smartair master - mcwhit holding (pty) ltd · connection of compair delcos multimaster bus delcos...

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.


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


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


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.


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


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


• 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


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


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


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


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 /


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


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


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


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


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


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


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


Information menu

▪ Information Menu Overview

▪ Timer Control Overview

▪ Current Profile

▪ Air Station Events

▪ Measured Values

▪ Operating Hours

▪ Statistics

▪ Software (Installed Version)


Information menu

GD Pilot Connect


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


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


Characteristics of each compressor

Instant information on each specific compressor

Service on

Events


Absolute operation hours of each

compressor

Workload of each compressor

Relative operation hours of

each compressor


Diagrams of line pressure and the compressed air demand

Compressed Air Demand


Smartace


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


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:


SmartAir MASTERSaving Energy

Thank You for your Time

smartair master - mcwhit holding (pty) ltd · connection of compair delcos multimaster bus delcos...

Documents