Piston compressor booster station Ace VII Zero Loss

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Overview
Ace VII Zero Loss is a 4-stage booster compressor with gas recovery designed for integration into industrial and breathing-air systems. It combines an open maintenance-friendly frame, independent activated-carbon filtration and multi-stage condensate management for continuous high-pressure operation.

Main features

• 4-stage pumping unit with gas recovery (first stage dedicated to gas recovery)
• Aluminum monoblock construction
• Forced lubrication with low-pressure gear pump; minimum lubricating oil pressure switch
• Pipes, fittings and nuts in AISI 316 stainless steel
• Intermediate condensate separators after 2nd and 3rd stages; high-pressure final condensate separator
• Safety valves after each compression stage
• Special cast iron cylinders with low-roughness lapping
• Heavy-duty roller bearings
• Forged aluminum connecting rods; forged steel crankshaft
• High-flow fill valves on 1st, 2nd and 3rd stages
• Hardened steel 4th stage with 6 special cast-iron piston rings
• 2nd and 3rd stages with thrust pads to eliminate lateral piston forces
• Hyperfilter activated-carbon filtration system (stand-alone)

Electric motor
The three-phase electric motor transfers motion to the pumping unit via a V-belt. Motor options for this model range from 11 to 15 kW. The motor is mounted on a tilting carrier plate to maintain constant belt tension.

Stand-alone filter system with Hyperfilter
The independent Hyperfilter unit with activated-carbon cartridge is mounted on a separate support and includes:

• Safety valve (configurable to customer requirements)
• Pressure-holding valve
• Separator and external Hyperfilter kit
• Leg kit
• Automatic condensate drain for intermediate and final separators (automatic purge every 7 minutes during operation)

Electrical cabinet

• Motor protection switch
• Autostop + Autostart functions
• Automatic drainage of separators between stages during operation (standard interval: every 15 minutes for 6 seconds)
• Interstage pressure gauges mounted in the frame to display operating pressure of each stage (useful for valve tightness checks and fault localisation)

Frame and controls
Open frame for easy maintenance and transport. Protective thermo-formed casing channels cooling air over cylinders and interstage piping. Control console includes interstage pressure gauges, internal temperature indicator, presence and phase-sequence alarm, oil shortage alarm, run/stop and manual condensate drain controls. Frame in steel with scratch-resistant powder coat RAL 9005 black.

Standard equipment

• Double Hyperfilter system (PED certified)
• Condensate separation system
• Frame colour: Black RAL 9005

Technical specifications

• Pumping unit: 4-stage with gas recovery (first stage dedicated to gas recovery)
• Suction pressure range: 2–5 bar
• Variable flow (approx.): 250–690 L/min
• Materials: AISI 316 stainless steel pipes, fittings and nuts; special cast-iron cylinders; forged aluminum connecting rods; forged steel crankshaft
• Lubrication: forced lubrication with low-pressure gear pump; minimum lubricating oil pressure switch
• Filtration: stand-alone Hyperfilter activated-carbon cartridge; double Hyperfilter system (PED certified)
• Condensate management: intermediate and final separators; automatic condensate drain (every 7 minutes); electrical-cabinet-controlled separator drainage (every 15 minutes for 6 seconds)
• Safety: safety valves after each stage; interstage pressure gauges for monitoring
• Frame: open, maintenance-friendly frame with thermo-formed protective casing; control console with alarms and indicators
• Motor: three-phase electric motor available 11–15 kW