SmartAir Master The intelligent compressed air management system - PowerPoint PPT Presentation

SmartAir Master The intelligent compressed air management system Developed by Compair to save your customers money

Customers will need more Energy Efficient Systems ▪ Why do we make more energy efficient compressor and controllers ? ▪ Facts aprox 70% of electrical energy is used in Industry ▪ According to Industry figures 10% of all energy used in industry is used to produce compressed air. ▪ By using a controller to run the system more efficiently it is estimated that most systems can reduce there energy consumption on compressed air plants by around 25%. ▪ Your customers are investing in more and more energy saving equipment. A Gardner Denver Company Page ▪ 2

SYSTEM PRE-FILL Start-up Compressors can be Pre-defined - Eliminates High Power Demand - Efficient Operation - Intelligent Response SmartAir Conventional system Pressure Pressure Target Target pressure pressure Process Process Time Time start start A Gardner Denver Company Page ▪ 3

Pressure reduction increased efficiency On a system with 2 x 75 kW and 1 x 132 = 20 kW reduction S A M reduces the pressure band to optimise the system efficiency- saving energy AIR SYSTEM PRESSURE ( BAR g ) 8.2 UPPER PRESSURE SET 8.0 POINT 7.8 7.6 WASTED WASTED WASTED ENERGY ENERGY ENERGY 7.4 7.2 7.0 LOWER Required Air System Pressure 7.0 bar ( 101.5 psi ) minimum PRESSURE 6.8 SET POINT 6.6 A Gardner Denver Company Page ▪ 4

OPERATION MODE „Energy Saving“ The S A M measures the rise and fall of pressure against time, and with the intelligent software, selects the most efficient combination of compressors meet the demand. Low Air Demand High The most inefficient way to run a compressor is off-load. An off load compressor can consume up to 30% of the full load power for zero output. On a 75 kW compressor this could mean off load the total power used could be nearly 30kW A Gardner Denver Company Page ▪ 5

SmartAir MASTER The Complete Compressed Air Management System Designed to reduce energy usage Innovative: Easy to Specify Easy to Install Easy to Commission Saves Energy and Increases performance Controls up to 12 compressors of any make or model Comprehensive status reports A Gardner Denver Company Page ▪ 6

Technical Data Display, Coloured graphic touch panel: 5,7”, resolution QVGA (320x240) Compressor connection via interface RS485 Max. 12 compressors: Fix speed, variable speed Max. cable length 1200m, 2-wire, protected cable Voltage supply 110V / 230V, 50 / 60Hz, adsorbed power 16 VA Extension module connection via interface RS485 (max. 4 extension modules) Customer connection via interface RS485: Protocol ModBus RTU, optional PROFIBUS 2 Analogue inputs 4..20mA, 24VDC, max. 500m Input 1: passive, pressure sensor Input 2: passive / active referring to connection to volume flow sensor 3 Digital inputs max 20m, > 20m coupling relay required 2 Digital outputs , Potential free relay outputs, Rating max. 250V / 1A SD memory card A Gardner Denver Company Page ▪ 7

A Complete package – ready for installation • Scope of Supply SmartAir Master • SmartAir Master in metal sheet cabinet, IP 54 • Line pressure sensor • Set of plugs to connect compressors • SD card • Quick start manual and CD-ROM hand book multi lingual Only few Accessories - easy to select • Compressor module (STD): Fix speed compressor • Compressor module (VSD): Variable speed compressor • PROFIBUS module • Extension module (max 4 to 1 SmartAir Master) • Sensor for volume flow • Control box lock • Web server module incl. Visualisation • Data logging report • Sensor for temperature • Sensor for dew point A Gardner Denver Company Page ▪ 8

Energy Savings by Low Operating Pressure Without Management System With Management System Pressure Band Control Pressure- Cascade- Control Compressor 1 7.5 bar Compressor 2 Total pressure Compressor 3 Compressor 4 Energy saving Large Compressor 5 pressure band band 6.7 bar Small Compressor 1- 5 pressure 6.5 bar 6.5 bar band  p = 0,8 bar Pressure reduction by 3 x L45-7.5 3 x 1.4 kW 4.20 kW 2 x L110-7.5 2 x 5.2 kW 10.40 kW Total power less at 6.7 bar 14.60 kW At 8000 working hours/year Energy saving 116,800 kWh Cost saving at 0.10 € / kWh 11,680 € / Year A Gardner Denver Company Page ▪ 9

Intelligently controls the complete installation ModBus-RTU Customer's PLC PROFIBUS (optional) RS485-3 SmartAir Master to control the air station bzw. digital I/O Dig.input RS485-2 RS485 Dig. input DI-1 Selection switch to activate a profile Dig. input DI-2 Dig.inputs Analogue input AI-1 Selection switch to activate a profile RS485-1 Connection of: ➢ Compressors ➢ Communication ➢ Air treatment systems Line pressure sensor L30 L30 L45SR Compressor 1 Compressor 2 Compressor 3 Receiver Dryer Filter A Gardner Denver Company Page ▪ 10

SmartAir Master SmartAir Master (100016136) Compressor Analog input AI-1 module (VSD) Line pressure sensor (100016222SIM) (100003136) + Analog input AI-2 Compressor Connection Programmable to different functions (Sensors see Accessoires) module plug SureScan RS485-1 (ZS1055047) (STD) (100016166) RS485-2 DELCOS 1000 DELCOS Pro DELCOS 3100 GD Pilot MK DELCOS XL GD Pilot RS485-3 SureScan SureScan-LSR Accessoires (Customer) Fixed speed Sensors max. 1 Module max. 1200m max. 4 Modules max. 1200m max. 12 Compr. max. 1200m Digital input Line pressure sensor DI-1..3 SD card 100003136 Digital output (10001613 Volume flow sensor (Kit) DO-1..2 8) ZS1055781 2x2x0,5..1,5m Dew point sensor m² 100014803 twisted pair Temperature sensor and 100016229 screened (100003989) Compressor Compressor Manuals module module Programmer guide ModBus-RTU (GB/US) ZS1060126 (STD) (VSD) Programmer guide PROFIBUS (GB/US) (100016166) (100016222SI Extension ZS1060127 M) Software update guide Module ZS1060125 PROFIBUS Webserver ModBus-RTU 230V/50-60Hz Compressor Connections module module (100016226) ZS1061822 (Visualization) Checklist Compressor connections (100016156) 110V/50-60Hz ZS1062760 230V/50-60Hz (100016230) Standard or Speed regulated (ZS1055779) Digital inputs DI-1..8 Miscellaneous Half/full load compressor Digital outputs DO-1..2 110V/50-60Hz compressor SD card reader (3phase asynchronous motor (ZS1055780) Analog inputs AI-1..2 ZS1069300 max. 500A rating current) (Sensors see Accesoires) Interface Converter USB-RS485 ZS1073178 Interface Converter RS232-RS485 A Gardner Denver Company Page ▪ 11 100004858 V03 Keylock Smartair Master ZS1049510

Former Installation Connection of CompAir DELCOS SmartAir 5 & 8 / Metacentre MultiMaster bus DELCOS 3100 DELCOS 3100 DELCOS 3100 Gateway Gateway Gateway DELCOS 3100 DELCOS 3100 DELCOS 3100 Gateway Not required at SmartAir Master A Gardner Denver Company Page ▪ 12

Compressor Module STD SmartAir Master Standard fixed speed compressor Installation via, DIN rail TS 35, 24-230V UC no coupling relay required Module required for: 2 plugs RS485 interface Delcos 3000, Surescan, Hydrovane, LED indication at inputs and outputs GD & all competitor fixed speed compressor controls 3 digital inputs Standby, no fault Motor running Full load 3 digital outputs Remote load enable Remote Load Remote half / full load A Gardner Denver Company Page ▪ 13

Compressor Module VSD SmartAir Master Variable speed drive compressor Installation via, DIN rail TS 35, 24-230V UC no coupling relay required 2 plugs RS485 interface Module required for: LED indication at inputs and outputs Delcos3000RS, Quantima, Hydrovane, GD & all competitor variable speed compressor controls 4 digital inputs Standby, no fault Motor running On Load Speed Modulated line pressure Line pressure sensor compressor A Gardner Denver Company Page ▪ 14

Compressor Extension Module SmartAir Master Downstream equipment Supply voltage versions 1.) 230V / 50/60Hz 2.) 110V / 50/60Hz 2 relay outputs (programmable) 2 analog inputs 8 digital inputs Temperature sensor Pressure Refrigeration dryer, Adsorption dryer, Filter, Condensate Management, etc. sensor ( Future development ) A Gardner Denver Company Page ▪ 15

Advanced touch-screen display Features: ▪ Latest microprocessor technology ▪ So far in 17 languages available ▪ Intuitive user guidance Benefits: ▪ Easy to use ▪ Comprehensive information ▪ Provides all performance data on a view A Gardner Denver Company Page ▪ 16

Unique setting-up function Commissioning Wizard Features: ▪ Guidance via series of on-screen prompts ▪ Set-up guidance for commissioning engineer ▪ Ensuring the correct settings of parameters The GD Pilot Connect is now ready for operation. Benefits: ▪ Easy and quick installation ▪ Safe and reliable operations ensured ▪ No special training requirements GD Pilot Connect A Gardner Denver Company Page ▪ 17