RELIABLERELIABLERELIABLE
COMPRESSED AIR CONDENSATE M
ANAGEMENT AND ENERGY SAVING PRODUCTS
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
ENVIRONMENT SAFEGUARDADDING VALUE
AIR SAVINGPRODUCTS
AIR-SAVER G1AIR-SAVER G2LOCATOR-EV
JORC Industrial BVPretoriastraat 28NL-6413 NN HeerlenThe Netherlands
Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79
INDEXChapter Content Page
1 Introductiontocompressedairleakages, 3 acommonproblem 4
2 Addvaluetoacompressedairsystem 5 Graphs 63 LOCATOR-EV 7 Specifications 8
4 AIR-SAVERG1 9 Specifications 10
5 AIR-SAVERG2 11 Specifications 12
6 Installation 13 Accessories 14
Version2016
AIR &
ENERG
Y SAVIN
G PRO
DU
CTS
Air
sav
ing
prod
ucts
Informationprovidedherewithisbelievedtobeaccurateandreliable.However,noresponsibilityisassumedforitsuseorforanyinfringementofpatentsorrightsofothers,whichmayresultfromitsuse.Inaddition,JORCreservestherighttoreviseinformationwithoutnoticeandwithoutincurringanyobligation.
SAVING AIR IS SAVING MONEY
CTA Industrial is a global condensate management specialist ofDutch origin offering condensate drains,oil/water separators and airsaving products to distributors, dealers and OEM’s in morethan 100 countries. CTA Industrial is dedicated to settingthestandard in helping our customers manage theircondensate management requirements.
Introduction to saving compressed air
Compressedairisusedwidelythroughoutindustryandisoftenconsideredthe“fourthutility”.Almosteveryindustrialplant,fromasmallmachineshoptoanimmensepulpandpapermill,hassometypeofcompressedairsystem.Inmanycases,thecompressedairsystemissovitalthatthefacilitycannotoperatewithoutit.Aircompressorsystemscanvaryinsizefromasmallunitof5horsepower(hp)tohugesystemswithover50,000hp.
Inmanyindustrialfacilities,aircompressorsusemoreelectricitythananyothertypeofequipment.Inefficienciesincompressedairsystemscanthereforebesignificant.Energysavingsfromsystemimprovementscanrangefrom20-50%ormoreofelectricityconsumption.Formanyfacilitiesthisisequivalenttothousands,orevenhundredsofthousandsofeurosofpotentialannualsavings.Aproperlymanagedcompressedairsystemcansaveenergy,reducemaintenancecost,decreasedowntime,increaseproductionthroughputandimproveproductquality.
Compressedairsystemsconsistofasupplyside,whichincludescompressorsandairtreatment,andademandside,whichincludesdistribution,storagesystemsandend-useequipment.Aproperlymanagedsupplysidewillresultinclean,dryandstableairbeingdeliveredattheappropriatepressureinadependable,cost-effectivemanner.
Aproperlymanageddemandsideminimiseswastedairandusescompressedairforappropriateapplications.Improvingandmaintainingpeakcompressedairsystemperformancerequiresaddressingboththesupplyanddemandsidesofthesystemandhowthetwointeract.Thecompressoristhemechanicaldevicethattakesinambientairandincreasesitspressure.Controlsservetoregulatetheamountofcompressedairbeingproduced.
Thetreatmentequipmentremovescontaminantsfromthecompressedairandaccessorieskeepthesystemoperatingproperly.Distributionsystemstransportcompressedairtowhereitisneeded.Compressedairstoragecanalsoservetoimprovesystemperformanceandefficiency.
INTR
OD
UCT
ION
TO
CO
MPR
ESSE
D A
IR Chapter 1
3
LEAKA
GES, A
COM
MO
N PRO
BLEM
LEAKAGES, A COMMON PROBLEM
Airleaksareaconcernforanyoneoperatingacompressedairsystem.Theaverageplantwithnoformalleakmanagementprogramcanhaveairleaksthatcanpossiblywasteupto30percentofthetotalaircapacity.
Leakswillcausecompressorstorunatfullloadforlongerperiodsoftime.Thecompressorswillnotonlyusemoreenergy,butmayalsoneedadditionalmaintenanceduetotheincreasedloads.
Leakscangivethefalseimpressionthatadditionalcompressorsarerequiredtomeetthedemandforcompressedair.
COMMON LEAK POINTS
• Quickconnectionfittingshaveo-ringstosealthehoseconnections.Adamagedormissingo-ringwillcausetheconnectiontoleak.
• FRL’s(filter,regulator&lubricator).Inletandoutletconnectionsandbottomdrainagepointscanleak.
• Theweldsfoundonpipejointsandpipeflangescanleakduetovibrations,ageorimproperwelding.
• Floatormechanicaltypecondensatedrainscanalsobeasourceofairleaks,becausetheoperatingmechanicscangetstuckinthe“open”position.
• Pipethreadconnections,airtoolsandmanymoresourcescanbethecauseofairleakages.
LOCATOR-EV
TheLOCATOR-EVisanultrasonicairleakdetectorandisanecessarytoolinaleakpreventionprogram.
TheLOCATOR-EVislightweightandeasytooperate.Thereliableandaccuratedetectioncapacitymakesitahighlyefficientairleakdetector.Airleakturbulenceorfrictionproducehighfrequencyultrasonicwavesandarenormallyhigherthan20kHz.Thisistypicallyabovetherangeofhumanhearinglevels.
TheLocatoriseasytouseandhighlyeffectiveinfindingcompressedairleaks.
AIR-SAVER
Thecompressedairthatisstoredinthereceivercanleakoutthroughtheabovementionedsourcesofairleaks.Thisisadirectwasteofenergyandmoney.
TheAIR-SAVERisinstalledontheairpipingthatcomesoutofareceivertank.Itcanbeprogrammedtoautomaticallyopenjustpriortothestartofaworkshiftandclosejustaftertheendoftheworkshift.
TheAIR-SAVERisanimprovementtoanycompressedairsystemwiththeabovementionedairleakproblemsandhasafastpayback.
Chapter 1
4
AD
DIN
G V
ALU
E
THE VALUE OF AN AIR-SAVER
TheAir-Saverisinstalledjustbeyondtheairreceivertank.Itcanbeprogrammedtoautomaticallyopenjustpriortothestartofaworkshiftandclosejustaftertheendoftheworkshift.Bydoingsoyousavecompressedairandreduceenergycosts.
Compressedairleakagesarecommonandmoreimportantlyverycostly.GraphAandB(nextpage)illustratethevalueoftheAIR-SAVERwheninstalled.Atypicalinstallationisillustratedbelow.
IngraphAandBthelightbluelinedemonstratestheoperatingmovementsofthecompressor,ortoputitinotherwords–ENERGY USAGE.
Graph AshowsacompressedairsystemwithoutanAIR-SAVERinstalled.At4pmtheworkingshiftisoverandthecompressedairleakagesforcethecompressortocontinuallybringtheairpressureuptotherequiredlevel(eventhoughnooneisworkinginthisparticularexample).
Theresultisthatthecompressorkickedin20timesduringtheperiodinwhichnoonewasrequiringcompressedair!Compressedairlossesoccurthroughpipeworkconnectionleakages,leakingfloattypedrains,flowmetersetc.
Graph BshowsthesamecompressedairsystembutnowwithanAIR-SAVERinstalled.Thelightbluemovementsarethecompressorinrunningmode.At4pmyouseethattheworkingshiftendsandthattheAIR-SAVERisprogrammedtoclose.
TheresultofclosingtheAIR-SAVERisthatthepressureinthepipeworkbeyondtheAIR-SAVERislostasyouseethepressuredropsto0bar.Theproducedcompressedairstoredintheairreceiverissavedandthecompressordoesnotrequiretokickonandofftobringtheairpressureuptoacertainlevel.
SavingsachievedwiththeAIR-SAVERare:
• Valuableandexpensivelyproducedcompressedair.• Electricityforrunningthecompressor.• Wearingpartsofthecompressor.• Compressorservicingcostsduetounnecessarycompressoroperatinghours.• Otherwearingpartslikecompressedairfilterelementsduetounnecessaryoperating
hours.
Chapter 2
5
GRAPH A: COMPRESSED AIR SYSTEM WITHOUT AN AIR-SAVER
GRAPH B: COMPRESSED AIR SYSTEM WITH AN AIR-SAVER
Chapter 2
6
LOCA
TOR-
EV
Chapter 3
7
LOCATOR®-EVUltrasonic air leak detector
PRODUCT FEATURES
TheLOCATOR-EVislightweightandeasytooperate.Thereliableandaccuratedetectioncapacitymakesitahighlyefficientairleakdetector.Airleakturbulenceorfrictionproducehighfrequencyultrasonicwavesandarenormallyhigherthan20kHz.Thisistypicallyabovetherangeofhumanhearinglevels.
Theultrasonicwavescantravelinairandarehighlydirectional.ThisdirectionalaspectallowstheLOCATOR-EVtoisolatetheultrasonicsoundamongstotherexternalfactorysounds,whichwillproveveryusefulinpreventivemaintenance,troubleshooting,qualitycontrolanddiagnosticdatacollectiononanycompressedairsystem.
COMMERCIAL BENEFITS
• Costcompetitiveofferingarapidpay-back.• Ultrasonicleakdetectionoffersaquickandeasywaytolocateleaks.• ProductiondoesnotneedtobedisturbedwhentheLOCATOR-EVisbeingused.• Fullyautomatic-nomaintenance.• Privatelabellingispossible.
TECHNICAL ADVANTAGES
• Suppliedinhardprotectivecase,completewithheadsetandarubberfocussingprobe.• Lightandeasytooperate.• Leakswillbedetectedfromadistance(upto10meters).• Highlyeffectiveinlocatingairleaks,evenduringarunningfactoryproduction.• Verylittletimeisrequiredtolocateleaksthroughoutafactory.• Aprofessionalheadsetisincluded.
The LOCATOR-EV is an ultrasonic air leak detector that detects compressed air leaks.
LOCATO
R-EV - SPECIFICATIO
NS
Chapter 3
8
PRODUCT SPECIFICATIONS
Construction HandheldABSultrasonicprocessor
Circuitry SMT/Solidstatehybridheterodynereceiver
FrequencyResponse 36000–44000Hz.
Indicator 10segmentleakindicationLEDbar
Power 9voltalkalinebattery(included)
Headset Noiseisolatingtype:doubleheadsetwiredmonophonic Impedance:16ohms.Over23dBnoiseattenuation.
Responsetime Approx300milleseconds
Ambientoperatingtemp. 10–60degreesC.(50–140degreesF)Relativehumidity 10–95%
Weight 0.25Kg
PRODUCT DIMENSIONS
Suppliedinitsownardcase.
Visualandaudibleleakindication.
Hardhatearphonesareoptionallyavailable.
AIR
-SAV
ER G
1 Chapter 4
9
AIR-SAVER®G1Compressed air energy saver
PRODUCT FEATURES
Atypicalcompressedairsystemhasairlossthroughpipeworkconnections,leakingfloattypedrainsetc.
TheAIR-SAVERG1willopentheballvalveatthebeginningofaworkingshiftandclosetheballvalvewhentheworkingshiftisover.Fromthatpointon,allcompressedairwillremainintheairreceiveruntilthenextworkingshift,ratherthanbeinglostthroughleakages.
Thecleverandversatileprogrammingfeatureallowsforcustomerspecificsettingsandistotallyadaptabletotheworkinghoursofeachindividualfactory.
TheAIR-SAVERG1canbeinstalledinallpipelinesystemsupto1”.RemoteswitchingkitsareavailabletooperatetheAIR-SAVERG1fromadistance.
COMMERCIAL BENEFITS
• Microprocessorcontrolled(7dayprogramfeature-multiplecyclespossibleeachday).• Menulanguageselectionfeature(English,German,Spanish,FrenchandDutch).• Easytoprogram(intuitive).• Eachindividualdaycanbeprogrammedaccordingtospecificworkingdayshift
requirements.• LCDdisplayingtheprogramcycleandthecurrenttime.• Externalpushbuttoncontrols(disassemblynotnecessary).• Batterylifeindicationinthedisplay.• Fullyautomatic-nomaintenance.• Smallcompactdesign.• Privatelabellingoptions.
TECHNICAL ADVANTAGES
• 1”Orifice.• FPMandPTFEseals.• Stainlesssteelball,valveisnickelplatedbrass.• Slowballvalverotation90degreesin30seconds (designedtoavoidwater-hammerwhenopeningorclosing).• Extendedprogrammingfeaturesrelatingtovalveopenandclosecycles(100cycles/week).
The AIR-SAVER G1 is installed in thecompressed air line after the air receiver.The AIR-SAVER G1 opens and closes the airsupply to the factory, based on customerspecific working shifts.
AIR-SAV
ER G1 - SPECIFICATIO
NS
Chapter 4
10
PRODUCT SPECIFICATIONS
Supplyvoltage 115Vor240VAC/DC50/60HzPowerconsumption 7WduringcyclerotationOpening/Closingduration 30sec./90°
Operatingtemperature 0°Cto+60°CValve NickelplatedbrasswithstainlesssteelballConnection 1”BSPorNPTPressurerange 0to16bar(230psimaximum)Manualoverride Yes
Environmentalprotection IP54
Indicators LCDindicatingprogramandcurrenttimeTimerdisplay 24hoursBattery 4xAAAminipenlightbatteries.
CEcertified
PRODUCT DIMENSIONS
Built-inquartzcontrolledtimerwithLCDdisplay
Remotecontroloption 1”Stainlesssteelrotationball.
Shouldtherebeanelectricalpowerfailure,thentheballvalvecanbemanuallyopenedorclosed.
AIR
-SAV
ER G
2 Chapter 5
11
AIR-SAVER®G2Compressed air energy saver
PRODUCT FEATURES
Atypicalcompressedairsystemhasairlossthroughpipeworkconnections,leakingfloattypedrainsetc.
TheAIR-SAVERG2willopentheballvalveatthebeginningofaworkingshiftandclosetheballvalvewhentheworkingshiftisover.Fromthatpointon,allcompressedairwillremainintheairreceiveruntilthenextworkingshift,ratherthanbeinglostthroughleakages.
Thecleverandversatileprogrammingfeatureallowsforcustomerspecificsettingsandistotallyadaptabletotheworkinghoursofeachindividualfactory.
TheAIR-SAVERG2canbeinstalledinallpipelinesystemsupto2”.RemoteswitchingkitsareavailabletooperatetheAIR-SAVERG2fromadistance.
COMMERCIAL BENEFITS
• Microprocessorcontrolled(7dayprogramfeature-multiplecyclespossibleeachday).• Menulanguageselectionfeature(English,German,Spanish,FrenchandDutch).• Easytoprogram(intuitive).• Eachindividualdaycanbeprogrammedaccordingtospecificworkingdayshift
requirements.• LCDdisplayingtheprogramcycleandthecurrenttime.• Externalpushbuttoncontrols(disassemblynotnecessary).• Batterylifeindicationinthedisplay.• Fullyautomatic-nomaintenance.• Smallcompactdesign.• Privatelabellingoptions.
TECHNICAL ADVANTAGES
• 2”Orifice.• FPMseals.• Stainlesssteelball,valveisnickelplatedbrass.• Slowballvalverotation90degreesin105seconds (designedtoavoidwater-hammerwhenopeningorclosing).• Extendedprogrammingfeaturesrelatingtovalveopenandclosecycles(100cycles/week).
The AIR-SAVER G2 is installed in the compressed air line after the air receiver.
The AIR-SAVER G2 opens and closes the air supply to the factory, based on customer specific working shifts.
AIR-SAV
ER G2 - SPECIFICATIO
NS
12
Chapter 5
PRODUCT SPECIFICATIONS
Supplyvoltage 115Vor240VAC/DC50/60HzPowerconsumption 7WduringcyclerotationOpening/Closingduration 105sec./90°
Operatingtemperature 0°Cto+60°CValve NickelplatedbrasswithstainlesssteelballConnection 2”BSPorNPTPressurerange 0to16bar(230psimaximum)Manualoverride Yes
Environmentalprotection IP54
Indicators LCDindicatingprogramandcurrenttimeTimerdisplay 24hoursBattery 4xAAAminipenlightbatteries.
CEcertified
PRODUCT DIMENSIONS
Built-inquartzcontrolledtimerwithLCDdisplay
Remotecontroloption 2”Stainlesssteelrotationball.
Shouldtherebeanelectricalpowerfail-ure,thentheballvalvecanbemanuallyopenedorclosed.
INST
ALL
ATIO
N
TheAIR-SAVERtypicallygetsinstalledafterthereceiver(airtank).Oncecloseditretainsthecompressedairbuiltupinthereceiverandalsoensuresthatthecompressordoesnotrununnecessarilyduringmomentswhenitisnotrequired.
Inaddition,theAIR-SAVERcanbeusedtosectionoffcertaincompressedairpipelinesifnotrequired.
INSTALLATION
Detailedinstructionmanualswillguideyouthroughthesimpleinstallationprocedure.Ourinstructionmanualsaredesignedwithmanyillustrationsandsimpletext.
Inaddition,theJORCinstructionmanualsaresetupinvariouslanguages.
POSITIONING
Chapter 6
13
Installation
ACCESSO
IRES
Theairpipelineisoftenpositionedhighup,undertheceiling.AttendingtotheAIR-SAVERtomanuallyopenorclosethevalvecanbetimeconsuminginthisconfiguration.Tosimplifythisprocedureweofferaremoteswitchingkitwitheither1.7meteror5metercable.
Theremoteswitchingkitallowsforopen/closecontrolateyeheight.
JORCcansupplytheAIR-SAVERpre-wiredtotheremoteswitchingkitoritcanbeorderedasaseparateitem.Connectingandinstallingtheremoteswitchingkitisasimpleandstraightforwardprocedureforwhichwehavedesignedaninstructionmanualtoo.
REMOTE SWITCHING KIT
Chapter 6
14
Air-Saver accessories
Replacementvalveskitsareavailable.
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