Piston compressor booster station Ace V Plus

reciprocatingairgas

Overview
Ace V Plus is a 4-stage booster breathing-air compressor (2+2 in parallel) engineered for continuous industrial service and for production of breathing air compliant with DIN EN 12021 when fitted with original filter cartridges. The unit combines a heavy-duty pumping assembly with dedicated purification and condensate management systems for high-pressure applications.

Main features

• 4-stage heavy-duty pumping unit (2+2 in parallel)
• Aluminum monoblock construction
• Forced lubrication via low-pressure gear pump
• First stage configured for gas recovery
• 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
• Forged aluminum connecting rods
• Forged steel crankshaft
• High-flow valves on stages 1–3
• Roller bearings sized for intensive operation
• Hardened steel fourth stage with six special cast-iron piston rings
• Thrust pads on 2nd and 3rd stages to eliminate lateral piston forces
• Activated-carbon Maxifilter system

Electric motor
The three-phase electric motor transmits motion to the pumping unit via belt drive. Motor power options available: 9 kW, 11 kW or 15 kW.

Purification system (Hyperfilter)
The Hyperfilter purification system is installed after the final compressor separator and before the pressure maintenance valve. With original filter cartridges it provides treatment of breathing air to DIN EN 12021 standards. An interstage separator between the 2nd and 3rd stages removes bulk moisture from the purification circuit. Filtering capacity (inlet air at 20°C, 200 bar): 52,500 m³.

Electrical cabinet

• ON/OFF switch with motor protection
• Electromechanical pressure switch to stop the compressor at final pressure
• Drainage of all interstage separators and of the final separator during operation
• Timer for automatic condensate drain device
• Integrated no-load startup (automatic discharge at each shutdown)
• Condensate collection tank: 5 L (silenced) — effective capacity ≈ 3 L for environmental disposal
• Interstage pressure gauges for monitoring stage pressures and valve tightness

Frame and controls
Open vertical-frame layout for easy maintenance. External oil level and drain. Control console equipped with interstage gauges, oil pressure gauge, internal temperature indicator, phase-sequence and oil-shortage alarms, run/stop and manual condensate drain controls. Frame in steel with scratch-resistant powder coating Black RAL 9005.

Standard equipment

• Dual PED-certified Hyperfilter system
• Compressor control with automatic condensate drainage
• Electronic pressure switch
• Interstage control manometers
• Frame color Black RAL 9005

Technical specifications

• Pumping unit: 4-stage heavy-duty (2+2 in parallel)
• Materials: AISI 316 piping/fittings; special cast-iron cylinders; forged aluminum connecting rods; forged steel crankshaft
• Lubrication: forced via low-pressure gear pump
• Condensate management: intermediate separators, high-pressure final separator, timed automatic drainage, 5 L collection tank (≈3 L usable)
• Safety: safety valves after each stage; phase-sequence and oil shortage alarms
• Filtration/purification: Hyperfilter system; Maxifilter activated carbon; filtering capacity ~52,500 m³ (20°C, 200 bar)
• Motor: three-phase electric, options 9 / 11 / 15 kW
• Monitoring: interstage pressure gauges, oil pressure gauge, internal temperature indicator
• Finish: open steel frame with Black RAL 9005 powder coating
• Intended use: compression of technical gases and production of breathing air for industrial applications