Ultima Sales Presentation 4-26-19

April 25, 2019
Ultima
75-160kW Oil Free Compressor
Ultima – What is it?
 A differentiated 2-Stage Dry Screw Oil-Free compressor (75kW – 160kW)
 Utilizes low and high pressure two-stage dry screw air ends individually driven by variable
speed permanent magnet synchronous motors
 Each motor operates at >97% efficiency (greater than IE4) and runs at ~20,000 rpm
 Highest efficiency two-stage dry screw compressor on the market
 Provides large turn down range and delivers low off load power (8kw)
 Significantly smaller footprint (47%) at 63-70dBA noise performance
 Water-cooled or air-cooled
 Patented Technology
 Compressor control
 Pulsation dampeners
 Enclosed cooling system
2 ©2019 Gardner Denver. All rights reserved. This PowerPoint includes information confidential to Gardner Denver.
Superior Design
 Traditional oil free compressors are  Ultima uses ultra-high efficiency

driven by a single motor. A gear box motors to independently drive each
drives both the low and high air end, replacing the gearbox and
pressure air ends. Gearboxes require the single motor.
oil and create friction that result in  This allows the air ends to turn at
added energy loss. different speeds, maximizing
efficiency at all outputs
Traditional Two-Stage Design
 Use a single motor to drive both the low and high pressure stages
 As the demand changes, the air end speeds need to change
 Conventional designs can only optimize the speed of one air end stage
 This means that either the low or high pressure stage will no longer be
running at the optimum speed for maximum efficiency
 If the main motor speed reduces by 10% then both stages follow
 However to achieve the optimum running condition the low pressure stage
may need to drop by X % and the high pressure stage by Y%
Ultima – Electronic Gear Box
 As factory air demand changes (demand profile), compressors slow down or speed
up to meet the demand
 With each stage being individually driven, the intelligent on board controller (Digital
Gearbox™) maximizes the efficiency by individually controlling the speed of each
stage, perfectly matching the delivery ratio for optimum efficiency
 This creates a variable speed oil free compressor with the highest levels of efficiency
across the full turndown range, up to 13% better than the nearest competitor
Airends driven at different speed ratios

dependant on the demand, maximizing the
efficiency of each airend individually
Next Generation Motors
 Traditional asynchronous motors have internal losses resulting in performance drop

 Ultima’s permanent magnet synchronous motors have low internal losses allowing
for a more compact design with exceptional levels of efficiency that exceed IE4
 Ultima motors rotate at speeds up to 22,000 rpm and are >97% efficient!
 Due to the design of the motors they are extremely compact
 To create a motor with the highest level of efficiency, Ultima motors are water
cooled
 This also benefits heat recovery with more heat available for the heat exchanger
Cool water in – Hot water out
Exceptional Design
 When any variable speed compressor gets to the minimum speed, it goes into idle
run, wasting energy
 Ultima uses 50 to 68% less energy than a conventional 2 stage compressor and a
160kW compressor uses only 8 kW while running in idle
 Air inlet valves are used on most compressors to control the volume of air entering
the air end. They create pressure drop which results in wasted energy. They can also
be expensive to maintain. Ultima’s engineering team has designed a control concept
that eliminates the need for the inlet valve, further increasing efficiency by
eliminating pressure drop.
No Air Inlet Valve required
Unique Closed Package Design
Starter Box is
Air Cooled
Air
Water-Cooled Package is 98% water cooled!
- No opening to environment
- Lower noise level, 63–69 dBA
- Easy installation (no customer ducting required)
Water (no heat – only max. 2…3% heat from starter box )
- Up to 13% more heat available
for heat recovery than competition
Water Cooled Components:

- intercooler
- aftercooler
- air end jacket cooling
- 1st and 2nd stage permanent magnet motors
- 1st and 2nd stage VFD’s
- thermal radiation from air end / coolers etc
Air Starter Box is

Air Cooled
Air
Air-Cooled Package is 100% air-cooled as
standard BUT…
- Heat Recovery option offers up to 98%
water cooling!
- Hybrid cooling mode allows both air
and water cooling!
- Low 64 – 70 dBA noise level
- Up to 13% more heat available
for heat recovery due to closed
Water Cooled Components:
- intercooler
package design
- aftercooler
- air end jacket cooling
- 1st and 2nd stage permanent magnet motors
- 1st and 2nd stage VFD’s
- thermal radiation from air end / coolers etc
 By utilizing the superior design of the closed loop water system, Ultima requires no external air
for internal package cooling
 Ultima processes cooling air within the compressor, utilizing an air/water heat exchanger to
cool the internal air, then recirculates it via the base frame around the compressor
 This also ensures that no dust, particulates or contaminates enter the inside of the compressor
 Installation is made easy with no requirement for ducting on water-cooled packages
 Compressor rooms can be kept to the minimum size, noise levels are greatly reduced and
machines can be easily installed at point of use.
 With the innovative design of the air intake system and a revolutionary new triple cyclic
pulsation dampener, this compressor has ultra-low noise levels that make it the quietest in the
industry @ only 63 dB(A) for a 75kw water-cooled machine
 Air entering the compression chamber is pre-filtered to ensure the highest quality oil free
compressed air. Also, the intake is near the floor where the coolest air is located
 With no external air requirement on water-cooled packages, the package is sealed ensuring no
contamination can enter the machine plus no ducting is required which means Ultima keeps
the compressor room size and installation requirements to a minimum
 With simple installation and low noise levels Ultima is also ideal for point of use applications
No air intake or outlet for water-cooled packages.

No ducting required.
Design Concept
Identical Arrangement
for LP and HP stage
No intake
regulator
Low pressure 3 way Cooler Condensate High pressure

stage 36 psi pulsation separator stage up to 145 psi
damper
Water-Cooled Ultima
Starter and control
box cooling
Compressed
air inlet
Air-Cooled Ultima
Starter and control

box cooling
Compressed
air inlet
Package Layout
Water-Cooled Ultima
Closed Loop Compression Air

Cooler Inlet Filter
Aftercooler
Compressed Air
Oil Cooler Discharge
1st Stage Airend
2nd
Stage
Drive Motor
Cooling Water
Oil Filter Inlet/Outlet
1st Stage
Oil Pump Closed Loop Intercooler Drive Motor
Coolant Pump
Package Layout
ADD ON: Fully
Integrated Air/Water Air-Cooled Ultima
Cooling Module
Cooling
Air Outlet
BASE: Ultima
Water Cooled
Cooling
Air Inlet
Electrical
Compressed Connection
Air Discharge
Package Layout
Air-Cooled Ultima
Radial Coolant
VFD Fans Reservoir Radiated Cooler
Air/Water
Cooler GD Pilot XTC
Controller
2nd Stage Moisture
Separator After-cooler
1st Stage Pulsation 2nd Stage Pulsation

Dampener Dampener
2nd Stage
1stStage
Airend
Airend 1st & 2nd Stage
1st Stage Moisture
Autodrains Inter-cooler Separator
Reducing Carbon Footprint
 Ultima uses 20% less parts than a conventional 2 Stage oil free compressor
 Not only does this increase the overall reliability of the compressor but also
results in a 30 % reduction in weight
 From a logistic point of view reducing both size and weight ensures carbon
footprint is kept to a minimum
Superior Air End Coating
 2 stage dry screw air end rotors are coated to:
– Prevent Corrosion
– Maximize efficiency
– Provide the best possible protection against rotor wear
 Not all coatings are the same, Gardner Denver uses a two layer hard coating process to ensure
maximum efficiency and protection through out the life of the compressor
 Other manufacturers use a two part process with a soft second stage Teflon – Graphite coating
which ensures good sealing on day one, but rapidly wears, reducing performance by as much
as 10% +, Interstage filter required with soft coating
Ultima
Ultima – Guaranteed Maximum Efficiency

throughout the life of the compressor
Product Range
Ultima– Oil Free Range
Ultima 160
247 to 842cfm @ 125psig
Ultima 132
Ultima 110 247 to 762cfm @ 125psig
247 to 633cfm @ 125psig
Ultima 90
247 to 505cfm @ 125psig
Ultima 75
247 to 403cfm @ 125psig
247cfm FLOW 842cfm
Product Overview Ultima 75
Flow Range:
247 to 403 cfm @ 125 psig
271 to 348 cfm @ 145 psig
Motor Size:
2 x 37.5 kW - Rated
Pressure :
Pressure Range: 58 to 145 psig
Nominal Pressure 145 psig
Cooling:
Water or Air Cooled
Voltages:
460V – 60Hz
400V – 50Hz
Flow Range:
247 to 505 cfm @ 125 psig
271 to 449 cfm @ 145 psig
Motor Size:
2 x 45 kW - Rated
Pressure :
Cooling:
Water or Air Cooled
Voltages:
460V – 60Hz
400V – 50Hz
Flow Range:
247 to 633 cfm @ 125 psig
271 to 574 cfm @ 145 psig
Motor Size:
2 x 55 kW - Rated
Pressure :
Cooling:
Water or Air Cooled
Voltages:
460V – 60Hz
400V – 50Hz
Flow Range:
247 to 762 cfm @ 125 psig
271 to 701 cfm @ 145 psig
Motor Size:
2 x 66 kW - Rated
Pressure :
Cooling:
Water or Air Cooled
Voltages:
460V – 60Hz
400V – 50Hz
Flow Range:
247 to 842 cfm @ 125 psig
271 to 834 cfm @ 145 psig
Motor Size:
2 x 80 kW - Rated
Pressure :
Cooling:
Water or Air Cooled
Voltages:
460V – 60Hz
400V – 50Hz
Value Proposition
Efficiency, Water-cooled U160
Ultima 160 ZR 160 VSD
125 PSI 125 PSI
kW CFM spec. Power kW CFM spec. Power
157.8 815.2 19.36 175.2 856 20.47
135.8 701.6 19.35 155.9 769 20.27
114.9 588.1 19.54 123.1 612 20.11
95.2 474.6 20.07 101.2 498 20.32
76.7 361.1 21.25 80.4 384 20.94
59.4 247.5 24.00 60.2 269 22.38
Ultima 160 VSD to ZR 160VSD Comparison

30
28
specific power (kW/100CFM)
26
24
Ultima 160
ZR 160 VSD
22
20
18
100 200 300 400 500 600 700 800 900
FAD (CFM)
Efficiency
Demand Profile
Power Consumption at Flow
Time Weighted Power Consumption
Energy Cost @ 0.10/kWh
$15,210 over 5 years

Efficiency, Water-cooled U75
Ultima 75 ZR 75 VSD
125 PSI 125 PSI
kW CFM spec. Power kW CFM spec. Power
87.10 425.47 20.47 94.0 422 22.27
81.33 389.88 20.86 67.7 299 22.64
75.67 354.29 21.36 51.1 212 24.1
70.13 318.71 22.01 42.1 159 26.48
64.73 283.12 22.86
59.40 247.53 24.00
Ultima 75 VSD to ZR 75VSD Comparions

30
28
specific power (kW/100CFM)
26
24
Ultima 75
ZR 75 VSD
22
20
18
100 200 300 400 500
FAD (CFM)
Efficiency
Demand Profile
Power Consumption at Flow
Time Weighted Power Consumption
Energy Cost @ 0.10/kWh

No Load Power Consumption
No Load Pwr Consumption

16000
kW Power Consumption
14000
12000
10000
8000
6000
4000
2000
0
75 90 110 132 160
Size of Compressor in kW
Ultima ZR Series
Compact Design
 The unique design of the Ultima results in an extremely small package
 The Ultima uses up to 85ft3 less (28%) volumetric area than a conventional
2 stage oil free compressor
 Ultima’s footprint is up to 47% smaller than the competition
 This allows easy installation in the smallest possible space
 In multiple machine installations this results in considerable building and

real estate savings
Compact Size, Water-cooled
 Ultima
– 85.4” x 54.9” x 78.4”
– 32.6 sq ft. footprint
– 212.7 cu ft volume
 ZR 55-90
– 85.8” x 57” x 86”
– 34.0 sq ft. Footprint (4.3% larger footprint)
– 243.4 cu ft volume (14.4% larger volume)
 ZR132-160
– 100” x 65” x 79”
– 45.1 sq ft. (38.7% larger footprint)
– 297.2 cu ft volume (39.7% larger volume)
Compact Size, Air-cooled
 Ultima
– 127.7” x 54.9” x 78.4”
– 48.7 sq ft. footprint
– 318.1 cu ft volume
 ZT 55-90
– 85.8” x 57.1” x 86”
– 34.0 sq ft. footprint (30.2% smaller footprint)
– 243.8 cu ft volume (23.4% smaller volume)
 ZT132-160
– 159.1” x 65” x 78.7”
– 71.8 sq ft. (47.4% larger footprint)
– 471 cu ft volume (48.1% larger volume)
Footprint/Noise Comparison, Water-cooled
Foot Print % Larger Foot
Model Length (in.) Width (in.) Height (in.) Noise dB(A)
(ft²) Print
GD Ultima
85.35 54.88 78.43 32.53 -- 69
U160
IR – IRN200H-
100.39 71.89 95.98 50.12 54.1% 78
OF VS
AC ZR160
100 65 78.7 45.11 38.7% 70
VSD
Kaeser
DSG20-2 131.69 68.9 93.9 63.01 93.7% 80
SFC650
GD EnviroAire
102.24 68.66 78.78 48.75 49.9% 79
TVS160
GD EnviroAire
102.24 68.66 78.78 48.75 49.9% 78
T160
GD EnvrioAire
102.24 68.66 78.78 48.75 49.9% 77
TVS132
Footprint/Noise Comparison, Air-cooled
Foot Print % Larger Foot
Model Length (in.) Width (in.) Height (in.) Noise dB(A)
(ft²) Print
GD Ultima
127.7 54.88 78.43 32.53 -- 70
U160
IR – IRN200H-
100.39 74.2 95.98 50.12 6.2% 79
OF VS
AC ZT160
159.1 65.0 78.7 71.8 47.4% 73
VSD
Kaeser
DSG260-2 135.25 68.9 93.9 63.01 32.9% 82
SFC
GD EnviroAire
102.24 68.66 78.78 48.75 49.9% 79
TVS160
GD EnviroAire
102.24 68.66 78.78 48.75 49.9% 79
T160
GD EnviroAire
102.24 68.66 78.78 48.75 49.9% 79
TVS132
Noise Level Comparison
Model Gardner Denver Ultima Atlas Copco Z w/VFD

Air-cooled
75 kW 64dBA 76dBA
160 kW 70dBA 73dBA
Water-cooled
75 kW 63dBA 74dBA
160 kW 69dBA 70dBA
5dBA = ~1.5 times volume loudness level
Ultima Flexible and Upgradeable
Ultima
1 machine covers the
complete range. With 110kW
model not available by Atlas
Copco
Atlas Copco Range
Model
ZR 75 2 sizes of
ZR 90 2 Frame sizes 4 Motor sizes
Airend
110 kW Not Available required required
ZR 132 required
ZR160
Ultima
Totally Flexible
Machine can be upgraded to
cover entire range
Ultima Options
Superior Heat recovery
 All the major components in the Ultima are water-cooled allowing for better heat
control across the complete machine for more efficient performance
 Ultima’s cooling philosophy maximizes energy recovery from the complete
compressor package
 Around 94% of the energy used in a compressor is converted into heat. The closed
loop cooling system in the Ultima cools all of the major components, removing heat
from the Motors, Inverters, Airends and Cabinet
 Resulting in up to 13% better overall heat recovery than a conventional 2 stage oil
free compressor, meaning even greater levels of efficiency can be achieved
Standard – cooling water in parallel Heat Recovery – cooling water in series
Rad Cooler
After Cooler
Inter Cooler
Intercooler
Rad Cooler Rad Cooler Intercooler Aftercooler
Aftercooler
 Outlet water temperatures up to 194°F

 98% of the heat can be recovered (approx. 13% more than standard)
 Water flow rate 40 gal/min
 Heat recovery connections are standard on water-cooled packages and
optional on air-cooled packages
iConn
Secure Data Management
iConn – Standard on Ultima
 iConn is a Digital Cloud Platform to support ‘Compressed Air

Analytics’
 iConn is designed to receive data from multiple sources
 iConn will manage data from compressors, ancillary systems and can
integrate all products which facilitate analytics around air services
 iConn grows with the customer
 iConn will support Non-GD based products
 iConn is a decision support tool, it can be automated with its rules
based engine, it can be real time, it can be enterprise connected
 ULTIMA is iConn enabled as standard
Value proposition Value proposition
• Real time • Predictive

Peace of maintenance •Different mechanisms of monitoring
monitoring Monitoring
mind
• Alarms, warnings • Warranty
• Equipment • Pro-active live
•Relevant information is continuously processed to
integration analytics
Processing predict premature failures
• Air audits • Alarms
• Data analytics Control • 24h services
• Security •Better performance, adequate maintenance
Savings avoiding breakdowns, potential tax reductions
iConn
•Carbon footprint, environmental impact

Ecology
•Productivity, resources, scheduling

Savings Optimizing
• Production
improvement
• Power cost savings
• Green advantages
iConn – Standard on Ultima
Assess Protect
Summary
Ultima Summary
Power, total cost of ownership, space, noise, reliability & environment
 Two high efficiency permanent magnetic motors >97% efficient [>>IE-4]

 No gear box required
 Best in class performance @ full load & partial load
 Very compact design [-47% footprint]
 Very low noise level − 63 dB(A)
 No intake regulator [only blow-off valve]
 LP & HP air ends are independently driven
 Best in class performance @ idle load (8kW)
 High efficiency cooling system
 Up to 13% more heat available for heat recovery
 Easy installation [no customer ducting required on water-cooled package]
Questions?

Ultima Sales Presentation 4-26-19

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ultima Sales Presentation 4-26-19

Uploaded by

Copyright:

Available Formats

April 25, 2019

 Highest efficiency two-stage dry screw compressor on the market

 Significantly smaller footprint (47%) at 63-70dBA noise performance

 Enclosed cooling system

 Traditional oil free compressors are  Ultima uses ultra-high efficiency

 As the demand changes, the air end speeds need to change

Airends driven at different speed ratios

 Traditional asynchronous motors have internal losses resulting in performance drop

Cool water in – Hot water out

No Air Inlet Valve required

Water Cooled Components:

Air Starter Box is

 Installation is made easy with no requirement for ducting on water-cooled packages

No air intake or outlet for water-cooled packages.

Low pressure 3 way Cooler Condensate High pressure

Starter and control

Closed Loop Compression Air

1st Stage Pulsation 2nd Stage Pulsation

Ultima – Guaranteed Maximum Efficiency

247cfm FLOW 842cfm

Ultima 160 VSD to ZR 160VSD Comparison

$15,210 over 5 years

Ultima 75 VSD to ZR 75VSD Comparions

$13,320 over 5 years

No Load Pwr Consumption

 The unique design of the Ultima results in an extremely small package

 Ultima’s footprint is up to 47% smaller than the competition

 This allows easy installation in the smallest possible space

 In multiple machine installations this results in considerable building and

Model Gardner Denver Ultima Atlas Copco Z w/VFD

5dBA = ~1.5 times volume loudness level

Standard – cooling water in parallel Heat Recovery – cooling water in series

 Outlet water temperatures up to 194°F

 iConn is a Digital Cloud Platform to support ‘Compressed Air

• Real time • Predictive

•Carbon footprint, environmental impact

•Productivity, resources, scheduling

 Two high efficiency permanent magnetic motors >97% efficient [>>IE-4]

You might also like