The Next Generation Elektronikon and ES Systems

The New Platform on Board in GA11-90 Range!

 Agenda

 Elektronikon on GA range 11-90

 Next generation Elektronikon
– sell the value of new features!

 ES systems based on new platform

– what’s new?

 Supporting tools: use them!

– Simulation tools ES4 & ES6, small VSD
– New animation on Elektronikon & ES, VSD

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 New Controls on Board
2009

Elektronikon Elektronikon Graphic

The platform for the Future !

In the complete GA range above 11 kW

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 Controller Strategy – GA30+ to 90 & GA15-22

GA GA+ GAVSD Z & AQ

GA15-22 & GA37-
5,5
7,5 GA45 as standard
11 Optional Graphic !
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18,5
Elektronikon
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26
30
37
45
55
75
90 Elektronikon
Elektronikon
Graphic

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 Serial Production Dates

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 Documentation on Global Business Portal

 Product connect
 Service diagram
 Dimension drawings
 AIB, ASL
 In/out phasing
– Product connect operational date dependent on order income
– Advance notice shall be given by Antwerp Product Company

 Pricing: More Value for same AMP!

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 Grouping File

 New Part no. available in the grouping

file for complete range

 Wuxi Product Company units

 Antwerp Product Company units

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 Impact on SALES Options:

 New part no. for options that will change

 New option ES4i/ ES6i

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 Modifications to come on GA Range

 GA 15-22 improved inlet filter-position

– Expected W22

 GA > 37+ with new integrated dryer

– Expected W18

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 The Elektronikon Evolution

1956 1985 Generation 1 1994 2001

1991 Generation 2

The 5th Generation!

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 Why is Elektronikon important?
The Elektronikon is the brain of the compressor

Measures Data Storage

Controls Protects
Communicates

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 Elektronikon New Hardware
 New 4th (Blue) led service indicator
 New interface with durable keyboard
 User friendly navigation system
 Upgradeable to graphical without re-cabling
 Web-server built-in for online visualisation

 CAN connection
 Ethernet connection
 IO expansion connection
 4 Digital inputs
 4 Analog inputs
 6 Digital outputs

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 Elektronikon Graphic New Hardware
 High quality 3,5” Graphical display
 New 4th (Blue) led service indicator
 New interface with durable keyboard
 User friendly navigation system
 Web-server built-in for online visualisation

 RS 485 connection  SD card

 CAN 2x connection  10 Digital Inputs
 Ethernet connection  7 Analog Inputs
 IO expansion connection  9 Digital Outputs
 Upgradeable with add on
In and Outputs

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 Standard vs Graphic – Control Features!

Control Features
Emergency stop
Overload relays
Remote start / stop (*)
Fault Water Drain ( not on GA15-22)
Outlet temp
Dryer LAT
Delivery pressure
General Alarm
(*) will be standard disabled

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 Standard vs Graphic - Options!

Control Features
Watercooled units in / out
Energy Recovery
DD / PD integrated filters
Remote pressure sensing
Remote pressure set
Remote load / unload (*)
Anti-condensation heater – main drive
Automatic / manual operation
(*) will be standard disabled

Upgrade to Graphic Required for above options on GA15-22 & GA37-45

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 Algorithms make the Difference!

Delayed Second Stop

Improved

Continuously pressure follow-up

Dryer saver cycle
Automatic Restart After Voltage Failure
Wide range of timers i.e clock based
new

Fan/Dryer Saver Cycle

ES4i/ ES6i Option

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 Elektronikon Graphic Interface

 Clear and  Protections

easy readout – Warning level
– Alarm level
 Available in
32 different
languages
 Graphical service plan Indication
– Running hours
– Real time in-between
 Clear icon service intervals
indications
and navigations
 Browser based
online compressor
status visualization

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 Graphical Service Plan Indicator

 Graphical visualization of the counters

 Real running hours (Effective hours compressor is running)
 Load
 Unload

 Real time hours (Real hours)

 Load
 Unload
 Standby
 Stopped
 Switched off

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 Graphical Service Plan Indicator

Example
Compressor is:
Loaded 8 hours
Unload 2 hours 10 running hours
Standby 6 hours 24 real time hours
Stopped 8 hours

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 Browser based online compressor status visualization

 What is needed
– Elektronikon (Standard or Graphic)
– Ethernet Cable / internal network
– Computer with Internet explorer 6.0 or higher

+ +

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 Key Figures new Elektronikon’s
Generation 4 Generation 5

Digital Input 3 4
Analog Input 2x temp + 1 Press 3x temp + 1 Press
Digital Output 6 6

Other 1 CAN 1 CAN + 1 ETHERNET + IO

Digital Input 10 10
Analog Input 3x temp + 2 Press 5x temp + 2 Press
Digital Output 9 9

Other 1 CAN + RS485 2 CAN + 1 ETH. + IO+ RS485

General SAME DIMENSIONS

µP 20 mips 300 mips

Memory 256k (RAM) + 1Mb 8Mb (RAM) + 16Mb

Display Monochrome 4 lines Graphical 3.5 ”

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 ES Systems Take you into the Future

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 ES Built on the Mk5 platform
The Elektronikon has the knowledge to steer multiple compressors

Measures Data Storage

Controls Protects
Communicates

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 Why Offering ES Controller?

 Benefits for the customer?

– To reduce the running cost of the complete compressor installation
$ Lower consumed power
$ Lower service cost
$ Reduce the running hours (Equal wear, stop time…)
$ Reduce leakages

 Benefits for Customer & Atlas Copco

– Create a good relationship and be “The compressed air consultant”
 Optimize the current installation
 Optimize the future installation

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 How Do ES Controllers Save Money
Key regulating principles

 Single measuring point reduces overhaul pressure band to

0.5 bar or 7 psi
 Reducing the operating pressure of the machines
 Multiple regulation functions embedded in the ES Controller

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 The Value Of Compressed Air
A Typical Example Of Possible Running Cost Reductions

 An installation with:
– 4 x 30HP oil lubricated compressors
– Running 80% loaded in a cascade
– 10 working hours per day
– 5 days a week, 47 weeks a year
– Compressors are not shut down during the night
Running Costs Without An ES Controller Running Costs With An ES Controller

Typical pressure band (cascade) 29 psi Typical pressure band (cascade) 7 psi
Energy cost ($ per kWhr) 0,1 Energy cost ($ per kWhr) 0,1
Leakage loss 20% Leakage loss 18%

Daytime running cost $77 Daytime running cost $72

Night time running cost $24 Night time running cost $0

Total running cost per year $23.676 Total running cost per year $16.838

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 The Value Of Compressed Air
A Typical Example Of Possible Running Cost Reductions

 In this example using an ES controller reduces costs by around 29%

 How can such a large reduction be accounted for?

Running Costs Without An ES Controller Running Costs With An ES Controller

Typical pressure band (cascade) 29 psi Typical pressure band (cascade) 7 psi
Energy cost ($ per kWhr) 0,1 Energy cost ($ per kWhr) 0,1
Leakage loss 20% Leakage loss 18%

Daytime running cost $77 Daytime running cost $72

Night time running cost $24 Night time running cost $0

Total running cost per year $23.676 Total running cost per year $16.838

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 ES Series (AII) – Multiple Compressors Control

ES 4i ES6i ES 6
ES integrated in ES integrated in compressor
Wall-mounted controller
compressor controller controller *Non MkIV and Mk5
controlled machines needs
4 compressors 6 compressors 6 compressors to be connected over CAN
box
1 VSD Up to 6 VSD (Atlas Copco) Up to 6 VSD (Atlas Copco)
No turbo No Turbo No Turbo ** Can also be ordered as
a factory fitted option see
Non-AC compressors* Non-AC compressors* Non-AC compressors (via IO) product connect.

8092 2914 94** 8092 2915 02** 8092 2883 36

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 Key Benefits that make the Difference!

ES4i ES6i ES6

Single point of measurement

Remote pressure sensor Optional Optional

Adapt net pressure at real need

Delay Second Stop (on compressor level)

Free Ethernet based basic monitoring -

Optimum usage of the regulating VSD

Multiple VSD control @ optimum speed - -

Compressor Priority Management

Equalization of running hours

Complete visualization Optional Optional Optional

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 Key Benefit : Browser Based Online Compressor Status
Visualization (Mk5 only)
Preferences: Default IP address : 196.168.100.100 Language
Metric / Imperial
Selection ES or
Elektronikon

Status of different Total net

machines pressure

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 Key Benefit: Multiple VSD @ Optimum Speed (ES6i only)
Use of the VSD to match flow fluctuations (in case of multiple Mk5 equipped VSDs)

 The ES6i can handle more then 1 Atlas Copco VSD

 1st VSD is speed regulating // 2nd 3rd… VSD will run @ optimum speed (≠ maximum
speed)

Fluctuating
Load
VSD

Base Load
Standard machines take the base load

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 A Typical Installation Example
Wiring Schematic With CANBox

CAN

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 New Data for the ES on the GBP

 FAQ on the ES4i & ES6i

 How to install:
– ES4i with remote pressure sensor
– …

 Installation proposal
– How to set-up installation
– …

 Sales presentation on ES

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 New Calculation Tool to Calculate Savings

 This is a calculation tool that calculates

the savings achieved by the ES
– Reduced pressure band
– Dual pressure band (or stopped)

 Savings will be calculated in

– Energy Savings
– CO2 savings

 Estimated time to make calculation 5

minutes
 This program can be found on the
Airexpert portal

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 VSD Saving Tool up to 30 kW

 Together with your customer

– Select your machine
– Draw your profile
– Select electricity cost and currency
– Fill in Pricing

 Present the saving within 10

minutes
 Improve sales efficiency

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 Simulation Tools on the Airexpert Portal

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 Usefull Elektronikon and VSD Flash Animation

Elektronikon & ES

Elektronikon Grafic
VSD technology

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 Top 5 to Remember

 Complete GA11-90 range will have new

controller embedded W15 latest

 New and Improved algorithms are

remarkable Customer benefits!

 New hardware with New user friendly

interface and web browser for
visualization!

 ES4i & ES6i with Multiple VSD

@Optimum speed VSD by extra license!

 New animations and simulations

available!

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 Questions?

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