Campus Theory

1. Theory Topic 9: The water separator drain valve

Overview

Throughout the different ranges, there are different types of water separators:

Older types Design 2006 Design 2008 Design 2016

Small range ED12
GA30-45 WD80
GA<90kW WSD Cdi16 EWD 330 M
GA>90kW WSD ERD

In the chapters below, you will learn how each design works.

Use the carrousel to go to the “Links” section, there you will also find:
• A PowerPoint training with more service details about the EWD330, ED12 and
WSD25.
• A manual of the LD200

WSD type water separator

The WSD type water separator is a moisture trap, used in the older versions of the GA30-55
and the range >90kW.

It is mounted after the aftercooler and before the air outlet. It removes any moisture that has
been condensed in the compressed air after leaving the after cooler.

Compressed air enters the moisture trap through the inlet. Because of the shape of the
housing, the air swirls around and the heavier, condensed moisture is separated from the
lighter air.
Moisture is collected at the bottom. When the moisture level reaches a certain height, it will lift
the float. This float opens a valve at the bottom. The compressed air inside the WSD ejects
the moisture out of the automatic outlet.

The moisture trap will only eject moisture when the compressor is on load.
In order to check the correct operation of the valve, there is a manual outlet connected to a
ball valve.

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 ED12

Small ranges of screw compressors G/GA/GX may be equipped with the Electronic Condensate drain ED12.
• Condensate that was separated from the compressed air, comes from the heat exchanger and is collected in a
receiver inside the ED12.
• When the condensate reaches a certain level, a floating device rises with the water level and activates the electrical
circuit through an optical sensor.
• The solenoid valve is powered and water is discharged through the flexible hose connected to the condensate
outlet.
The test button also activates the solenoid valve and allows you to manually discharge the ED12.

To see how the ED12 looks like, and how it has to be service, check out this video:
https://www.business-portal.net/pages/directlink.aspx?bpUniqueId=3E5EE779-F311-4B1B-BF8A-96242A3CC050

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 CDi16

The Cdi16 has been used in GA<90kW units before 2006.

• The valve to eject the condensate output is electronically controlled.

• Cdi16 opens an electromagnetic valve and discharges condense water out of the compressed air system without
compressed air loss.
• In 2008 and according to ECB AII0349 CDi16 drain was been replaced by EWD 330 M because the CDi16 drain
quality and reliability did not fulfill our brand promise.

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 EWD 330 M

The EWD 330 M replaces the CDi16, which improved its reliability.

This is how it works.

Collecting the condensate:
• The condensate enters the drain and collects in the sump.
• The solenoid valve allows pressure through the pilot supply line to the space above the diaphragm. This pressure
keeps the diaphragm closed.
• Because the pressurized space above the diaphragm is larger than the space below, an absolutely leak-proof seal
is ensured.
Draining the condensate:
• Once the condensate level reaches the upper limit of the probe, the solenoid valve is energized. This probe is a
capacitive sensor that continuously measures the liquid level.
• The solenoid valve closes the pilot supply line.
• The pressure on top of the diaphragm escapes via a channel towards the discharge pipe and the diaphragm lifts off
the valve seat.
• The pressurized condensate then forces its way into the discharge pipe.
• As the condensate drains away, the level probe monitors the speed at which the level drops, calculating exactly
when to shut the diaphragm, so that no air escapes.

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If a problem develops, such as a blocked outlet or faulty diaphragm, the drain switches to “fault mode”.
• Both the flashing alarm light and the voltage free contacts are activated.
• The drain switches to a “timer” mode. It will open and close the valve according to a sequence as indicated below.
This will continue until the problem is resolved. This way it is ensured that condensate is still being drained. Once
the fault is cleared, the EWD will automatically return to the normal mode of operation. If the fault is not repaired
automatically, maintenance is required.

EWD330 is always connected with the aftercooler with two flexible lines:
1. For water and compressed air discharging.
2. As a balancing line to avoid air trap in the condensation collector.

Standard, the EWD330M has the following features:

• Integrated manual drain:
- If the system is energized, the “Test” button gives the possibility to depressurize the system between
minimum pressure valve & outlet valve.
- in case of power loss or no power, there is a manual drain outlet valve.
• Viton membrane: added heat and chemical resistance against oil & condensate mixture

There are different types of EWD 330 drains. Here’s an overview:

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 ERD or Electronic regulated drain

For GA>90KW after 2008, it was decided to change the WSD to our own design: the Elektronikon regulated drain (ERD).

The drain consists of:

• a capacitive sensor which is incorporated in the drain collector
• and of a pilot valve which is placed outside the drain collector.

This is how it works:

• The condensate in the collector reaches the level of the capacitive sensor.
• A drain opening delay timer starts counting.
• As long as the delay timer is running, extra condensate will be collected and the level will rise even higher than the
position of the sensor.
• The pilot valve is normally closed, refer to ECB APFF 1819. But as soon as the delay timer has expired, it is
activated and the diaphragm opens the outlet.
• The condensate is discharged.

• From the moment that the sensor is not detecting any condensate anymore, a drain closing delay timer is started.
• The pilot valve will still drain the condensate during the run of this timer to make sure that the remaining amount of
condensate is drained.
• The pilot valve is deactivated when the timer has expired.
• The outlet closes quickly without wasting compressed air.

The ERD has:

• A reduced pressure drop
• Standard Electronic Water Drain (Atlas Copco Design)
• Simple design
• Regulated by MkIV
Solenoid valve needs to be replaced every 8000 hrs.

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 WD80

In the 2016 design of the GA 30 & 45, the WD80 has been introduced. This is an automatic drain valve. It works with a float
and has a manual drain port.

Visit the Business Portal:

To see the dimension drawings of the WD80:
https://storage.business-portal.net/storage/storage_012/StorageLib_00/156008ba-2499-44ec-8f75-
410f63b5c111/WD_80_Dim_Draw_EN_Antwerp_2933532000.pdf

To see how it looks and how the WD80 has to be serviced:

https://www.business-portal.net/pages/directlink.aspx?bpUniqueId=9A811A65-24A0-41AC-A9EA-762D5F01571C

Or you can check out the WD80 service instructions:

https://storage.business-portal.net/storage/storage_029/StorageLib_01/6bfd2b20-5c44-4489-9d5b-
a776104e7842/03_GA30-45_%20Drain%20overhaul_2946202900.pdf

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 LD200

• The automatic drain is connected by its inlet (1).

• Because the drain outlet is closed by the diaphragm (3), water is collected in the tank (2).
• As the water level increases, the float (4) rises.
• When it reaches the top level, the logic circuit detects this and opens the solenoid valve.
• This causes a pressure drop over the diaphragm and the condensate is forced out of the drain.
• When the bottom level is reached again, the float gives a signal to close the valve again.
No compressed air is wasted during the draining process.

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