smartair master - mcwhit holding (pty) ltd · connection of compair delcos multimaster bus delcos...
TRANSCRIPT
SmartAir Master
The intelligent compressed air management system
Developed by Compair to save your customers money
Page ▪ 2A 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 ▪ 3A Gardner Denver Company
SYSTEM PRE-FILL
SmartAirConventional system
Target
pressure
Time TimeProcess
start
Process
start
Pressure
Target
pressure
Pressure
Start-up Compressors can be Pre-defined
- Eliminates High Power Demand
- Efficient Operation
- Intelligent Response
Page ▪ 4A Gardner Denver Company
Required Air System Pressure 7.0 bar ( 101.5 psi ) minimum
S A M reduces the pressure band to
optimise the system efficiency- saving energy
LOWER
PRESSURE
SET POINT
UPPER
PRESSURE SET
POINT
AIR
SY
ST
EM
PR
ES
SU
RE
( B
AR
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 ▪ 5A Gardner Denver Company
Air DemandLow 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 ▪ 6A Gardner Denver Company
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
The Complete Compressed Air Management System
Designed to reduce energy usage
SmartAir MASTER
Page ▪ 7A 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 ▪ 8A 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 ▪ 9A 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
To
tal p
res
su
re
ba
nd
Compressor 5
Pressure- Cascade- Control
Small
pressure
band
7.5 bar
6.5 bar 6.5 bar
6.7 bar
Page ▪ 10A 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.inputsSelection switch to
activate a profile
Compressor 2 Compressor 3 Receiver Dryer Filter
Dig.input
Connection of:
➢ Compressors
➢ Communication
➢ Air treatment systems
Page ▪ 11A Gardner Denver Company
max. 1
200m
max. 4
Module
s
SmartAir Master
ModBus-RTUPROFIBUS
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
V03
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. 1
200m
max. 1
Module
RS485-2
Analog input AI-1
Analog input AI-2
RS485-1
max. 1
200m
max. 1
2 C
om
pr.
DELCOS 3100 DELCOS XLGD Pilot MK
Page ▪ 12A Gardner Denver Company
Metacentre
Gateway
Not required at
SmartAir Master
Connection of CompAir DELCOS
MultiMaster bus
DELCOS 3100 DELCOS 3100
DELCOS 3100
GatewayDELCOS 3100
Gateway
DELCOS 3100
DELCOS 3100
Gateway
Former Installation
SmartAir 5 & 8 /
Page ▪ 13A 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 ▪ 14A 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 ▪ 15A 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 ▪ 16A 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 ▪ 17A 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 ▪ 18A 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 ▪ 19A 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]
Sp
ec
ific
To
tal
Po
we
r
[kW
/m3
/min
]
Lowest power consumption at working range
Variable Speed Compressor
All variable speed compressors working at best operating point
Page ▪ 20A 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 ▪ 21A Gardner Denver Company
Information menu
GD Pilot Connect
Page ▪ 22A 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 ▪ 23A 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
occurred
between
SmartAir
Master and
this compressor
Compressor is
on-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 ▪ 24A Gardner Denver Company
Characteristics of each compressor
Instant information on each specific compressor
Service on
Events
Page ▪ 25A Gardner Denver Company
Absolute operation hours of each
compressor
Workload of each compressor
Relative operation hours of
each compressor
Page ▪ 26A Gardner Denver Company
Diagrams of line pressure and the compressed air demand
Compressed Air Demand
Page ▪ 27A Gardner Denver Company
Smartace
Page ▪ 28A 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 ▪ 29A Gardner Denver Company
Summary of main benefits
• Every Compressor 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
•
The compressed air generation continuously is adapted to the air
demand at optimised low pressure band.
High energy saving:
Page ▪ 30A Gardner Denver Company
SmartAir MASTERSaving Energy
Thank You for your Time