Atlas Copco Air Compressors. ZB VSD range Variable speed direct drive centrifugal air compressors for low pressure applications EFFICIENCY MATTERS

Transcription

1 Atlas Copco Air Compressors ZB VSD range Variable speed direct drive centrifugal air compressors for low pressure applications EFFICIENCY MATTERS

2 Extending the limits in energy efficiency, safety and reliability The shortest route to maximum profitability is to minimize operational cost. The design of the Atlas Copco ZB VSD compressors is focused on substantially saving energy, ensuring product safety only oil-free machines can exclude any contamination risk for 100% and guaranteeing the utmost reliability around the clock. And not just today, but day after day, year after year, with minimal maintenance cost, few service interventions and long overhaul intervals. Expertise Since 1903, Atlas Copco s philosophy has been to continually improve our products through intensive R&D, with the aim to maximize the value for our customers. Choice Atlas Copco masters each compression principle and offers the most energy efficient technology for the application. The right drive Fixed speed machines are fine at full load but when air demand fluctuates, a Variable Speed Drive ensures substantial savings. Complete safety Process, products and environment free from contamination 100% oil-free air guara nteed The integrated design Internal piping, Variable Speed Drive, 100 % matched components... the only way to ensure total reliability. Trouble-free installation & commissioning The ZB VSD centrifugal compressor is truly plug-and-play. Put it on a flat floor, connect the power line and the air outlet and push the start button. The professional follow-up Service Contracts will ensure you of the right preventative maintenance, immediate response and genuine spare parts all over the globe.

3 Optimal use Central control of a multi-compressor installation can reduce the pressure band and achieve the lowest overall energy cost. Energy Safety Reliability

4 The centrifugal air compressor of the new age The Atlas Copco ZB VSD (Variable Speed Drive) centrifugal air compressor is a completely innovative approach to low pressure compressed air applications. Because of the combination of revolutionary technologies, the ZB VSD offers a range of features and benefits that were previously impossible to combine into one machine. Approvals and performances EC directive 98/37/EC Low voltage directive 73/23/EC Pressure equipment directive 97/23/EC Electromagnetic compatibility 89/336/EC Noise level emission 67 db(a), acc. ISO 9614 test code UL approval Complete "all-in" package Standard Air inlet system (incl. filters) Sound enclosure Outlet check valve Blow-off valve (incl. silencer) Electronic controller Fully equipped electrical system VSD - Variable Speed Drive system Options LAN or Internet control/monitoring Aftercooler (water cooled) Fine inlet filters 1 µm

5 Innovative design brings numerous benefits Unparalleled savings in life cycle cost highest efficiency with VSD energy savings lowest maintenance cost reduced parts count for enhanced reliability Complete, compact size and low weight weight 1200 kg plug-and-play installation, no foundations small footprint (mm) very low cooling water usage, less energy to keep unit cool low installation costs Simple and safe "oil-less" design no oil at all no pumping system no oil heater no oil filter no journal bearings Caring for the work environment standard baffled sound enclosure blow-off silencer vibration-free operation extremely low noise level < 67 db(a) totally oil-free, no oil-induced environmental issues no speed increasing gears Contactless magnetic bearings no contact means no wear, no vibration, no friction no oil-lubricated journal or land bearings magnetic bearings dynamically align the rotor shaft on-board processor with real-time response unsurpassed machine lifetime dramatically reduced maintenance requirements

6 Standalone or integrated solutions For larger flow volumes, multiple ZB VSD units can be connected in parallel. Two, three or more units offer the advantages of a modular concept: higher availability reliability through redundancy wider operating range and efficiency space saving extremely low noise levels expandability Multiple compressor installation In multiple compressor installations, the ES central controller will ensure the optimal compressor mix. The total system can be monitored locally or remotely, via the network or from anywhere in the world Advanced Elektronikon monitoring & control Operating modes: constant pressure mode (flow range: %) constant flow mode remote 4-20 ma input (flow or pressure) Modular electronics The control cubicle houses the Elektronikon and the magnetic bearing controller. The Variable Speed Drive (VSD) cubicle houses a state-of-the-art fast switching frequency converter and efficient power conditioning devices. Control cubicle VSD cubicle Functions: control speed regulation surge control blow-off regulation safety monitoring self diagnosis communication internal, with frequency converter and magnetic bearing controller external ( Modbus, Profibus )

7 Efficiency matters CONVENTIONAL SINGLE STAGE CENTRIFUGAL TECHNOLOGY 100 % power supply Drive efficiency 83.4 % losses 2.5 % oil-pump, fans 5 % 10 % motor gear and bearings Direct drive technology The ZB VSD is directly driven by a permanent magnet synchronous motor, which is vastly superior to conventional types. It reduces energy losses and cooling requirements and offers a higher speed in a more compact design. A consistently high motor efficiency with low rotor losses is maintained across the entire speed range... both at full load and part load. Whereas conventional motors need power to excite a magnetic field in the rotor, the ZB VSD motor does not, thanks to the permanent magnets in the rotor. 100 % power supply ZB VSD DIRECT DRIVE CENTRIFUGAL TECHNOLOGY losses 1 % 3 % 1 % 3 % 9 % Drive efficiency 92.2 % pump, fans converter electric filter electric motor Total absence of pump losses With the impeller directly mounted onto the motor shaft and by absence of a gear box, the ZB VSD is totally oil-free, which excludes traditional oil-system losses. VARIABLE SPEED PERFORMANCE CHARACTERISTICS Highest efficiency impeller The unique stainless-steel backward lean impeller is a proprietary Atlas Copco design with labyrinth seals for highest efficiency with minimal air leakage. Relative pressure ratio ( P ) P A 100 % N n Relative speed ( ) Relative efficiency ( ) N A 100% % 98% 96%94% n a ZB l/s Relative volume flow ( V ) V A Broad operating range and no sacrifice of efficiency at part load conditions with Variable Speed Drive control.

8 Why Variable Speed Drive (VSD)? Because a VSD compressor precisely follows the varying air demand that is typical in most production facilities, it dramatically reduces the energy bill and provides many additional benefits. The result is a fast payback of the investment and huge yearly savings long after that. Direct energy savings Low load operation of a VSD compressor does not result in energy losses or in blowing off compressed air to the atmosphere. The precise pressure control of the VSD compressor allows a tighter and often lower discharge working pressure, Because energy constitutes the biggest portion of the life cycle cost of a compressor, these savings have a significant impact on the operational costs of your compressed air system. resulting in reduced energy consumption, less leak losses and a more efficient and optimized process. STABLE NET PRESSURE Pressure - standard load-unload Pressure - turbo-modulating Pressure - VSD investment maintenance energy energy savings with VSD 0.1 bar Process pressure Predicting your savings Call upon the expertise of Atlas Copco specialists and have an assessment carried out in your factory. A detailed report will show your current operation and the achievable savings when adding a VSD solution to your compressed air system. Tight control for superior process stability The constant net pressure obtained by the VSD compressor provides additional yearly savings: other base-load compressors will consume less leak losses always present in compressed air systems are significantly reduced. The stable pressure is highly beneficial to many processes, avoiding expensive production interruptions, product loss or quality issues.

9 NO CURRENT PEAKS No current peaks during start-up 800 VSD compressors can be started and stopped without limitation frequent start-stops no longer lead to current % Full load current 400 Star Delta DOL Soft Starter VSD peak penalties the electrical installation can often be rated for a lower current, meaning savings in investment Seconds Integrated VSD - The only way All Atlas Copco VSD compressors are EMC tested and certified. External sources do not influence the compressor operation, nor does the compressor disturb other equipment via emissions or via the power supply line. COMBINED MOTOR/CONVERTER EFFICIENCY 100 % integrated VSD non-integrated VSD minimum Motor speed maximum Electrical filters The Elektronikon system controls both the compressor and the integrated converter; this ensures maximum machine safety and allows easy networking of the compressor.

10 ZB VSD characteristics The ZB VSD series offers a variety of pressure ranges and flow cuts, to perfectly match the needs of your application. Multiple installation For flow ranges beyond that of an individual ZB VSD centrifugal compressor, multiple machines are easily teamed up to meet the flow requirements. Because they were designed to work in parallel, the overall system efficiency remains high, regardless of the flow demands. bar(e) 2.5 psig Pressure ZB 120 VSD ZB 160 VSD SYSTEM EFFICIENCY bar(e) ZB 80 VSD Volume flow ZB 100 VSD 7.25 m 3 /h cfm 0 psig System power % Single blower unit Multiple ZB VSD in parallel 1 1, 2, 3 & , 2 & st 1 & ZB 80 VSD % Pressure ZB 100 VSD System flow m 3 /h cfm Volume flow

11 Global presence Local service Atlas Copco offers a complete portfolio of Aftermarket products, unrivaled in today s compressed air industry. High quality service is delivered locally: Atlas Copco is present in 150 countries around the world. A sophisticated logistics concept brings genuine parts to your doorstep in record times, across the globe. These parts never carry a risk of incompatibility or premature failure. Cost effective service kits are available for periodic interventions based on running hours. Service Plans perfectly meet the needs of your business and ensure a productivity at peak level. Three levels are available: Total Responsibility Plan, Preventative Maintenance Plan and Inspection Plan. Fixed price repair is ideal for individual repairs; it is streamlined to allow for a quick flow from quotation to execution, without surprises. The element exchange program offers the customer the possibility of scheduled intervention rather than a reaction to an element failure. Consultancy services and on-site measurements help to optimize the complete air net, minimize leak losses and maximize energy savings. The following packages can be included individually or combined: in-depth system audits based on actual measurements of the air supply distribution system. remote monitoring via the Internet; negative trends can be detected before any actual failure of the equipment. energy savings via system control and management.

12 ISO 9001 A consistent quality earned us the industry s leadership and the customer s trust. ISO Atlas Copco s Environmental Management System forms an integral part of each business process. Never use compressed air as breathing air without prior purification in accordance with local legislation and standards. 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 Printed in Belgium - Subject to alteration without prior notice.