppm
Copper:
Maximum allowable concentration is lesser than 1 ppm
Iron and manganese:
Maximum allowable concentration lesser than 1 ppm

Electrical:
Electric cables have to provide with proper cable lugs and it has to be properly crimped
with cable.
If 2 run of cable provide in the compressor, both run of cable should be the equal
conductor sizes

Compressor
model (GA
air/water cooled)
GA 90
GA 110
GA 132
GA 160
Compressor model

GA 90
GA 110
GA 132
GA 160

Voltage/
Frequency

Cable
CU 3 core

Cable
AL 3 core

Drive motor
OLR (A)

415V/50Hz
415V/50Hz
415V/50Hz
415V/50Hz

95
120
185
240

150
185
240
150-2 runs

110
134
161
191

Max fuse rating

Class gl/Gg
Type - 2
2 * (3*224)
2 * (3*160)
2 * (3*250)
2 * (3*400)

Technical datas:
Compressor
Pressure ranges
model
(bar)
GA 90 A
7.5 /8.5 /10 /13
GA 110 A
7.5 /8.5 /10 /13
GA 132 A
7.5 /8.5 /10 /13
GA 160 A
7.5 /8.5 /10 /13
GA 90 W
7.5 /8.5 /10 /13
GA 110 W
7.5 /8.5 /10 /13
GA 132 W
7.5 /8.5 /10 /13
GA 160 W
7.5 /8.5 /10 /13

Max fuse rating

Class gl/Gg
Type - 1
355
315
400
500

Oil capacity
(liter)
69
75
93
100
63
63
85
85

Cooling water flow (l/s)

(temp rise 10 deg cel)

2
2.5
3
3.6

Commissioning procedures:
Gearbox, Motor is fixed with two metal spacers for transit purpose. Remove the metal
spacers before commissioning the compressor. Dont start the compressor without
removing metal spacers.

Ensure installation as mentioned above

For water cooled compressors, flush the water line pipes before connecting. Check that
the cooling water drain valves (customer installation) in the inlet and outlet lines are
closed and that the water shut off valves (customer installation) are open and check for
water flow
On full feature compressor check that the dryer by-pass valve is closed and that the dryer
inlet and outlet valves are open.
Ensure the oil level is proper in oil tank
Check whether proper lugs are provided in electric cable and confirm the tightness of
electrical cables. Check that earthing connection provided properly and megger the
motor.
Check incoming voltage and Transformer T1 & T2
Check wirings and ensure that there are no loose connections
Ensure the main fuses are as mentioned above
Check the motor rotation direction by bumping the motor. On air cooled compressor,
check rotation direction of the cooling fan motor.
Ensure the discharge pressure settings as required
Set the drive motor OLR, cooling fan motor OLR and ensure the correctness of the same
Ensure the compressor discharge valve in open condition
Start the compressor and run at unload for few minutes. Stop the compressor and top up
the oil if required.
Run the compressor at unload and check that it operates normally.
Load the compressor and observe running parameters and ensure that it operates
normally.
Check the current of main drive motor and compare with the limit ranges
Check correctness of sensors, electrical interlocking
Observe compressor running parameters for at least 2 to 3 hours
Ensure there are no air/oil leakages
Check and confirm loading/unloading cycle
Check whether manual/auto drains are working properly
Customer should be informed to monitor whether condensate is draining automatically
SPM values:
dBi settings: GA 90 110 : 20 (Motor: 10)
GA 132 160 : 25 (Motor: 10)
Reference level during load:
Measurement point
(1)
dBm
(3)
dBm
(7)
dBm
Mot A
dBm
Mot B
dBm

GA 90 160
25
25
20
20

Alert level: reference level during limit for new unit +20 dB

SPM Measurement points:

Service schedule:
Period
Daily

3 monthly

Running hours Operation

Check reading on display
Check that condensate is discharged during
loading
Operate safety valve
Remove, dismantle and clean float valve of
condensate traps
Clean compressor
Check for possible leaks

500
500
2000

4000

8000

Check coolers, clean if required

Remove air filter and inspect
Change oil refer oil change intervals mentioned
below
Have all flexible inspected
Have safety valve tested
Change below parts:
1.Check valve seal washer
2. Check valve o ring
3. Check valve o ring
4. Check valve spring
5. Air filter
6. Oil filer
7. Oil stop valve kit
8. Minimum pressure valve kit
9.Water separator drain valve kit
10. Seal washer oil filler plug
11. Seal washer gear casing
Change below parts :
1. Parts mentioned in 4000 hrs check
2. O ring oil filter housing
3. Thermostatic valve (7.5/8.5/10 bar)
4. Oil separator
5. Unloading valve kit
6. Flex master joint kit
7. Drain valve kit

Oil change intervals:

Roto inject fluid:
Ambient
temperature
Up to 25 deg cel
25 to 35 deg cel
Above 35 deg cel

Element outlet
temperature
Up to 90 deg cel
90 to 100 deg cel
Above 100 deg cel

* Whichever comes first

Service activities
Pre commissioning report
Commissioning report

Exchange interval* Max time interval

4000 hrs
3000 hrs
2000 hrs

1 year
1 year
1 year