Compresor de aire de tornillo rotativo con inyección de aceite Atlas Copco GA 160 VSD (VSD⁺)

Descripción

The Atlas Copco GA 160 VSD is the variable speed drive model with the largest motor in the GA 90-160 oil-injected platform. It pairs a SmartInjection compression element with an oil-cooled motor of IE4 class or better, and the Full Feature branch adds an integrated refrigerant dryer to the same package. The versions cover two pressure bands in 50 Hz and two ratings in 60 Hz, with free air delivery between 95 and 590 l/s depending on the setting.

Where the GA 160 VSD Sits in the Oil-Injected Range

The GA 90-160 platform forms the upper end of the oil-injected screw range, and the GA 160 VSD closes its top with 160 kW / 215 hp of installed power. Thousands of GA compressors run around the world in this duty class, and the installations concentrate where compressed air works around the clock: general industry, mining, power plants, metal plants and cement works. The jobs range from pneumatic tools, actuators and valves to ventilation, packing and palletizing machinery, soot blowing, fly ash handling and the pneumatic conveying of raw materials.

Two cooling layouts share the same platform. The air-cooled package releases the compression heat into the ambient air through its cooler section, while the water-cooled package connects to a cooling-water loop on site. The rated figures of the GA 160 VSD apply across both layouts, so the choice comes down to the infrastructure the plant already has.

Qué abarcan los términos «VSD» y «FF»

Two names describe the branches of the GA 160 VSD, and each adds one fact:

• VSD⁺ — variable speed drive: the drive adjusts the motor speed to the air demand, which holds the pressure band steady and brings energy savings of up to 35 percent at part load.
• FF — Funcionalidad completa: el paquete incluye un secador de refrigerante, por lo que el secado se realiza dentro del compresor en lugar de junto a él, sin necesidad de trabajos adicionales de instalación de cables ni tuberías.

The GA 160 VSD is built as the GA 160 VSD⁺ – 8.5 bar and GA 160 VSD⁺ – 10 bar versions at 50 Hz, and as the GA 160 VSD⁺ – 125 psi and GA 160 VSD⁺ – 150 psi versions at 60 Hz. Every version combines with both the Pack and the Full Feature scope, so a plant picks the pressure band first and the depth of air treatment second.

Technical Specifications of the GA 160 VSD

The table below condenses the GA 160 VSD into its headline figures:

Datos nominales a 50 Hz

Each 50 Hz version of the GA 160 VSD is listed at three settings, and the FAD span inside every row covers the full VSD speed range at that setting. FAD is measured at 7 bar for the 8.5 bar version and at 9.5 bar for the 10 bar version:

The installed motor power stays at 160 kW across all settings, and the sound level holds at 78 dB(A) at the work station. The 8.5 bar version peaks at 590 l/s (1,250 cfm) on its minimum setting, and the 10 bar version peaks at 492 l/s (1,042 cfm). Moving from the minimum to the maximum pressure setting inside one version trims the peak flow by 79 to 98 l/s, which is the trade-off for the higher pressure band.

Datos nominales a 60 Hz

The 60 Hz versions keep the three-setting structure, with the pressure bands written in psi and the motor rated at 215 hp:

The 125 psi version peaks at 590 l/s (1,250 cfm) on its minimum setting, and the 150 psi version peaks at 492 l/s (1,042 cfm). At 60 Hz reference conditions, the pressure dew point of the integrated refrigerant dryer sits between 2°C and 3°C (36°F to 37°F).

Dimensiones y peso

The footprint of the GA 160 VSD depends on the branch, and the integrated dryer of the Full Feature adds length to the package:

The Full Feature package is 400 mm longer and 450 kg heavier than the Pack, because the refrigerant dryer module rides inside the same canopy. Width and height are shared at 1,785 mm and 2,020 mm, so floor planning comes down to the length difference between the two branches.

SmartInjection y el tren de transmisión refrigerado por aceite

SmartInjection is the technology at the heart of the element. It provides the exact amount of oil the compression element requires, so the element works at peak efficiency across changing conditions instead of at a fixed compromise. Oil flows separately to the bearings for longer life and greater uptime, and the motor itself is oil-cooled, which removes the service interventions a conventional air-cooled motor needs. The drive train pairs the element with an IE4 class motor or better, and the air-cooled VSD FF branch carries an IE5 permanent magnet motor.

Protección IP66 y resistencia a las condiciones ambientales

The drive train of the GA 160 VSD is IP66 rated, which seals it completely against environmental dust and moisture. That rating is what lets the compressor run reliably in the toughest conditions: cement dust, mine particulates and humid intake air stay outside the drive train. The package operates at ambient temperatures up to 55°C / 131°F, the high ambient variant extends the fixed speed pack to 55°C and the VSD pack to 50°C, and the air-cooled VSD FF runs at temperatures up to 46°C / 115°F as standard.

Tecnología VSD+ y eficiencia energética

Energy dominates the operating bill of a compressor: over 80 percent of its lifecycle cost is the energy it consumes, and compressed air generation can account for more than 40 percent of a plant’s electricity bill. The GA 160 VSD attacks that share with variable speed drive. The motor speed follows the air demand automatically, energy savings reach up to 35 percent, and the average lifecycle cost of the compressor drops by 22 percent.

Estabilidad de la presión y rango de regulación

The integrated design holds the net pressure band within 0.10 bar (1.5 psi), and the compressor carries no speed windows that would jeopardize the savings or the stable net pressure. Turndown is maximized to 70-75 percent, so the GA 160 VSD keeps regulating deep into low demand instead of unloading early.

The highly efficient frequency converter sits in its own cubicle and stays stable in ambient temperatures up to 50°C / 122°F. The electric motor is designed for low operating speeds with dedicated attention to motor and compressor cooling, and the whole drive train is EMC tested and certified so compressor operation does not influence external sources and vice versa. Mechanical enhancements keep every component below critical vibration levels throughout the entire speed range.

Recuperación de energía en forma de agua caliente

El sistema opcional de recuperación de energía consta de un intercambiador de calor de acero inoxidable integrado con un circuito controlado por termostato. Recupera hasta el 78 % de la energía del motor integrado y del circuito de aceite del elemento en forma de agua tibia o agua caliente, sin que ello afecte negativamente al rendimiento del compresor. En las instalaciones con alimentación de caldera, procesos de lavado o carga de calefacción de espacios, ese calor recuperado sustituye al combustible o la electricidad que, de otro modo, la instalación tendría que consumir.

Artículo completo: El secador de refrigerante integrado

In the GA 160 VSD Full Feature, the refrigeration dryer is fully integrated in the compressor unit. The all-in-one layout reduces the floor space needed for the compressor room and removes the piping installation work a standalone dryer requires. The typical pressure dew point of the refrigerant dryer is 3°C (37.4°F) at reference conditions, and the dew point is continuously monitored while the machine runs.

Control del ciclo de ahorro y separación de aceite

El exclusivo y patentado sistema «Save Cycle Control» detiene la secadora cada vez que el compresor se detiene o se encuentra en modo de descarga, lo que reduce el consumo energético del sistema de tratamiento de aire. En cuanto al sistema de aceite, el separador utiliza varios cartuchos más pequeños en lugar de un único tambor grande, lo que simplifica y acorta las tareas de mantenimiento y minimiza el arrastre de aceite hacia la corriente de aire.

Supervisión y control

The Elektronikon MK5 Touch controller runs the GA 160 VSD from one full-color touch display. Clear icons and intuitive navigation give fast access to all of the important settings and data, the controller monitors the running conditions and the maintenance status, and the built-in remote control and notification functions come with a simple integrated webpage as standard. Support covers 31 different languages, including character-based languages.

SMARTLINK y Optimizer 4.0

SMARTLINK monitors the compressed air installation over the ethernet: customized reports track the energy efficiency of the compressor room, components are replaced on time to keep uptime high, and early warnings avoid breakdowns and production loss. With the Elektronikon unit controller, a plant switches between two setpoints manually or automatically, and the sophisticated algorithm runs the drive motor only when needed while the desired setpoint is maintained.

Installations with several machines add Optimizer 4.0. It starts and stops compressors to minimize excess pressure, regulates the VSD so the output stays proportional to the demand, and adjusts the system pressure automatically to compensate for pressure drops caused by filters, piping and dryers. The result is the full energy saving potential of VSD across the whole compressor room instead of a single machine.

Opciones que amplían el paquete

• High ambient variant — reliable continuous operation in hot and humid climates up to 55°C / 131°F for the fixed speed pack and 50°C / 121°F for the VSD pack.
• Medición de pulsos de choque: supervisión continua mediante SPM del elemento compresor y los cojinetes del motor, con niveles de alarma y parada programados durante la puesta en marcha, de modo que la revisión se realice cuando el estado de los cojinetes lo requiera.
• Protección térmica del motor: cinco sensores de temperatura PT-1000 en el motor principal, dos en los cojinetes y tres en los devanados, cuyos datos se muestran en el Elektronikon con alarmas y paradas programadas para proteger el motor.
• Aceite apto para uso alimentario: la opción de aceite Roto-Foodgrade para plantas de envasado, farmacéuticas y de alimentación y bebidas, en las que se permite el contacto ocasional dentro y en las inmediaciones de las zonas de procesamiento de alimentos.
• Prueba de presencia y de rendimiento: visita a la fábrica y presencia en la prueba de rendimiento estándar, de conformidad con la norma ISO 1217:2009, anexos C y E (4.ª edición).

Applications of the GA 160 VSD

Mining operations run the GA 160 VSD for dust bag filtration, service air, ventilation air and pneumatic tools, where reliability and robustness decide the shift plan. Power plants keep a continuous supply of compressed air for soot blowing and fly ash handling, and metal plants use it for instrumentation, plant air and the pneumatic conveying of raw materials or ash.

Cement works are among the biggest consumers of compressed air, with most of the air spent on transporting raw materials inside the factory. Moisture and dust in the environment impair compressor performance and push energy and maintenance costs up, and this is exactly where the IP66 drive train, the grouped service area and the slide out coolers of the platform earn their place. General industry completes the picture with packing, palletizing and the daily pneumatic workload of a production hall.

Service and Support Around the GA 160 VSD

Las piezas de recambio están agrupadas para facilitar el acceso; todos los componentes están diseñados para facilitar su mantenimiento, y el diseño patentado en forma de pórtico permite un acceso completo a cada componente cuando se requiere un mayor acceso. Cada componente está diseñado para reducir a la mitad el tiempo de mantenimiento en comparación con los diseños tradicionales, lo que mantiene un alto nivel de disponibilidad a lo largo de la vida útil de la máquina. Los planes de mantenimiento opcionales cubren las reparaciones, el mantenimiento preventivo y las piezas de recambio, y los fluidos y lubricantes de Atlas Copco están adaptados al equipo con aditivos antioxidantes y antiespumantes.

Seadweer supplies genuine Atlas Copco spare parts and service kits for the installed base of the GA 160 VSD and its Full Feature branches. For the drive motor overhaul scope on the GA VSD+ platform, see the GA VSD+ Motor Overhaul Kit. Envíanos el modelo del compresor junto con las piezas que necesitas y te confirmaremos los artículos correctos junto con el presupuesto de una sola vez.

Preguntas frecuentes

What does VSD+ mean on the GA 160 VSD?

It marks the variable speed drive: the motor speed follows the air demand, which brings energy savings of up to 35 percent and holds the net pressure band within 0.10 bar. Turndown reaches 70-75 percent without speed windows.

Is the GA 160 VSD an oil-injected machine?

Sí. Se trata de un compresor de tornillo rotativo con inyección de aceite; el aceite sella y enfría el elemento de compresión antes de que el separador lo extraiga de la corriente de aire. El funcionamiento sin aceite corresponde a las plataformas independientes ZR y ZT.

How much heat can the GA 160 VSD recover?

El sistema opcional de recuperación de energía recupera hasta el 78 % de la energía del motor integrado y del circuito de aceite del elemento calefactor. El calor sale del equipo en forma de agua tibia o agua caliente a través de un intercambiador de calor de acero inoxidable.

What does FF add to the GA 160 VSD?

FF stands for Full Feature: the package integrates a refrigerant dryer with a 3°C / 37°F pressure dew point and patented Save Cycle Control. The branch adds 400 mm of package length and 450 kg of weight.

How loud is the GA 160 VSD?

The sound pressure level is 78 dB(A) at the work station across all versions and settings. The value is the A-weighted emission sound pressure level measured at the work station.

Which industries run the GA 160 VSD?

La minería, las centrales eléctricas, las plantas metalúrgicas y las cementeras son los principales usuarios, y la industria en general completa la base. Todos ellos valoran el sistema de transmisión IP66, el amplio rango de regulación y la recuperación de calor opcional en funcionamiento continuo.