Transcript SFC - KAESER

SFC Product Introduction
SFC
Sigma Frequency Controlled
Compressors
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
1
SFC Product Introduction
Why Variable Speed Drives (VSD) are Desirable
• Match power to demand
• Minimum in-rush starting
current
• Near perfect motor power
factor
• Regulate work flow
• Decrease flow of product or
mixture
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
2
SFC Product Introduction
Typical Power Consumption vs. CFM Demand
for Compressors with Modulation Control
Flow
Single Compressor Capacity
700
100
600
90
500
75
400
60
300
45
200
30
100
15
0
0
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
% of Power
cfm
Power %
3
SFC Product Introduction
cfm
SFC Compressor = Variable Capacity = Lowest Power
700
100
600
90
500
75
400
60
300
45
200
30
100
15
0
0
% of Power
SFC Unit Matches the Power to the Demand
Typical Power Consumption vs. CFM Demand for Compressor with SFC Control
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
4
SFC Product Introduction
Minimum In-Rush Starting Current
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
5
SFC Product Introduction
Minimum Unloaded Power
100%
Unlimited motor starts per hour
“Unloaded Time”- maximum one minute
% AIR DEMAND
50%
0%
100%
50%
Load no-load
SFC Control
Unloaded time
0%
TIME
 2008 Kaeser Compressors, Inc., USA (V4.1)
Six starts per hour
“Unloaded Time” - ten minutes
“Specifications are subject to change without notice”
6
SFC Product Introduction
An Explanation of Power Factor
• Measurement of how efficiently
power is used
460 VAC
Power Used = 150 kW

• At any given instance, inductive
loads may require more power
than the motor rating
• Power factor relates the
difference to an angle 
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
7
SFC Product Introduction
Near Perfect Power Factor Means
Lower Power Costs
• When a power factor is perfect,
the power supplied at any given
instance is exactly equal to the
power used.
460 VAC
Power Used = 150 kW
• Power companies typically
charge a higher rate for facilities
with a poor power factor.
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
8
SFC Product Introduction
Summary of Advantages
• Input power matches demand
• Fine pressure band to +/- 1 psig
• Minimum unload time
• Low starting in-rush current
• Near unity power factor
• Longer motor/airend life
• Fast return on investment
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
9
SFC Product Introduction
Summary of Advantages
• Control meets UL standards
• Oversized controller
• Improves power factor to 99%
• Soft start included
• Unlimited starts per hour
• Protection from phase loss
and incorrect direction of
rotation
• All parameters factory preset
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
10
SFC Product Introduction
SFC Exclusives
Optimized Sigma Profile Airends
• Very high efficiency
Original
• Increased displacement
• Large airends = Slower speeds
• Improved sealing between
rotor tip and housing
New
• More airends
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
11
SFC Product Introduction
SFC Exclusives
• Sigma ControlTM interface
• Standard Kaeser motors
• MASTERDRIVE on SFC 18 and up
• MICROMASTER on SFC 18S and
below
• Drive cabinet ventilation fan(s)
• Shielded motor cables
• Power separation
• Oversized IP54 rated cabinet
• Shielded control cables
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
12
SFC Product Introduction
SFC Standard Features
(Optional on Competitive Units)
• EPAct-compliant TEFC drive
motors
• Standard Siemens MASTERDRIVE
on SFC 18 and up (MICROMASTER
on SFC 18S and below)
• Complete low sound enclosure
• Pressurized fluid drain
• 4-micron inlet filter
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
13
SFC Product Introduction
SFC Standard Features
(Optional on Competitive Units)
• Removable enclosure panels
• Powder-coat paint
• High-efficiency radial cooling
fan(s)
• High-efficiency separator
• Internal and external vibration
isolators
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
14
SFC Product Introduction
Traditional VSD Applications
• Refrigeration compressors
• Centrifugal fluid pumps
• Conveyor systems
• HVAC systems
• Soft start applications
• Mixers
• Generators
• Regenerative blowers
• Positive displacement blowers
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
15
SFC Product Introduction
How Does the SFC Work?
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
16
SFC Product Introduction
Pulse Width Modulation Frequency Drive
AC power
enters here
(fixed voltage
and frequency).
Standard three phase
induction motor
responds to varying DC
pulses by varying the
motor speed.
The DC voltage
output is stabilized
(regulated).
+
AC-DC
Converter
DC Link
AC power is
converted to DC.
DC-AC
Converter
(IGBT)
AC
Motor
Control logic signals each of (6)
insulated gate bipolar transistors to
open or close, creating pulses of DC
power which simulate an AC output.
Control logic calculates pulse
time intervals for desired
voltage and frequency.
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
17
SFC Product Introduction
Pulse Width Modulation Frequency Drive
Pulses of DC power cause current to flow in a sinusoidal (AC) path.
DC Voltage
+
-
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
18
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
AC Power In
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
19
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
• Contactor
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
20
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
• Contactor
• Line reactor *
* Only on SFC 18 and
larger models
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
21
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
• Contactor
• Line reactor
• Frequency converter input
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
22
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
• Contactor
• Line reactor
• Frequency converter
input
• Frequency converter
capacitors
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
23
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
• Contactor
• Line reactor
• Frequency converter input
• Frequency converter
capacitors
• Frequency converter
power inverter
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
24
SFC Product Introduction
SFC Drive Components
• Radio interference
suppression filters
• Contactor
• Line reactor
• Frequency converter input
• Frequency converter
capacitors
• Frequency converter
power inverter
• Frequency converter
output
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
25
SFC Product Introduction
Proper SFC Application
For Multi-Unit Installations
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
26
SFC Product Introduction
SFC Unit: First to Load, Last to Unload
Air Flow Demand
700
600
500
cfm
400
SFC
300
200
100
SFC
Base Load 1
SFC
0
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
27
SFC Product Introduction
SFC Unit: First to Load, Last to Unload
p (psig)
110
SFC
OFF
Package 1OFF
Δp SFC
Package 2OFF
Δp1
Package 3OFF
100
SFC regulating pressure
Δp2
SFCON
Package 1ON
Package 2ON
90
Δp3
Package 3ON
85
Min. air main pressure
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
28
SFC Product Introduction
What is a Control Gap?
SFC too small
SFC
Needed
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
29
SFC Product Introduction
FAD / air consumption
What is a Control Gap?
max. = 242 cfm
load = 237 cfm
Base load 1
min. = 55 cfm
unload = 0 cfm
BSD 50
SFC 37
Variable load
unload = 0 cfm
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
30
SFC Product Introduction
What is a Control Gap?
1) A control gap is created any time a demand could exist that would
cause more than one compressor to cycle.
FAD / air consumption
711
customer’s
air demand
474
Control gap
SFC cycles
237
Variable load
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
31
SFC Product Introduction
What is a Control Gap?
2) With the SFC undersized, each time a base load compressor comes
on another control gap is created.
FAD / air consumption
726
Demand = 244 cfm
Base load 1 = 237 cfm
484
SFC load = 7 cfm
(Base load 1 cycles)
SFC cycles
242
Variable load
Base load 1
Variable load
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
32
SFC Product Introduction
What is a Control Gap?
3) The more base load units there are, the more control gaps are
created.
Demand = 486 cfm
Base load 1 = 237 cfm
726
Base load 2 = 237 cfm
FAD / air consumption
SFC load = 12 cfm
(Base load 2 cycles)
Variable load
484
Base load 1 cycles
Base load 1
SFC cycles
242
Variable load
Base load 1
Base load 2
Variable load
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
33
SFC Product Introduction
What is a Control Gap?
• A control gap exists when demands may cause more
than one compressor to cycle.
• Control gaps can occur in multi-unit installations with
or without variable speed compressors.
• To avoid control gaps in variable speed applications,
the largest cycling base load compressor must be
smaller than the SFC’s control range.
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
34
SFC Product Introduction
Proper Application of the SFC unit
Example: Select a properly sized SFC for our customer’s
system if they already have (2) BSD 50 compressors.
SFC
Needed
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
35
SFC Product Introduction
Proper Application of the SFC unit
Solution:
Step 1: What is the capacity of the largest cycling base load
compressor? 237 cfm @ 110 psig
Step 2: Select a compressor with a control range that is slightly larger
than the capacity of the largest cycling base load compressor:
Calculate SFC 55 control range
control range = capacity @ max. speed - capacity @ min. speed
control range SFC 55 = 381 - 82 = 299 cfm
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
36
SFC Product Introduction
Proper Application of the SFC unit
A SFC 55 could be selected when using BSD 50 base
load units to eliminate control gaps.
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
37
SFC Product Introduction
FAD / air consumption
Proper Application of the SFC Unit
max. = 381 cfm
load = 237 cfm
min. = 82 cfm
Base load 1
SFC 55
unload = 0 cfm
Variable load
unload = 0 cfm
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
38
SFC Product Introduction
Proper Application of the SFC Unit
1) Even properly sized, a single control gap may occur if the
customer’s demand can be very low.
FAD / air consumption
726
Customer’s
air demand
484
381
SFC cycles
242
SFC 55
Variable load
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
39
SFC Product Introduction
Proper Application of the SFC Unit
2) As demand increases and base load units are loaded, the SFC is
still left with enough demand to operate in its control range.
726
Demand = 383 cfm
FAD / air consumption
Base load 1 = 242 cfm
SFC load = 139 cfm
(SFC speed slows)
484
381
SFC 55
Variable load
242
Base load 1
SFC 55
Variable load
Time
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
40
SFC Product Introduction
Proper Application of the SFC Unit
3) So the SFC is able to slow down and speed up to match all the
compressors’ output capacity to the existing demand capacities
without control gaps!
726
FAD / air consumption
Demand = 625 cfm
Base load 1 = 242 cfm
623
SFC 55
Variable load
484
Base load 2 = 242 cfm
SFC load = 131 cfm
(SFC speed slows)
Base load 1
SFC 55
Variable load
242
Base load 1
Base load 2
SFC 55
Variable load
 2008 Kaeser Compressors, Inc., USA (V4.1)
Time
“Specifications are subject to change without notice”
41
SFC Product Introduction
Proper Application of the SFC Unit
• Applied as part load
compressor (40 - 85% loaded)
• First compressor on/ last off
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
42
SFC Product Introduction
Proper Application of the SFC Unit
• Applied as part load
compressor (40 - 85% loaded)
• First compressor on/ last off
• Narrow pressure band
• Large load variances with
no pattern
• High power cost
• Areas with rebates
• Areas with power factor
penalties
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
43
SFC Product Introduction
Comparison of Typical “Real-Life” Savings
Purchase Price
Typical Installation
13%
10% Maintenance
Energy 77%
22% SFC Savings
SFC Installation
Energy 50%
18% Purchase Price
10%
Maintenance
 2008 Kaeser Compressors, Inc., USA (V4.1)
“Specifications are subject to change without notice”
44