SmartAir Master

The intelligent compressed air management system

Developed by Compair to save your customers money
 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.

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 SYSTEM PRE-FILL

Start-up Compressors can be Pre-defined

- Eliminates High Power Demand
- Efficient Operation
- Intelligent Response

Conventional system SmartAir

Pressure Pressure

Target Target
pressure pressure

Process Time Process Time

start start

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 Pressure reduction increased efficiency

On a system with 2 x 75 kW and 1 x 132 = 20 kW reduction

S A M reduces the pressure band to
optimise the system efficiency- saving energy
AIR SYSTEM PRESSURE ( BAR g )

8.2
UPPER
8.0 PRESSURE SET
POINT
7.8

7.6
WASTED WASTED WASTED
7.4 ENERGY ENERGY ENERGY

7.2

7.0
Required Air System Pressure 7.0 bar ( 101.5 psi ) minimum LOWER
6.8 PRESSURE
SET POINT
6.6

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 OPERATION MODE „Energy Saving“

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.

Low Air Demand High

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

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 SmartAir MASTER

The Complete Compressed Air Management System

Designed to reduce energy usage
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
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 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

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 A Complete package – ready for installation

• Scope of Supply
• SmartAir Master in metal sheet cabinet, IP 54 SmartAir Master
• 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

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 Energy Savings by Low Operating Pressure

Without Management System With Management System

Pressure- Cascade- Control Pressure Band Control

Compressor 1
7.5 bar
Compressor 2
Total pressure

Compressor 3
Compressor 4
Large
pressure
Compressor 5 Energy saving
band
band

6.7 bar Small

Compressor 1- 5 pressure
6.5 bar 6.5 bar
band
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

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 Intelligently controls the complete installation

ModBus-RTU
RS485-3 PROFIBUS (optional) Customer's PLC
SmartAir Master bzw. digital I/O to control the air station
Dig.input
RS485-2 RS485

Dig. input DI-1

Selection switch to
activate a profile
Dig. input DI-2

Analogue input AI-1 Dig.inputs

Selection switch to
activate a profile
RS485-1
Connection of:
➢ Compressors
➢ Communication
➢ Air treatment systems
Line
pressure
sensor

L30 L30 L45SR

Compressor 1 Compressor 2 Compressor 3 Receiver Dryer Filter

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 SmartAir Master
SmartAir Master (100016136)
Compressor
Analog input AI-1 module (VSD)
Line pressure sensor (100016222SIM)
(100003136) +
Analog input AI-2
Programmable to different functions (Sensors see Accessoires) Compressor Connection
module plug SureScan
RS485-1 (STD) (ZS1055047)
(100016166)

RS485-2

DELCOS 1000 DELCOS Pro

GD Pilot DELCOS 3100 GD Pilot MK DELCOS XL

RS485-3 Accessoires SureScan SureScan-LSR

(Customer) Fixed speed
Sensors
max. 1 Module
max. 1200m

max. 4 Modules
max. 1200m

max. 12 Compr.
max. 1200m
Digital input Line pressure sensor
DI-1..3 SD card 100003136
Digital output (10001613 Volume flow sensor (Kit)
DO-1..2 8) ZS1055781
2x2x0,5..1,5m
Dew point sensor
m²
100014803
twisted pair
Temperature sensor
and
100016229
screened
Manuals Compressor (100003989) Compressor
Programmer guide ModBus-RTU (GB/US) module module
ZS1060126 (STD) (VSD)
Programmer guide PROFIBUS (GB/US) (100016166) (100016222SI
Extension ZS1060127 M)
Module Software update guide
ZS1060125
PROFIBUS Webserver ModBus-RTU 230V/50-60Hz Compressor Connections
module module (100016226) ZS1061822
(100016156) (Visualization) 110V/50-60Hz Checklist Compressor connections
230V/50-60Hz (100016230) ZS1062760
(ZS1055779) Standard or Speed regulated
Digital inputs DI-1..8 Half/full load
Miscellaneous compressor
110V/50-60Hz Digital outputs DO-1..2 compressor
SD card reader (3phase asynchronous motor
(ZS1055780) Analog inputs AI-1..2
ZS1069300 max. 500A rating current)
(Sensors see Accesoires)
Interface Converter USB-RS485
ZS1073178
Interface Converter RS232-RS485
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Keylock Smartair Master
ZS1049510
 Former Installation

Connection of CompAir DELCOS

Metacentre SmartAir 5 & 8 /
MultiMaster bus

DELCOS 3100 DELCOS 3100 DELCOS 3100

Gateway Gateway Gateway

DELCOS 3100 DELCOS 3100 DELCOS 3100

Gateway
Not required at
SmartAir Master

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 Compressor Module STD

SmartAir Master
Standard fixed speed compressor
Installation via, DIN rail TS 35, 24-230V UC
no coupling relay required

Module required for:

2 plugs RS485 interface
Delcos 3000, Surescan, Hydrovane,
LED indication at inputs and outputs GD & all competitor fixed speed
compressor controls

3 digital inputs Standby, no fault

Motor running
Full load

3 digital outputs Remote load enable

Remote Load
Remote half / full load

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 Compressor Module VSD

SmartAir Master
Variable speed drive compressor
Installation via, DIN rail TS 35, 24-230V UC
no coupling relay required
2 plugs RS485 interface
Module required for:
LED indication at inputs and outputs
Delcos3000RS, Quantima,
Hydrovane, GD & all competitor
variable speed compressor controls

4 digital inputs Standby, no fault

Motor running
On Load
Speed

Modulated line pressure

Line pressure sensor compressor

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 Compressor Extension Module

SmartAir Master
Downstream equipment
Supply voltage versions 1.) 230V / 50/60Hz
2.) 110V / 50/60Hz
2 relay outputs
(programmable)

8 digital inputs 2 analog inputs

Refrigeration dryer, Adsorption dryer, Filter, Condensate Management, etc. Pressure Temperature sensor
sensor ( Future development )
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 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

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 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

The GD Pilot Connect is now ready for operation.

Benefits:

▪ Easy and quick installation

▪ Safe and reliable operations ensured

▪ No special training requirements GD Pilot Connect

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 No Need to Select Operating Options

OPERATION MODE „EQUAL RUNNING HOURS“

Compressor Compressor Compressor Compressor Compressor
1 2 3 4 5
0h 0h 0h 0h 0h
A B C D E
23h 17h 11h 8h 2h
E D C B A
25h 48h 22h 19h 26h
C E B A D
36h 49h 48h 51h 40h
A D C E B

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

OPERATION MODE „TIMER ROTATION“

Priority 1 Priority 2

Compressor Compressor Compressor Compressor Compressor

1 2 3 4 5
40m³/min 42m³/min 15m³/min 10m³/min 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

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the sequence of the compressors.
 Variable Speed Compressor

All variable speed compressors working at best operating point

L37RS Compressor - Specific Power vs Flow

8.5
Specific Total Power

8.0
[kW/m3/min]

7.5

7.0

6.5

6.0
1.0 2.0 3.0 4.0 5.0 6.0 7.0
Free Air Delivery [ m3/min]

Lowest power consumption at working range

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 Information menu

▪ Information Menu Overview

▪ Timer Control Overview
▪ Current Profile
▪ Air Station Events
▪ Measured Values
▪ Operating Hours
▪ Statistics
▪ Software (Installed Version)

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 Information menu

GD Pilot Connect

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 Permanent Indication

The whole air station at a glance

Pressure range Current network demand

Current line pressure

Compressor status indicator

Current Profile in use

Last warning or Alert

Link to information screens Reset

Link to programming screens SD Card (used for data logging)

Current date and time

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 Compressor Status Indication

The whole air station at a glance

Compressor Compressor Compressor Compressor Compressor is Compressor A shutdown Communication

is in currently is in blow- is in standby is in motor on-load. Variable is on-load but has been error has
switched off. down phase mode waiting start phase. speed machines yellow triggered. occurred
(start protect for signal to show loading as indicates a between
active) start. a percentage. warning SmartAir
Master and
this compressor

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 Characteristics of each compressor

Instant information on each specific compressor Events

Service on

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 Workload of each compressor

Absolute operation hours of each

compressor

Relative operation hours of

each compressor

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 Compressed Air Demand

Diagrams of line pressure and the compressed air demand

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 Smartace

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 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

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 Summary of main benefits

The compressed air generation continuously is adapted to the air

demand at optimised low pressure band.

High energy saving:

• 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
•

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 SmartAir MASTER
Saving Energy

Thank You for your Time

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