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Atlas copco air managment
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New age control and monitoring
Managing a multiple compressor installation
used to be a complex art. Today, with Atlas Copco’s
ES systems, it’s an opportunity.
It gives you the tools to optimise the overall efficiency,
reliability and maintainability of your installation,
from behind your desk or from around the world.
In addition, ES allows you to save big on energy costs.
This not only benefits our environment, but directly
improves your bottom line.
The ES series links an unlimited number of
individual compressor controllers to monitor and/or
control the total system locally or remotely.
airnet
P
Flow
Dew
poin
t
ES-X
AIRConnect TM
ES1000
ES2000
ES3000
ES2000 + AIRConnect TM
ES1000-X + AIRConnect TM
AIRConnect TM features
• remote monitoring around the clock
• all measured data available on-line, including vibration monitoring (SPM)
• automatic notification of warnings/shutdowns via e-mail or SMS
• remote diagnosis, eliminating unnecessary service visits
• pro-active, efficient scheduling of maintenance
• can be included in an Atlas Copco ServicePlan
• upgradeable to AirOptimizer TM, the energy optimisation service
Central controllers
sequencing of load/unload compressors
sequencing of VSD and
load/unload compressors
sequencing of turbos, VSD and
load/unload compressors
Monitoring systems
monitoring via the Local Area Network
(LAN)
monitoring via the Internet
Note: AIRConnect ™ is available as an Aftermarket Service only.
ES talks to the world
Any of the controller and monitoring functions
can be combined to exactly offer you the level of
control and insight that your facility needs.
Examples:
controls VSD and load/unload compressors, with
monitoring via the Internet
controls load/unload compressors, with monitoring
via the LAN and the Internet
The control software behind ES is extremely
sophisticated. The built-in algorithms continuously
compute real-time data and combine those with
customer preferences, machine parameters and
compressor room specifics.
ES control priorities:
1. ensure the minimum required pressure at all times,
to keep your processes running smoothly
2. user selectable preferred operating mode:
• optimised energy savings
• equal wear of the machines
• forced sequence
3. precise finetuning, based on intelligent scoring
system of several parameters
• optimal specific energy requirement for the
required flow
• priority of compressors
• calculated flow difference
• customer specified preferences
This scoring system, based on artificial intelligence
techniques, allows every compressor room to be
highly optimised, whatever the configuration.
No other controller will match the ES
in air delivery accuracy, energy savings and overall
reliability.
Smart control reduces the cost of air
Actual position of the inlet guide
vanes (IGV) and blow-off valve
(BOV) of a turbo compressor.
Indication of compressor problem
(not ready to start or shutdown).
Status of the communication link
between ES and the compressor.
Net pressure and user selectable
pressure settings.
Switching to ES control integrates
the compressors one by one.
Compressor type and user
selectable name.
Compressor number; lit when
integrated, flashing when isolated.
Compressor status: stopped, unloaded,
fully loaded and – for turbo and VSD –
indication of the operating zone.
Brings compressor under ES control
or isolates it from the system,
e.g. for service or repairs.
Actual speed of a Variable Speed
Drive (VSD) compressor.
Warning and shutdown levels,
either fixed or as an offset to the
pressure settings.
Every multi-compressor room* will benefit from
an ES central controller, but for larger installations it’s
a basic requirement for central control. Some of these
cases are…
• more than four standard compressors
• two or more VSD compressors
• one or more turbo compressors
• more than 300 kW installed power in the
compressor room
• flow or dewpoint has to be measured
• remote monitoring is required
(through LAN or Internet)
* For small installations, the latest Elektronikon® controllerscan be equipped with an integrated sequencer.
Required Minimum Pressure
Average Pressure
The right compressor
The ES always chooses the best matching
compressor to start or stop. It takes in account both the
type and size, for the current and anticipated air
delivery needs.
For each bar of reduction in the average pressure,
you save 7% in energy consumption of the
compressors. Moreover, the average leak losses in
an air system are 13% lower.
These two savings alone justify the installation of
an ES . But there is more.
In a traditional multiple compressor installation, the
load/unload pressures are offset to prevent compressors
from starting simultaneously and to ensure stability in the
air net. This not only limits the ability to closely match the
air demand, but it creates a large pressure band.
Because the ES maintains the optimal mix of compressors,
based on the calculated (or measured) air delivery, there is
no need for offsetting pressure values.
The resulting pressure band is a fraction of the non-
regulated system; the difference becomes even more
important as the number of compressors increases.
Time
Smart control benefits the bottom line
Pressure band reduction
One of the most prominent benefits of an
ES1000/2000/3000 central controller is the significant
reduction in pressure band of the overall system.
WITHOUT ES WITH ES
Net Pressure
6 - 7.7 bar 6 - 6.3 bar
Local Control8 bar
compressor compressor
ESdryer+ filters
dryer+ filters
airreceiver
The optimum zone
Each compressor has its own specific energy
versus flow characteristics. For each type of
compressor – VSD or turbo – the shape and position
of the optimum operating zone varies significantly.
The reliability, energy efficiency and longevity of
a compressor will benefit greatly if it can operate
within this zone. The ES2000/3000 systems will
make sure they do.
The right schedule
All ES controller systems have a programmable
week timer built-in, which allows for different
pressures at different times in the week.
This allows you to take in account variations in air
demand and required minimum pressure because of
shifts, batches or weekends.
The exact net pressure
Without the ES, the compressors will work at
higher pressure to overcome the variable pressure drop
caused by dryers and filters.
The accurate control by the ES, based on exact
measurements, allows the load/unload pressures to
much tighter limits. Once more, energy consumption
and air net leaks are reduced and energy is saved.
VSD
TURBOWITH IGV
BLOW-OFF
SpecificEnergy
SpecificEnergy
Flow
Flow
On-screen in-depth information
MONITORING ON-SITE
ES-X allows for the monitoring of all machines
in the compressor room continuously and from a
distance, via the company Local Area Network.
MONITORING FROM ANYWHERE
With AIRConnect TM, the compressor room
becomes a part of the Internet and regularly sends its
data from each compressor in the air system to a
centralised database.
Service people can monitor all machines via an
Internet connection. It allows them to monitor the
compressor room remotely, anticipate problems and
increase the uptime of machines and production
processes.
Access to AIRConnect TM is limited to authorised
personnel only. Different users can have different
types of access. On the remote PC, a certificate is
needed to gain access, using the secure encryption
technology that is common in internet banking
applications.
WWW
AIROptimizer TM – AIRScan TM
Condition based maintenance
ES
Customer’s Local Area Network compressor compressor
DataWarehouse
CustomerCentre Distributor
(optional)
1. Logging of events
• starts and stops
• shutdowns and warnings
• changes of settings and status
= perfect tool for troubleshooting
INFORMATION ON THE PERFORMANCE OF THE COMPRESSOR ROOM
The ES air management system collects and stores
data from each compressor in a centralised and secure
data warehouse. Active software agents continuously
monitor and query the stored data. They can issue pre-
warnings in order to anticipate on problems in the
compressor room.
• high reliability: redundancy of servers and 24 hr
surveillance reduce the risk for AIRConnect TM failures
and limit downtime
• an up-to-date pre-warning system allows condition
based maintenance: this leads to higher uptime of all
devices in the compressor room
• remote upgradeability of the ES software to the
newest versions
Atlas Copco offers consultancy services, whereby
experts can do on-site measurements to further
optimise system performance, or propose a complete
energy optimisation, tailored to your specific
installation.
2. Reports and graphs
• performance reports
• financial reports
• graphs of all measuring points
Technology you can trust
The ES series is built around proven
microprocessor technology and a flat TFT touch
screen. It’s extremely reliable because it has no
moving parts that can accumulate dirt or get stuck.
The system is highly modular and field
programmable. This allows for software updates,
upgrades to a more performing model, expansion of
communications capabilities and external links, and
addition of future functionalities…without any
changes to the hardware. Selected models can even
be upgraded remotely, via the Internet.
• wide variety of communication options:
– 2 RS-232C interfaces
– 1 RS-485 interface
– 6 current loop inputs for pressure, flow,
dewpoint and power; 1 output
– 4 digital inputs and outputs
– internet connection via Ethernet
(cable or DSL) or optional modem
• 10.4” TFT touch screen with wide viewing angle;
no moving parts or buttons
• battery backup keeps all settings during power outage
• integration into plant control systems via Modbus,
Profibus or Ethernet
• StrongArm microprocessor, proven
in industrial control and
telecommunication systems
• flash memory for updates and
expansions that are field
upgradeable or even remotely
programmable
• easy to service, uncluttered
well laid-out electronics boards
ES-X
ES + AIRConnect TM
ES-X + AIRConnect TM
ES1000
ES1000-X
ES1000 + AIRConnect TM
ES1000-X + AIRConnect TM
ES2000
ES2000-X
ES2000 + AIRConnect TM
ES2000-X + AIRConnect TM
ES3000
ES3000-X
ES3000 + AIRConnect TM
ES3000-X + AIRConnect TM
UP
GR
AD
AB
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+ – – – –
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+ – – – +
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Central control Central control Central control Monitoring Monitoring
of load/unload of VSD of turbo via LAN via the Internet
The smart family
All ES products share the same hardware. This
common microcomputer platform allows for easy
upgrades from a basic monitoring system to the most
sophisticated monitoring and control system.
The available models and software options are
detailed in the table below.Unlimited path for growth
Any ES controller can be field upgraded to a
higher model. Controllers that are initially installed
without remote monitoring, can be expanded to
include LAN and/or internet monitoring. Similarly,
monitoring units can be upgraded to include the
central controller functions.
This extreme degree of flexibility allows your
compressor room to grow with your needs, without
the need of replacing any controller hardware.
ISO 99001A consistent quality earnedus the industry’s leadership
and the customer’s trust.
ISO 114001Atlas Copco’s
Environmental ManagementSystem forms an integral part
of each business process.29
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www.atlascopco.com
The
face
of i
nnov
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What sets Atlas Copco apart as a company is our
conviction that we can only excel in what we do, if we
provide the best possible know-how and technology to really
help our customers produce, grow and succeed.
There is a unique way of achieving that - we simply call
it the Atlas Copco way. It builds on interaction, on long-term
relationships and involvement in the customers' process,
needs and objectives. It means having the flexibility to adapt
to the diverse demands of the people we cater for.
It's the commitment to our customers' business that
drives our effort towards increasing their productivity through
better solutions. It starts with fully supporting existing
products and continuously doing things better, but it goes
much further, creating advances in technology through
innovation. Not for the sake of technology, but for the sake
of our customer's bottom line and peace-of-mind.
That is how Atlas Copco will strive to remain the first
choice, to succeed in attracting new business and to maintain
our position as the industry leader.