Atlas Copco Air Management

ES control and monitoring systems

ENERGY SAVINGSIN A WORLD OF AIR

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.

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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

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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

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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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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.