Integrated energy and cost efficiency
KAESER’s “EB 291 C” and “EB 421 C” rotary blowers are supplied connection-ready with integrated mains power supply equipment and monitoring. With drive powers from 18 to 75 kW, they cover deliveries of 15 to 39 m³/min up to 1000 mbar (g) or 500 mbar (partial vacuum). Key applications for these new blowers include pneumatic conveying of powdered goods, water treatment and generation of blowing air. Sharing the same design, CBC and DBC series blowers are available for air deliveries from 4.7 to 39 m³/min.
EBC blowers can be supplied ready for operation including all sensors and star-delta starter, or with frequency converter for flexible speed control. The complete system packages are CE and EMC certified, which means less work for both the operator and system provider when it comes to planning, installation, certification, documentation and commissioning. A range of motors is also available to accommodate various performance requirements, whilst noise and pulsation reduction measures ensure quiet operation at all times.
As one would expect from an industry leader such as Kaeser Kompressoren, these innovative rotary blower systems are based on inherently intelligent design: System operators not only benefit from significant energy and operational cost savings, but are also able to take advantage of considerable savings for installation, planning, commissioning and certification. The blowers also provide exceptional reliability and availability. Moreover, their space-saving component layout results in an exceptionally compact footprint. Also, as these blowers have been designed to allow all service work to be carried out from the front of the unit, it is possible to install several blowers side by side. Components such as control valves, which would normally be installed externally, are incorporated into the equipment and are controlled via the blower’s internal “Omega Control” controller. Planning, installation and documentation of centralized blower stations is therefore made even simpler.
Of course, operating costs do not just depend on the efficiency of the individual components within the station. Various other factors play a key role, such as actual pressure and air demand, selection of appropriate and suitably matched blowers and drive systems, as well as tailored sequencing control. This is where an Air Demand Analysis (ADA) can prove invaluable: With help from such detailed analysis it is possible to determine how compressed air demand varies over time, how efficiently a blower station is operating, and to what extent availability and efficiency can be further enhanced. The “KAESER's Energy Saving System” (KESS) is another powerful optimization tool. This specialized planning software enables different system variants to be simulated and compared with one another, and their respective potential savings to be calculated. Transparency of future servicing and maintenance costs is also essential when considering the total life cycle costs of both individual blowers and stations as a whole. Needless to say, this task requires the kind of knowledge and expertise that only an experienced compressed air system provider such as KAESER Kompressoren can offer.
Welcome to the future
KAESER KOMPRESSOREN’s revolutionary modular concept takes compressor controller technology to the next level and beyond. Welcome to the world of Sigma Control 2.
It’s now more than a decade since the Coburg-based compressed air systems provider introduced its ground-breaking ‘Sigma Control’ internal compressor controller, the innovative “PC in a compressor.” The integration of an industrial PC as standard in every compressor not only enabled cost-effective control, but also allowed networking capability between individual units and with master control systems. This breakthrough provided the keystone for today’s integrated system approach to compressed air production by enabling continuous advances in energy performance and improved reliability of complex compressed air systems.
Enhanced communication and efficiency
The core strengths of Kaeser’s ‘Sigma Control’ compressor controller are its ability to optimise energy efficiency and to communicate seamlessly both internally with the compressor as well as externally with master control systems. Unsurprisingly therefore, Kaeser’s development engineers also applied these outstanding features to the new generation Sigma Control 2, or SC2 as it is referred to more succinctly. However, wishing to make the Sigma Control 2 even more versatile than its predecessor, what Kaeser’s engineers came up with for the SC2 was an innovative modular design that creates a “division of labour” between the main control unit and the separate input/output modules. As a result, this unique concept makes the SC2 even easier to maintain and to communicate with.
Sigma Control 2 is equipped with its own web server, which allows direct communication with the compressor via intranet/internet. So, within the scope of Kaeser’s Teleservice facility for example, password-protected compressor settings and operational data can be called up and adjusted on any PC with an internet browser without the need for additional expensive software. Compressor operation and maintenance are therefore made even easier, as is regular monitoring of cost- and energy efficiency.
Sigma Control 2 communicates internally with the compressor via input/output modules that are tailored with differing inputs, outputs and floating contacts to meet the specific needs of the various compressor ranges. This future-proof concept therefore offers exceptional flexibility.
User-friendly and reliable operation
It is not only the compressor that benefits from the SC2’s fast and efficient communications, the user does too: The large operating panel is dominated by an LED-backlit, 256 x 128 pixel, greyscale LCD screen on which plain text messages can be easily read across eight 30-character lines. Nine LED indicators signal additional operational parameters and conditions, and 13 membrane keys labelled with easy to understand icons ensure unmistakeable input of the various commands.
The operating panel communicates directly with the “main control system”, the core of the Sigma Control 2. It comes with four interfaces for active and passive communication:
Sigma Control 2 provides high level security with its integrated RFID (Radio Frequency Identification) functionality. Not only does this technology ensure secure log-in for users and/or KAESER service engineers, but also safeguards the system against unauthorised changes or operation. This security feature has been added to further standardise servicing in order to ensure high quality standards and to provide continuous quality assurance for service work.
Kaeser rotary screw compressors are already being equipped with the new Sigma Control 2 controller which will eventually become standard on all ranges.
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