Atlas Copco Air Management

ES control and monitoring systems

ENERGY SAVINGS
IN A WORLD OF AIR

New age control and monitoring

Managing a multiple compressor installation

used to be a complex art. Today, with Atlas Copcos
ES systems, its 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

Dewpoint

Flow

control the total system locally or remotely.

airnet

ES talks to the world

Central controllers

Monitoring systems

ES1000

sequencing of load/unload compressors

ES-X

ES2000

sequencing of VSD and

AIRConnect

monitoring via the Local Area Network

(LAN)
TM

monitoring via the Internet

load/unload compressors
ES3000

sequencing of turbos, VSD and

Note: AIRConnect is available as an Aftermarket Service only.

load/unload compressors

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:
ES2000 + AIRConnect TM
controls VSD and load/unload compressors, with
monitoring via the Internet

ES1000-X + AIRConnect TM
controls load/unload compressors, with monitoring
via the LAN and the Internet

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

Smart control reduces the cost of air

Indication of compressor problem

The control software behind ES is extremely

(not ready to start or shutdown).

sophisticated. The built-in algorithms continuously

Status of the communication link

compute real-time data and combine those with

between ES and the compressor.

customer preferences, machine parameters and

compressor room specifics.

Actual position of the inlet guide

vanes (IGV) and blow-off valve
(BOV) of a turbo compressor.

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

Net pressure and user selectable

in air delivery accuracy, energy savings and overall

pressure settings.

reliability.
Switching to ES control integrates
the compressors one by one.

Compressor number; lit when

Compressor status: stopped, unloaded,

integrated, flashing when isolated.

fully loaded and for turbo and VSD

indication of the operating zone.

Actual speed of a Variable Speed

Compressor type and user

Drive (VSD) compressor.

selectable name.

Brings compressor under ES control

or isolates it from the system,
e.g. for service or repairs.

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 its
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 controllers

can be equipped with an integrated sequencer.

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.

Net Pressure

W ITHOUT ES

W ITH ES

Average Pressure
Required Minimum Pressure
Time

In a traditional multiple compressor installation, the

Because the ES maintains the optimal mix of compressors,

load/unload pressures are offset to prevent compressors

based on the calculated (or measured) air delivery, there is

from starting simultaneously and to ensure stability in the

no need for offsetting pressure values.

air net. This not only limits the ability to closely match the

The resulting pressure band is a fraction of the non-

air demand, but it creates a large pressure band.

regulated system; the difference becomes even more

important as the number of compressors increases.

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.

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.

Local Control
8 bar

6 - 7.7 bar

compressor

compressor

dryer
+ filters

dryer
+ filters

air
receiver

ES

6 - 6.3 bar

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

The optimum zone

much tighter limits. Once more, energy consumption

and air net leaks are reduced and energy is saved.

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.

Specific
Energy

The reliability, energy efficiency and longevity of

a compressor will benefit greatly if it can operate
within this zone. The ES2000/3000 systems will
VSD

make sure they do.

Flow
Specific
Energy

The right schedule

B LOW - OFF

All ES controller systems have a programmable

T URBO
WITH IGV

week timer built-in, which allows for different

pressures at different times in the week.
Flow

This allows you to take in account variations in air

demand and required minimum pressure because of
shifts, batches or weekends.

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.

Condition based maintenance

The ES air management system collects and stores

compressor

Customers Local Area Network

compressor

data from each compressor in a centralised and secure

data warehouse. Active software agents continuously
ES

monitor and query the stored data. They can issue prewarnings in order to anticipate on problems in the
compressor room.

WWW

Customer
Centre

high reliability: redundancy of servers and 24 hr

surveillance reduce the risk for AIRConnect TM failures

Data
Warehouse

Distributor
(optional)

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

AIROptimizer TM AIRScan TM

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.

INFORMATION ON THE PERFORMANCE OF THE COMPRESSOR ROOM

1. Logging of events

2. Reports and graphs

starts and stops

performance reports

shutdowns and warnings

financial reports

changes of settings and status

graphs of all measuring points

= perfect tool for troubleshooting

Technology you can trust

The ES series is built around proven

easy to service, uncluttered
well laid-out electronics boards

microprocessor technology and a flat TFT touch

screen. Its 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 functionalitieswithout any

StrongArm microprocessor, proven

in industrial control and

changes to the hardware. Selected models can even

be upgraded remotely, via the Internet.

telecommunication systems

flash memory for updates and

expansions that are field

10.4 TFT touch screen with wide viewing angle;

no moving parts or buttons

upgradeable or even remotely

programmable

battery backup keeps all settings during power outage

integration into plant control systems via Modbus,

Profibus or Ethernet

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

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.

Unlimited path for growth

The available models and software options are

detailed in the table below.

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.

ES-X
ES + AIRConnect

TM

ES-X + AIRConnect

TM

ES1000
ES1000-X
ES1000-X + AIRConnect

TM

ES2000
ES2000-X

Central control

Central control

Monitoring

Monitoring

of load/unload

of VSD

of turbo

via LAN

via the Internet

ES2000-X + AIRConnect TM

ES3000

ES3000-X

ES3000 + AIRConnect TM

ES2000 + AIRConnect

TM

ES3000-X + AIRConnect

TM

UPGRADABLE

ES1000 + AIRConnect

TM

Central control

The face of innovation

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
ISO 9001
A consistent quality earned
us the industrys leadership
and the customers trust.

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.

Atlas Copcos
Environmental Management
System forms an integral part
of each business process.

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.

2935 0436 12 - Printed in Belgium - Subject to alterations without prior notice

ISO 14001

www.atlascopco.com