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Single-stage VPM (VFD+PM) Screw Air Compressor

UD-VPM Series

Working Pressure 7-10 [bar] 102-145 [psig]

Free Air Delivery 1.65-70.3 [m3/min] 58-2483 [cfm]

Working Power 11-355 [kw] 15-476 [hp]

Industries:  Sewage Treatment  Textile

  Food & Beverage  Medical 

Transportation  Petrochemical Industry  Packaging  Paper & Printing 

Pharmaceutical  Power Industry

Description
UCS Single Stage VFD Speed Regulation Screw Air Compressor UD-VFD Series adopts
vector control technology, which ensures small temperature rise of the motor and the
appropriate torque can obtain within a wide rotation speed range to drive air
compressor stably.

Vector control technology separately controls excitation and torque the two vectors of
stator current, and then composes and converts them into parameters control signals
of frequency converter to achieve adequate control of electromagnetic torque.

In this way, the motor can keep running at low temperature even at low speed. This
efficient frequency conversion technology can suppress the inevitable noise and
harmful harmonics in the standard frequency converters. The new generation of
appropriative vector frequency conversion control is used to convert DC to AC, which
improves the resistance to high temperature, has higher conversion efficiency, saves
energy consumption and improves reliability.

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Principle of UD-VFD Series

The variable frequency drive (VFD) air compressor takes the user-end system pressure as the control object, constitutes the closed-loop control system
with frequency converter, pressure sensor, and VFD motor. The VFD working pressure may be set directly through the operation panel. The sensor
detects the system pressure and converts it into a 4 ~ 20mA current signal to provide feedback to the controller. The controller compares the PID
calculation with the working pressure under system frequency conversion setting, thus controlling the output frequency of the converter, and changes
the speed of the motor to ensure the accurate matching between the output and the air demand of the user to accomplish the goal of constant pressure
air supply and energy saving.

Product Features
·       Adopt international brand variable frequency drive for the VFD motor;
·       Advanced total frequency conversion structure and system;
·       Advanced vector control technology;
·       Frequency conversion soft start, less impact on the power grid, more reliable operation, longer life;
·       High-efficiency energy-saving reduces about 30% ~ 50% energy consumption;
·       Constant pressure air supply, pressure fluctuation can be stable within ±0.01Mpa, effectively improving the quality of air source;
·       The noise level is lower, about 3 to 7 decibels lower than that of a conventional compressor.

High-Efficiency Energy-Saving Air End

·       UCS air end highly recognized by the air compression industry with its sophisticated design and precision manufacturing.
 · By adopting large diameter and the balanced length-diameter ratio of the screw rotors, the optimized design based on the new 4th generation
rotor moulded line subjected to higher-efficiency, so that the contact surface, contact line, leak triangle and hydrodynamic characteristics of
rotors could reach the optimal performance, further improved the volume efficiency. This screw rotor then has high adiabatic efficiency and low
power consumption.

·       By using imported large-sized heavy-duty bearing and unique bearing layout while ensuring the bearing rigidity, the bearing capacity is much
improved, service life lengthened, and its high reliability could keep even under the extreme condition.
·       The lip type shaft seal of the spiral groove fits with the shaft sleeve made of high-grade bearing steel, ensuring the wear resistance of the
shaft seal and shaft sleeve. The shaft seal has a pumping function with high reliability and leakage resistance.

Cabinet Structure Design

The cabinet structure is divided into cooling and heating chambers which means better heat dissipation. All the functional components are located in the
cooling section to extend service life.
 
The rational layout design obtained a national patent integrating the electrical mechanism, making it easy to operate and could install without a
foundation on the site. Inside, the cooling and heating chambers do not affect each other and expand the internal space of the cabinet. The optimized
internal air circulation ensures comprehensive cooling of all functional components, extending their service lives. On the outside, the closed type
removable cabinet with built-in high-quality fire retardant and sound insulation sponges reduces noises effectively.
 
This structure design not only meets the environmental protection requirements but is also accessible to service.

Vulnerable Part

High-Efficiency Particulate Air (HEPA) Filtration:

Heavy-duty air filtration system powered by Donaldson USA, with filtration accuracy up to 99.9% for particles greater than 3μm. Suitable for all kinds of
heavy dust environments.
Oil Filter:
Donaldson oil filters, high grade of clean filtration, effectively protect the safe operation of the air end bearing, extend the service life of the air end.

Oil and Air Separation System:

Euro design efficient oil and air separation core, glass fibre filter material, long life, more efficient, no need for frequent replacement. The aggregate
separation core and the oil return device work together, recover and recycle the lubricating oil effectively, avoiding oil over-spraying and ensuring the oil
content of the compressor exhaust ≤2ppm.

All New Temperature Control and Oil Filter Combination Valves

This patent awarding design integrates the temperature control and oil filter valves, making the internal piping connection more concise and having
fewer leakage points that reduce the occurrence rate of fault. More importantly, it further decreases the pressure drop, achieves more energy-saving,
and avoids obstacles like tube vibration fracture and leakage in the separated installation of the oil filter base and temperature control value.
Temperature Control Valve
Powered by AMOT of the UK
Accurately controls the oil return temperature at 65°C. If the oil return temperature is too high, the oil film will damage and results in oil deteriorate,
cooling, and sealing degrade, also easily to carbon deposit; if the oil temperature is too low, the water will separate from the air, and the oil will emulsify
and deteriorate, affecting the service life of the air end. Therefore, the temperature control value is the critical assurance of the stable operation of our
compressor.

EPC Intelligent Control System

UCS Compressors are equipped with an Electronic Pressure Controller (EPC) to guarantee the automatic intelligent operation of the machine. By
examining exhaust pressure, temperature and other sensor data, the inlet valve controls the exhaust pressure between the upper and lower limits of the
preset pressure to output stable pressure. When the compressor idling too long, the system will automatically shut down and restart when the air supply
is requested, not only outputting constant pressure but also reaching the energy saving. Meanwhile, the system may rapidly diagnose all field faults
during the operating process, furthest ensuring the reliable operation of the compressor and extending the service life.

Local Control
·       The display language in English and Chinese, soft-touch buttons, and the menu operation are intuitive, rapid and convenient.
·       User may preset and control the delay time of star-delta switching, starting, loading, shutdown, overpressure and others during the
operation.
·       Allow users to view and manage field faults.
·       User may store and search history faults through classified types and occurrence times.
·       Internal calendar with accurate timing and allow adjustment.
·       User may accumulate and store the operating time, loading time, unloading time, and filter service time.
·       User may check all preset parameters and cumulative time at any time during operation.
·       User may modify and store parameters to preset when required.

Linkage Control
User may set 1 compressor as the central unit and others as the auxiliary or standby units (maximum 16 units) to constitute the linkage control of many
compressors, assuring the economic and stable air supply, and may automatically adjust the start/stop sequence of each compressor by employing EPC
and balance the accumulated working time of each compressor.

Remote Control
The distributed control system (DCS) remotely controls the startup, shutdown, fault output and early warning signal through passive dry contacts.

Master Computer Control

·       The master computer remotely interlock controls two or more compressors, collects and displays field signals, coordinates control and
computer operation. By setting master computer parameters, the user may obtain the comprehensive management of the compressor units at
any time to receive stable compressed air within the set pressure range.
·       Acquire and display much field data
·       Vivid graphical interfaces
·       Monitoring the operating status of equipment
 ·       Records essential data to the database
·       Automatically generate data history report for later analysis
·       Setting of operating parameters of the compressor controller
·       Trend curves of pressure, temperature and other parameters
·       Real-time and history alarm
·       The operating is permissions secured. Require password to essential operations.
·       Single compressor unit test
·       Maintenance or replacement reminder of vulnerable compressor parts

* UCS COMPRESSOR provides a variety of PLC system centralized control schemes according to the actual needs of users, effectuates man-machine
interface through IPC, LCD and configuration software, and communicates with DCS in the user system to remote monitoring, which has the advantages
of multi unites control and independent solid development ability.

Variable Frequency Speed Regulation Technology & Ideal Energy Saving Effect
Using UCS Variable Frequency Speed Regulation Screw Air Compressor, you do not need to worry about complicated electrical installation and
programming. The compressor unit is constructed entirely before leaving the factory; it will immediately work when the power source is connected. The
pressure change of the air system is continuously detected, and the rotation speed is adjusted accurately using powerful EPC, keeping the outlet air
consistent with the demand of the user system at all times. The response time of EPC calculation is at the millisecond level, and the correction to speed
completes within 3ms to accurately control the outlet air pressure within 0.1bar. Our built-in filter assures safe and reliable operation of the frequency
converter. During the use process, you do not need to trouble about problems such as "harmonic wave" and "radio frequency interference". The
dedicated  Automatic Energy Optimization  (AEO) function guarantees the frequency converter provides the motor's minimum power accurately
according to the actual load. It could save up to 10% power and reduce the compressor noises.

Starting and Operation

The figure shows the comparison among several starting modes. It observed that the frequency inverter slowly accelerates starting and is steadier than
soft starting and avoiding the peak current. After beginning the rated pressure, the frequency inverter performs step-less speed regulation, tracks air
output through pressure detection, then outputs the required air volume with the pressure unchanged, completely eradicating the energy waste of
loading and unloading fixed speed compressor.

Constant Pressure Power Saving

The figure compares working pressure between the standard compressor and variable frequency speed regulation compressor. It observed that the
standard compressor frequently loads and unloads between the minimum required force and 1.5bar higher, which wastes 10.5% more energy on
producing the 1.5bar pressure than the frequency-controlled pressure that stabled at the minimum necessary pressure (Every 1 bar pressure increased
consumes 7% more power). Additionally, the zero-air standby consumes 45% more no-load energy during unloading. Therefore, the constant pressure air
supply saves energy and extends the unit's service life while loading and unloading and eliminates the unfavourable factors that affect user's production
from unstable pressure.

For example, the compressor with an annual energy consumption of 250KW (the used air volume is 50%), the operating time is 6,000h/year.

Compare the volume adjustment with standard compressors; the VFD compressors may reduce power consumption by 42%, saving energy of about
570,000kWh annually. (A suitably sized air storage tank must install to increase the energy-saving effect.)

Cost Comparison

Modularised Vector Frequency Inverter

UCS UD-VFD series compressors carry with new generation modularized high-performance frequency inverter, which is custom-made by international
OEM under the requirements of UCS. The development, design and manufacturing follow the principles of complete matching of UCS compressors; the
R&D and production of compressor characteristics, hardware, software, power module, printed circuit board and accessories assure reliable quality. The
frequency inverter can automatically match with a motor, read and check the motor's parameters in real-time to ensure the best matching between the
frequency inverter and motor.
 ·       The motor is disconnected from the load when the frequency inverter is initially set. The frequency inverter can automatically unload the
motor.
·       Immune to the fluctuations in the power system, if the input voltage is -10%, the frequency inverter will automatically compensate the
output voltage to the motor's rated voltage.
·       One frequency inverter may drive multiple standard compressors to linkage control.
·       The optimized fault protection effectuates the all-around protection from the frequency inverter to the motor.
·       Small torque fluctuation, fast speed compensation, strong load impact resistance and equipped with an internal electric reactor.
·       The multi-speed and built-in PLC functions automatically control multi-frequency logics.
·       Stable output frequency, strong immunity from interference; certified tests at various laboratories.
Personalized function:
·       Starting torque: 0.5HZ/150% (SVC).
·       Speed regulation range: The energy-saving effect is significant at 1:100.
·       The SFV, constant speed precision, may up to +/-0.5%.
·       Overload capacity: 60s at 150% rated current and 1s at 180% rated current.
·       Allowing live check on peripheral equipment when power is on, such as grounding and short circuit.
UCS VFD screw compressors may accurately change the speed of the motor according to the volume change of the used air, under the principle of stable
exhaust air pressure; the compressor outputs air volume at the required level and consumes the energy that is only needed for outputting required
compressed air to reach the purpose of energy-saving. The future saved energy cost shall significantly exceed the value of the compressor.

Patent Protection
By continually investing in R&D, the product development and new technology application pace accelerated. At present, UCS has registered near 100
national patents covering the critical technology and integrated layout of compressor and integration improvement of parts. These patents address a
range of compressor problems, such as internal temperature rise and maintenance difficulties under different operating conditions. Through the unique
design and integration, the equipment can better meet the use requirements and services, in line with environmental protection requirements, fully
demonstrating the excellent quality of products.

Quality Assurance
In 2003, UCS Compressor was accredited with ISO9001 Quality Management System and ISO14001 Environmental Management System Certificates. The
company strictly follows the quality requirement of Crosby's "doing it right the first time", persists in the working standard of "zero defect", regards the
"It is immoral to produce a defective product" as the criteria of measuring the quality. UCS devotes itself to the continuous improvement of products all
the time.

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