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PERMANENT MAGNET VARIABLE SPEED (PMVF) 2-STAGE COMPRESSORS

PERMANENT MAGNET VARIABLE SPEED (PMVF) 2-STAGE COMPRESSORS

Next generation compressors promise outstanding efficiency – the ultimate combination for new screw compressor range.

PERMANENT MAGNET VARIABLE SPEED (PMVF) 2-STAGE COMPRESSORS

Southern Cross Compressors announce the imminent launch of permanent magnet, variable frequency technology combined with next generation, 2-Stage screw airends. Developed by parent company Kaishan Corporation, these revolutionary new compressors offer industry a unique integrated systematic optimisation of the compressor unit, advanced permanent magnet motor and  Kaishan 2-stage technology to achieve outstanding energy efficiency.

Martin Curd, Southern Cross National Sales Manager stated, “This unique integrated combination is a game changer in the compressed air industry offering unsurpassed efficiency in compressors all the way down to 22kW. We can now offer a superior range of advanced energy saving compressors for virtually any industry application”.

2-Stage air compressors are up to 20% more efficient compared to a typical single stage compressor. As the compression ratio is spread over two distinct airends, customers get the benefits of both higher efficiency and longer bearing life.

Kaishan general manager Dr Yan Tang, one of the world’s foremost experts in air compressor development stated. “With global energy costs constantly rising, we are continually developing higher efficiency compressors that meet and surpass international energy standards. The high ◦◦efficiency of our newly developed 2-Stage screw units is the fundamental reason for our PMVF compressor’s class leading performance. Our unique package design and engineering offers obvious technological advantages including screw compressor unit efficiency, drive motor efficiency and overall unit control”.

Rare earth material technology gives the permanent magnet synchronised motors higher possible rotating speeds, wider operating parameters and increased energy efficiency. Within its wide operating speed range the PMVF compressors are able to maintain extremely high motor efficiency compared to those utilising conventional drive motors.

With an operating variable speed turndown range of 7:1 (conventional VS compressors 4:1), Kaishan’s PMVF operates at peak efficiency even with an 80% reduction in air output. It also offers far greater integrated control precision through an advanced PID control algorithm providing highly stable supply pressures.

The fully enclosed, oil cooled PM motor generates very little heat resulting in a longer life. No cooling fan means significantly lower noise and less fan drag compared to conventional motors. The motor is heat resistant to 180⁰ C and cannot be magnetised. With no external electrical excitation, the rotor utilises rare earth technology to eliminate speed slippage, fundamental wave iron and cope per loss maintaining a power factor close to 1.

The precision speed adjustment capability (1/30000) greatly reduces discharge fluctuations of the new range of air compressors.

Motor angular position sensors are not required, simplifying the system and improving both stability and reliability. Torque can be compensated at any angle within 360⁰ to achieve perfect torque control and the utilisation of bus voltage is greater than 93% being much greater than conventional inverters.

Once a mains frequency screw air compressor deviates from its designated working specifications, its efficiency drops. Kaishan’s PMVF technology is able to adjust the motor’s rotating speed according to demand variables in the required air volume at any time. By regulating the volume of air output, the compressor is able to maintain maximum efficiency under all usage demands from 15-100%. Particularly in widely fluctuating demands, Kaishan’s PMVF type air compressors demonstrate a remarkable energy saving capacity as high as 50% over conventional types.

Southern Cross is in the final stages of obtaining all necessary statutory approvals for the new range which is expected to be launched later this year.

COMPARISON TO MAINS FREQUENCY SCREW AIR COMPRESSORS

Total efficiency values were recorded during development trials comparing the usage of a 37kW conventional air compressor with a MPVF type based on 8000 identical operating hours per annum. The results displayed an energy saving of 281,200kW with the conventional model compared to 183,250kW with the Kaishan PMVS model…  An astounding saving of 97,680kW 

Why permanent magnet motors?

The AC induction motor is often referred to as the workhorse of the industry because it offers users simple, rugged construction, easy maintenance and cost-effective pricing. Despite its popularity, the AC induction motor has limitations: It is not a constant-speed machine, it is not inherently capable of providing variable-speed operation and they are energy intensive to operate.

Permanent magnet motors are the next generation offering both excellent performance with fewer losses and therefore lower operating costs.

A conventional induction motor consists of two key parts: a stator and a rotor. The electric current passes through the stator to produce a rotating magnetic field. This in turn induces a current in the rotor, which creates a second magnetic field. The interaction between these two magnetic fields produces turning torque, causing the rotor to turn.

The induction motor shaft and the magnetic field do not turn at the same pace. Due to losses in bearings and other elements, the rotor cannot keep up with the field and turns below the magnetic field synchronous speed. This is called slip, measured in RPM, which increases with increasing load.

High-speed permanent magnet motors offer increased energy efficiency compared to conventional asynchronous induction motors. A permanent magnet motor utilising an oil cooled housing offers not only reliable operation, but significantly lower losses.

Permanent magnet synchronous torque motors offer higher torque and fewer losses with faster acceleration and deceleration, compared to asynchronous induction type motors, and this is advantageous with compressors as they rapidly vary their output to match customer demand.

  • Energy efficiency over a wide speed range
  • Desired output power in smaller frame sizes
  • Variable speed operation in constant-torque and variable-torque applications
  • Lower routine and long-term maintenance

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Compressed air considerations for food industry applications

FOOD PROCESSING & PACKAGING


Most of Australia’s food processing and packaging industries rely on compressed air to provide power for production demands which vary greatly from industry type to seasonal variations. The selection of the right air compressor and system to match such needs is critical, not only for maximum productivity but to minimise the impact of rising energy costs.

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Compressed air audit reveals potential savings in excess of $300,000

 

Many industries around the world are waking up to the potential for savings in compressed air generation costs.

While compressed air generation is vital throughout the world to power production in major industries, it has become a constantly increasing cost factor due to rising energy prices. This is of particular concern for Australian industry dependent on keeping expense down to remain competitive.

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Custom KHE Compressors go to sea

Salmon farm relies on Southern Cross Compressors

On a recent holiday tour of the Apple Isle, I was fortunate enough to mix business with pleasure by visiting Huon Aquaculture’s salmon farming facilities at Hideaway Bay on Tasmania’s South east coast.

I wanted to see how the company had utilised a series of air compressors in their operations. These compressors were from Southern Cross Compressors Australia Pty Ltd, a client company of mine and I was to write a short piece on their use by Huon.

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Want to save energy? Two-stage air compressor technology

Southern Cross CEO, Mark Ferguson: “If Australian industry really wants to get serious about saving energy then it needs to take a close look at ‘two-stage’, air compressor technology. As energy costs continue to outstrip other business input expenses it is critical, more than ever before, to find new ways to save power. Two-stage compressors may just be one of the answers.”

“Many customers get fixated with the capital cost of an air compressor and whilst those that want to save energy costs, will look a little deeper and review service costs, very few understand the long-term total operating cost of compressed air,” says Ferguson. “The largest cost related to producing compressed air is in energy, and this typically represents the highest energy usage in the plant. With continuously rising energy costs it’s an area in which businesses can readily address to achieve substantial potential savings,” he adds. “Two-stage compressors really are low hanging fruit”.

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We are expanding! Kaishan Group launches global expansion

As China’s number one air compressor company boasting four large production facilities throughout the country, Kaishan produces more than 30,000 rotary screw compressors and 250,000 reciprocating compressors annually for application and installation throughout the world.

Kashan’s entry into the global market was launched through the acquisition of Southern Cross Compressors Australia in 2012. Southern Cross has operated successfully in the local market for over 30 years and now offers the Australian market a greatly expanded range of quality air compressors (from 3 to 6000kW power) backed by an experienced sales and technical services team.

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Compressed Air… is it a sustainable power source for industry?

With the rapidly rising cost of electricity, the answer to this headline question is complicated, with many variables affecting the real efficiencies relating to cost versus application.Most industries in Australia and throughout the world rely on compressed air as a major source of energy to operate equipment such as pneumatic controls, air tools, pumps, valve actuators, pistons and large-scale processes. Compressed air is used because it is a clean, safe and convenient energy source, but compressed air is also an expensive energy source. In fact, approximately 10% of the electricity supplied to Australian industry is used to compress air.

The continued effectiveness of compressed air as an industrial power source lies in today’s technological advances in compressor design, control methods, reticulation design and the maintenance of systems to ensure optimum operational effectiveness.

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Compressed air leaks may be costing you money

save energy air compressors industrialCompressed air leakage is costing Australian industry millions of dollars every week with many systems wasting up to 50% of the air they generate.

We know that generating compressed air to operate your industry is costly in terms of energy usage, maintenance and down time and yet all these costs can be dramatically reduced by simply detecting leaks and fixing them!

At Southern Cross, we specialise in the detection and repair of compressed air leaks in all types of systems. Call now for a free leak assessment and save money. National sales and service 1300 098 901

 

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You could save thousands on your energy bills

It will cost you nothing to find out!

More and more companies are discovering that they are wasting many thousands of dollars every year in energy costs though inefficiencies in their compressed air systems.

Air leaks, incorrect settings, receiver and dryer inadequacies, blocked filters, poor maintenance practices and often wrongly specified equipment for the demand can add massive costs to your business.

Using state of the art detection equipment, our qualified technicians can find all the inefficiencies in your C.A. system and fix them.

With our vast experience, Southern Cross Compressors can assess, repair and service all types and brands of compressed air systems.

We also make and install a wide range of compressors and ancillary equipment to suit every application.

Call now – the potential savings may surprise you.

National sales and service 1300 098 901

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Air Compressor Health Tips

Get the most out of your compressor with these helpful air compressor health tips

With these air compressor health tips, the correct compressor system for your needs and a good maintenance program, you will be able to extend the life of your compressor, reduce running costs and increase efficiency.

Daily system checks

Is your compressor system part of your daily inspection checklist? We highly recommend that following daily checks are conducted and recorded every day:

  • Oil levels?
  • Any oil leaks?
  • Is there too much incoming voltage?
  • Does the control line filter need draining?
  • Are there any unusual noises or vibrations?
  • Are the gauges and indicators in normal operation?

Gauges and indicators can help you spot air leaks and monitor temperatures. The differentials across your compressor filter to check for air pressure (usually measured in PSI).

Overheating is a common problem with air compressors that have not been regularly checked and maintained. Ensure that your air compressor is kept in a well-ventilated area so that it can breathe and cool down, especially when the weather heats up in summer.

If the compressor system appears to be vibrating too much or making more noise than usual, ask us to take a proper reading.

Weekly system checks

  • Is the safety valve working?
  • Do the air receivers need draining?
  • Is the moisture separator draining?
  • Does water need to be drained out of the oil?

Monthly system checks

  • Clean the after-cooler and oil cooler
  • Wipe down the entire air compressor unit (dust increases chances of overheating)
  • Air filter service (sooner if the compressor is operating in extremely dusty or dirty conditions)

Quarterly system checks

  • Change the oil filter
  • Check the full load amps
  • Change the petroleum oil
  • Scan the compressor unit for loose bolts and re-tighten
  • Have an oil sample taken (we can test the sample to see if the oil needs to be changed)

Yearly system checks

  • Lubricate the motors
  • Check the safety shut-down system
  • Change the air filter every 2,000 hours
  • Change the oil separator every 4,000 – 8,000 hours

Your air compressor health in our safe hands

Our approach to compressed air maintenance will help to:

  • Increase the life expectancy of your air compressor asset
  • Prevent air compressor breakdown and subsequent business loss
  • Ensure that your air compressor system meets your needs at every cycle of your operations
  • Give you peace of mind knowing that we are reducing your energy costs by ensuring that your compressor is running efficiently

See more about our air compressor service, repair and maintenance here. For a limited time, we are offering a free air audit and quote, so contact us today!

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Winery Energy Saving Tips: Minimise Your Environmental Footprint

Winery energy saving. How much money will you save with a properly configured air compressor system?

Taylors case study

Taylors Wines in Clare Valley, North of Adelaide, has been producing a variety of red, white and sparkling wines since 1969. The site consumes just under 1,700,000kWh of energy per year, and Taylors wanted to know how they could create winery energy saving and reduce their environmental footprint.

Taylors were also motivated by the desire to be known as “Australia’s best wine company applying best practice principles in environmental management to enhance sustainable business activities and products“, and requested an audit of their air compressors.

While there wasn’t much room for improvement in the wine press, there was a significant improvement opportunity that presented itself in the bottling plant. In the bottling plant, two 15kW air compressors were running loaded for 57% of the time. By replacing these two units with a single 25kW air compressor with variable speed controls, Taylors were able to save an estimated 30% in energy use.

As compressed air experts, we understand how to assess your winery compressed air needs with your output and operational goals in mind. We frequently conduct energy audits to identify:

  • Incorrect compressor selection
  • Air leaks and pressure drops
  • Inappropriate usage
  • Poor reticulation design
  • Inadequate ventilation
  • System pressure settings

Poor maintenance also usually leads to loss in energy efficiency, increasing your energy bill and risk of break-down, business down-time and loss of product. Contact us today about an energy assessment and start saving money!

This study was reported by the Australian Government Department of Industry, Government of South Australia and South Australian Wine Industry Association Incorporated.

Some more energy-saving tips for wineries

Both operational and new winery businesses can reduce energy in their most common systems, which include:

  • Chilling and refrigeration
  • Lighting
  • Water heating
  • Plant and equipment
  • Air compressors

Ensure that your chillers are regularly maintained. Check for ice build-up and damage, ensuring that delivery lines and external coils are kept clean. A refrigeration engineer may help you achieve energy efficient systems. Insulate wine tanks and install variable speed controls. Efficient insulation will help prevent any condensation, ice build-up, minimising the overall cooling load.

Your staff may also be educated about energy efficiency and implementation of any strategic plansCellar fridges and any water fountains should also be turned off after hours.

Motion sensors will help reduce lighting energy use, and areas designed to allow for natural lighting will reduce the need for light installation. Check you light bulbs and ensure they are energy efficient.

Ensure that when not in use, equipment is switched off. Variable speed controls may be used to manage power output. Motors that are regularly serviced and put on energy saving modes will help reduce energy use and increase efficiency.

Consider solar heating for water heating devices where possible, and refrain from installing over-sized services or tanks with poor energy ratings. Insulate hot water lines to minimise heat loss, and use any waste heat from chiller or refrigeration systems to re-heat hot water. Timers will also help eliminate energy costs for after-hours.

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Advanced Scroll Compressor Technology

Lower energy use and achieve higher efficiency with scroll compressor technology

We recently introduced the Ganey range of advanced lubricated scroll compressor technology that delivers exceptional efficiency with minimal moving parts.

If you operate a small to medium sized business and currently use a piston-type reciprocating compressor, you are likely paying too much to operate those machines with limited energy efficiency. By updating your compressor to the advanced scroll compressor technology, you can enjoy smooth, vibration-free operation that is proven to be more reliable than piston-type compressors.

The Ganey range of scroll compressor is known for its compact, low-noise operation with its dynamically balanced, non-contact orbital scroll for quiet performance. Its compact size allows for smaller installation spaces.

With a Ganey scroll compressor, you benefit from:

  • Reliable performance and ultra quiet operation
  • Advanced control and monitoring
  • Compact design with no vibration
  • Direct drive (no drive belts to replace)
  • Compressed air supply with lower energy bills
  • Built-in temperature and overload protection

Contact us for more information about how you can start lowering your energy bills and increasing compressed air output with a Ganey scroll compressor! If you’re looking for air compressor accessories, see them here. If you’re looking for our 2 stage compressors, see them here!

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