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

Page ▪ 2 A Gardner Denver Company

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.

Page ▪ 3 A Gardner Denver Company

SYSTEM PRE-FILL

SmartAir Conventional system

Target pressure Time Time Process start Process start Pressure Target pressure Pressure

Start-up Compressors can be Pre-defined

• Eliminates High Power Demand
• Efficient Operation
• Intelligent Response

Page ▪ 4 A Gardner Denver Company

Required Air System Pressure 7.0 bar ( 101.5 psi ) minimum S A M reduces the pressure band to

• ptimise the system efficiency- saving energy

LOWER PRESSURE SET POINT UPPER PRESSURE SET POINT

AIR SYSTEM PRESSURE ( BAR g )

8.2 8.0 7.8 7.6 7.4 7.2 7.0 6.8 6.6

WASTED ENERGY WASTED ENERGY WASTED ENERGY

Pressure reduction increased efficiency

On a system with 2 x 75 kW and 1 x 132 = 20 kW reduction

Page ▪ 5 A Gardner Denver Company Air Demand Low High

OPERATION MODE „Energy Saving“

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 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.

Page ▪ 6 A Gardner Denver Company

Innovative: Easy to Specify Easy to Install Easy to Commission Saves Energy and Increases performance Controls up to 12 compressors

• f any make or model

Comprehensive status reports The Complete Compressed Air Management System Designed to reduce energy usage

SmartAir MASTER

Page ▪ 7 A Gardner Denver Company

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

Page ▪ 8 A Gardner Denver Company

• Scope of Supply
• 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 Complete package – ready for installation

SmartAir Master

Page ▪ 9 A Gardner Denver Company

Without Management System With Management System

Large pressure band

Energy Savings by Low Operating Pressure

Pressure reduction by p = 0,8 bar 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

Compressor 1- 5 Pressure Band Control

Energy saving

Compressor 1 Compressor 2 Compressor 3 Compressor 4

Total pressure band

Compressor 5

Pressure- Cascade- Control Small pressure band

7.5 bar 6.5 bar 6.5 bar 6.7 bar

Page ▪ 10 A Gardner Denver Company

SmartAir Master

Intelligently controls the complete installation

Compressor 1

L30 L30 L45SR Line pressure sensor RS485-1 Analogue input AI-1

• Dig. input DI-2
• Dig. input DI-1

RS485-2 RS485-3

• bzw. digital I/O

ModBus-RTU PROFIBUS (optional) Customer's PLC to control the air station Selection switch to activate a profile RS485 Dig.inputs Selection switch to activate a profile

Compressor 2 Compressor 3 Receiver Dryer Filter

Dig.input

Connection of: ➢ Compressors ➢ Communication ➢ Air treatment systems

Page ▪ 11 A Gardner Denver Company

• max. 1200m
• max. 4 Modules

SmartAir Master

ModBus-RTU PROFIBUS module

(100016156)

Webserver module (Visualization)

230V/50-60Hz (ZS1055779) 110V/50-60Hz (ZS1055780)

SmartAir Master (100016136)

Line pressure sensor (100003136) Programmable to different functions (Sensors see Accessoires) 2x2x0,5..1,5m m² twisted pair and screened (100003989) DELCOS Pro GD Pilot DELCOS 1000 Standard or Half/full load compressor Speed regulated compressor (3phase asynchronous motor

• max. 500A rating current)

Compressor module (STD)

(100016166)

Compressor module (VSD)

(100016222SI M) RS485-3 (Customer) SD card (10001613 8) Digital input DI-1..3 Digital output DO-1..2

Accessoires

Sensors Line pressure sensor 100003136 Volume flow sensor (Kit) ZS1055781 Dew point sensor 100014803 Temperature sensor 100016229 Manuals Programmer guide ModBus-RTU (GB/US) ZS1060126 Programmer guide PROFIBUS (GB/US) ZS1060127 Software update guide ZS1060125 Compressor Connections ZS1061822 Checklist Compressor connections ZS1062760 Miscellaneous SD card reader ZS1069300 Interface Converter USB-RS485 ZS1073178 Interface Converter RS232-RS485 100004858 Keylock Smartair Master ZS1049510

Compressor module (STD)

(100016166) SureScan Fixed speed

Compressor module (VSD)

(100016222SIM) +

Connection plug SureScan

(ZS1055047) SureScan-LSR

Extension Module

230V/50-60Hz (100016226) 110V/50-60Hz (100016230) Digital inputs DI-1..8 Digital outputs DO-1..2 Analog inputs AI-1..2 (Sensors see Accesoires)

• max. 1200m
• max. 1 Module

RS485-2 Analog input AI-1 Analog input AI-2 RS485-1

• max. 1200m
• max. 12 Compr.

DELCOS 3100 DELCOS XL GD Pilot MK

Page ▪ 12 A Gardner Denver Company

Metacentre

Gateway

Not required at SmartAir Master

Connection of CompAir DELCOS

MultiMaster bus DELCOS 3100 DELCOS 3100

DELCOS 3100

Gateway

DELCOS 3100

Gateway

DELCOS 3100

DELCOS 3100

Gateway

Former Installation

SmartAir 5 & 8 /

Page ▪ 13 A Gardner Denver Company

3 digital inputs Standby, no fault Motor running Full load 3 digital outputs Remote load enable Remote Load Remote half / full load

Installation via, DIN rail TS 35, 24-230V UC no coupling relay required 2 plugs RS485 interface LED indication at inputs and outputs

Standard fixed speed compressor

SmartAir Master

Compressor Module STD

Module required for: Delcos 3000, Surescan, Hydrovane, GD & all competitor fixed speed compressor controls

Page ▪ 14 A Gardner Denver Company

4 digital inputs Standby, no fault Motor running On Load Speed

Installation via, DIN rail TS 35, 24-230V UC no coupling relay required 2 plugs RS485 interface LED indication at inputs and outputs

Line pressure sensor compressor

Modulated line pressure

SmartAir Master

Variable speed drive compressor

Module required for: Delcos3000RS, Quantima, Hydrovane, GD & all competitor variable speed compressor controls

Compressor Module VSD

Page ▪ 15 A Gardner Denver Company

Refrigeration dryer, Adsorption dryer, Filter, Condensate Management, etc. Pressure sensor Temperature sensor ( Future development ) 2 relay outputs (programmable)

Supply voltage versions 1.) 230V / 50/60Hz 2.) 110V / 50/60Hz

8 digital inputs 2 analog inputs

Compressor Extension Module

SmartAir Master

Downstream equipment

Page ▪ 16 A Gardner Denver Company

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

Page ▪ 17 A Gardner Denver Company

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 Benefits: ▪ Easy and quick installation ▪ Safe and reliable operations ensured ▪ No special training requirements

The GD Pilot Connect is now ready for operation.

GD Pilot Connect

Page ▪ 18 A Gardner Denver Company

Priority 1 Priority 2 Compressor 1 40m³/min Compressor 2 42m³/min Compressor 3 15m³/min Compressor 4 10m³/min Compressor 5 12m³/min A B C D E B A E C D A B D E C

After an adjustable time the SmartAir switches over automaticly the sequence of the compressors.

No Need to Select Operating Options

OPERATION MODE „TIMER ROTATION“

2h A 8h B 11h C 17h D 23h E 51h E 19h A 0h D Compressor 4 48h C 22h B 0h C Compressor 3 40h B 49h D 36h A 26h D 48h E 25h C 0h E 0h B 0h A Compressor 5 Compressor 2 Compressor 1

OPERATION MODE „EQUAL RUNNING HOURS“ The SmartAir will automatically sequence the compressors to maintain equal running hours For installations where the ability to carry out routine planned maintenance on all compressors at the same time is advantageous

Page ▪ 19 A Gardner Denver Company

L37RS Compressor - Specific Power vs Flow

6.0 6.5 7.0 7.5 8.0 8.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Free Air Delivery [ m3/min] Specific Total Power [kW/m3/min]

Lowest power consumption at working range Variable Speed Compressor

All variable speed compressors working at best operating point

Page ▪ 20 A Gardner Denver Company

Information menu

▪ Information Menu Overview ▪ Timer Control Overview ▪ Current Profile ▪ Air Station Events ▪ Measured Values ▪ Operating Hours ▪ Statistics ▪ Software (Installed Version)

Page ▪ 21 A Gardner Denver Company

Information menu

GD Pilot Connect

Page ▪ 22 A Gardner Denver Company

Current line pressure Pressure range Current network demand Compressor status indicator Link to information screens Link to programming screens Current Profile in use Last warning or Alert Current date and time Reset SD Card (used for data logging)

Permanent Indication The whole air station at a glance

Page ▪ 23 A Gardner Denver Company

Compressor is in standby mode waiting for signal to start. Compressor is on-load but yellow indicates a warning Compressor is in motor start phase. A shutdown has been triggered. Communication error has

• ccurred

between SmartAir Master and this compressor Compressor is

• n-load. Variable

speed machines show loading as a percentage. Compressor is in currently switched off. Compressor is in blow- down phase (start protect active)

Compressor Status Indication The whole air station at a glance

Page ▪ 24 A Gardner Denver Company

Characteristics of each compressor

Instant information on each specific compressor

Service on Events

Page ▪ 25 A Gardner Denver Company

Absolute operation hours of each compressor

Workload of each compressor

Relative operation hours of each compressor

Page ▪ 26 A Gardner Denver Company

Diagrams of line pressure and the compressed air demand

Compressed Air Demand

Page ▪ 27 A Gardner Denver Company

Smartace

Page ▪ 28 A Gardner Denver Company

Summary of main features

• SAM automatically selects the most efficient

combination of up to 12 compressors same or different in size, fix speed and variable speedEasy to use TS-GUI (Touch Screen Graphical User Interface)

• Intelligent energy saving compressed air control at a

small pressure band

• Software assistant at commissioning
• Instant overview of Air Station status
• Instant overview of individual compressor status
• Real time clock, with battery back up
• 12 different operation profiles can be defined
• Profile selection automatic or via digital input
• Indication of statistics, events, diagrams
• Digital inputs and outputs for remote monitoring and

control

Page ▪ 29 A Gardner Denver Company

Summary of main benefits

• Every Compressor of different size and type is selected to
• perate at its most efficient performance range.
• Avoiding inefficient idle running by selecting the correct

size of compressor.

User friendly operation and installation:

• Easy installation by 2 wire ModBus structure connection
• Easy commissioning via step-for-step assistant

(help function)

• Actual status overview on the whole installation
• Maintenance indication, easy analysis of failure event
• No additional hardware required at actual
• The compressed air generation continuously is adapted to the air

demand at optimised low pressure band.

High energy saving:

Page ▪ 30 A Gardner Denver Company

SmartAir MASTER Saving Energy

Thank You for your Time