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

Transcription

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

2 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 2

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

4 AIR SYSTEM PRESSURE ( BAR g ) 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 UPPER PRESSURE SET POINT WASTED ENERGY WASTED ENERGY WASTED ENERGY Required Air System Pressure 7.0 bar ( psi ) minimum LOWER PRESSURE SET POINT Page 4

5 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 Page 5

6 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 Page 6

7 Technical Data Display, Coloured graphic touch panel: 5,7, resolution QVGA (320x240) 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 7

8 A Complete package ready for installation 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 SmartAir Master Only few Accessories - easy to select module (STD): Fix speed 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 Page 8

9 Total pressure band Energy Savings by Low Operating Pressure Without Management System With Management System Large pressure band 7.5 bar Pressure- Cascade- Control Pressure reduction by p = 0,8 bar 3 x L x 1.4 kw 4.20 kw 2 x L x 5.2 kw kw Total power less at 6.7 bar At 8000 working hours/year Energy saving Cost saving at 0.10 / kwh Pressure Band Control Energy saving ,680 / Year kw 116,800 kwh 6.7 bar 6.5 bar 6.5 bar Small pressure band Page 9

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

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

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

13 Module STD SmartAir Master Standard fixed speed compressor Installation via, DIN rail TS 35, V UC no coupling relay required 2 plugs RS485 interface LED indication at inputs and outputs Module required for: Delcos 3000, Surescan, Hydrovane, 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 Page 13

14 Module VSD SmartAir Master Variable speed drive compressor Installation via, DIN rail TS 35, V UC no coupling relay required 2 plugs RS485 interface LED indication at inputs and outputs Module required for: 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 Page 14

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

16 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 16

17 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: The GD Pilot Connect is now ready for operation. Easy and quick installation Safe and reliable operations ensured No special training requirements GD Pilot Connect Page 17

18 No Need to Select Operating Options OPERATION MODE EQUAL RUNNING HOURS 1 0h A 23h E 25h C 36h A 2 0h B 17h D 48h E 49h D 3 0h C 11h C 22h B 48h C 4 0h D 8h B 19h A 51h E 5 0h E 2h A 26h D 40h B 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 OPERATION MODE TIMER ROTATION Priority 1 Priority m³/min 2 42m³/min 3 15m³/min 4 10m³/min 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. Page 18

19 Specific Total Power [kw/m3/min] Variable Speed All variable speed compressors working at best operating point L37RS - Specific Power vs Flow Free Air Delivery [ m3/min] Lowest power consumption at working range Page 19

20 Information menu Information Menu Overview Timer Control Overview Current Profile Air Station Events Measured Values Operating Hours Statistics Software (Installed Version) Page 20

21 Information menu GD Pilot Connect Page 21

22 Permanent Indication The whole air station at a glance Pressure range Current network demand Current line pressure status indicator Current Profile in use Last warning or Alert Link to information screens Reset Link to programming screens Current date and time SD Card (used for data logging) Page 22

23 Status Indication The whole air station at a glance is in currently switched off. is in blowdown phase (start protect active) is in standby mode waiting for signal to start. is in motor start phase. is on-load. Variable speed machines show loading as a percentage. is on-load but yellow indicates a warning A shutdown has been triggered. Communication error has occurred between SmartAir Master and this compressor Page 23

24 Characteristics of each compressor Instant information on each specific compressor Events Service on Page 24

25 Workload of each compressor Absolute operation hours of each compressor Relative operation hours of each compressor Page 25

26 Compressed Air Demand Diagrams of line pressure and the compressed air demand Page 26

27 Smartace Page 27

28 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 28

29 Summary of main benefits The compressed air generation continuously is adapted to the air demand at optimised low pressure band. High energy saving: Every of different size and type is selected to operate 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 Page 29

30 SmartAir MASTER Saving Energy Thank You for your Time Page 30