Plant Air Energy Saving

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Joseph Lucas
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1 Compressor power Figures show reliable effects. Company A performance Electricity CO2 Cost 1400 kw We help you save energy. We help you to improve and standardize your equipment, and adopt new equipment. We also proactively promote activities through official organizations, such as holding seminars at the energy-saving center. < themes> 3000 kw 0.9 t reduction/year 80 million reduction/year Company B performance Electricity CO2 Cost Proposal for a 7000 kw kw 1.7 t reduction/year 150 million reduction/year Plant Air Energy Saving Plant air Air leakage 15% 20% reduction Contributes to CO2 emissions reduction Tools 5% Others 10% Air Air 20% Electric power Compressor power (kw) After improvement Air blow 50% Before improvement Air Blow Blowing by Air Gun Air Purge PRESSURE kpa OUT MPa W SET Lower Pressure in the Piping Line Low Power Consumption Air Line Maintenance P-E09-6A

OUT PRESSURE kpa INDEX Recommend Equipment Air Blow Lower Pressure in the Piping Line MPa Nozzles for Blowing Series KN P. 1 S Couplers Series KK130 P.

2 OUT PRESSURE kpa INDEX Recommend Equipment Air Blow Lower Pressure in the Piping Line MPa Nozzles for Blowing Series KN P. 1 S Couplers Series KK130 P. 10 <Related Equipment> Compact Manometer Series PPA P. 1 Low Power Consumption W 3/4/5 Port Solenoid Valve Series SY/VQ/VF S0700 P. 11 Blowing by Air Gun Blow Gun Series VMG P. 2 Energy Saving Type 2 Port Solenoid Valve Series VXE P. 12 Air Purge Coolant Valve Series SGC P Color Display Digital Flow Switch Series PFM P. 3 Refrigerated Air Dryer Series IDF E P. 13 Pressure Valve Series ASR P. 4 Refrigerated Thermo-chiller Series HRZ Back cover Regulator with Backflow Function Series AR K/ARM/ARJ P. 5 Air Line Maintenance SET Digital Flow Switch for Air Series PF2A Back cover Direct Operated Precision Regulator Series ARP P. 6 Digital Flow Switch for Water Series PF2W Back cover Compact Cylinder with Solenoid Valve Series CVQ P. 7 Non-rotating Double Power Cylinder/ Double Power Cylinder Series MGZ P. 8 2-Color Display High- Precision Digital Flow Switch Compact Digital Pressure Switch Series ISE30A Back cover Series ISE10 Back cover Booster Regulator Series VBA P. 9 2-Color Display Digital Pressure Switch Series ISE80 Back cover

Nozzles for Blowing Air Blow Series KN Reduction of

facilitating effective pressure use With nozzle

a less bent copper tube Installing a nozzle (ø2) at

Copper tube with many bends Direct air blow by

nozzle 285 l/min Blow Annual operating cycles:

reduction) 8,550 m 3 /year ( 12,830/year)

5/m 3 Use to measure workpiece collision pressure.

3 Nozzles for Blowing Air Blow Series KN Reduction of the air with a small diameter nozzle Blow circuit facilitating effective pressure use With nozzle Without nozzle Nozzle Circuit Making it shorter with a less bent copper tube Installing a nozzle (ø2) at the end of the copper tube Reduced air Circuit Copper tube with many bends Direct air blow by copper tube Flow rate per nozzle 171 l/min Blow time: 2 sec. Annual operating cycles: 900,000 40% Flow rate per nozzle 285 l/min Blow time: 2 sec. Annual operating cycles: 900,000 5,130 m 3 /year ( 7,700/year) ( 5,130/year reduction) 8,550 m 3 /year ( 12,830/year) Corresponding value: Air unit 1.5/m 3 Use to measure workpiece collision pressure. Standard sensing head/knp Related Equipment Standard sensing head Needle sensing head/knp Needle sensing head Compact manometer Series PPA 1

Blow Gun Blowing by Air Gun Series VMG 20% reduction in power with the SMC blow gun + S coupler + coil tube Blow gun facilitating effective pressure use Pressure loss of 1% or less (Nozzle diameter:

4 Blow Gun Blowing by Air Gun Series VMG 20% reduction in power with the SMC blow gun + S coupler + coil tube Blow gun facilitating effective pressure use Pressure loss of 1% or less (Nozzle diameter: ø2.5) Filter regulator S coupler Coil tube coupler coil tube VMG Nozzle ø2.5 Air gun Nozzle ø3 Circuit Impact pressure: MPa (Distance: 100 mm) Blow time: 10 seconds (Frequency: 12 times/hour) Working hours: 10 hours/day (250 days/year) Total working hours: 8,300 hours Compressor pressure: 0.5 MPa Air : 257 l/min Power by compressor 1.25 kw ( 155,625/year) 20% Reduced power Circuit Impact pressure: MPa (Distance: 100 mm) Blow time: 10 seconds (Frequency: 12 times/hour) Working hours: 10 hours/day (250 days/year) Total working hours: 8,300 hours Compressor pressure: 0.6 MPa Air : 287 l/min Power by compressor 1.56 kw ( 194,220/year) ( 38,595/year reduction) Corresponding value: Electricity unit 15/kWh Refer to the energy saving program and catalog for details. 2

the exhaust port of a part presence sensor A simple part presence circuit using a digital flow switch. MPa 0.

4 Exhaust port Detection nozzle Detection port This cannot be used at a place where it is possible for water

Reduced air Detection nozzle Circuit PFM Detection nozzle diameter: ø2.0 Supply pressure: 0.

5 3 6 0 PULL SET PULL SET Color Display Digital Flow Switch Air Purge Series PFM Series PFMV Reduction of the air from the exhaust port of a part presence sensor A simple part presence circuit using a digital flow switch. MPa 0.4 MPa 0.4 Exhaust port Detection nozzle Detection port This cannot be used at a place where it is possible for water or oil to enter or remain in the piping between a detection nozzle and a sensor. Reduced air Detection nozzle Circuit PFM Detection nozzle diameter: ø2.0 Supply pressure: 0.2 MPa Circuit ISA2-H Detection nozzle diameter: ø2.0 Supply pressure: 0.2 MPa 0 l/min ( 0/year) 22 l/min 100% ( 7,430/year reduction) Excluding air from a detection nozzle Corresponding value: Air unit 1.5/m 3 Operating time: 15 hours/day, 250 days/year 4,950 m 3 /year ( 7,430/year) Excluding air from a detection nozzle 3

Pressure Valve Series ASR Reduction of the air by regulating the non-operating return-stroke side Construction combining a regulator with check valve and a flow control valve When the retraction side

6 Pressure Valve Series ASR Reduction of the air by regulating the non-operating return-stroke side Construction combining a regulator with check valve and a flow control valve When the retraction side is on the non-operating side that does not require power Pressure valve ASR Air-saving Valve Pressure regulation on the return stroke side Pressure regulation by replacing the speed control valve on the retraction side with ASR Valve Same pressure during operating and return strokes 0.5 MPa Operating stroke 0.5 MPa Operating stroke Return stroke 0.2 MPa Return stroke 0.5 MPa Reduced air Circuit Bore size: ø50 Stroke: 200 mm Pressure on the extension side: 0.5 MPa Pressure on the retraction side: 0.2 MPa Circuit Bore size: ø50 Stroke: 200 mm Pressure: 0.5 MPa 3.3 l 4.3 l When it is operated 900,000 times/year 25% When it is operated 900,000 times/year 3,011 m 3 /year ( 4,520/year) 3,902 m 3 /year ( 5,850/year) ( 1,330/year reduction) Corresponding value: Air unit 1.5/m 3 4

Regulator with Backflow Function Series AR K Series ARM10/11 Series ARJ210 (X209) Series ARM5 Series ARJ1020F Lowering of

return-stroke side When the retraction side is on the non-operating side that does not require power Operating stroke

5 MPa Pressure regulation by adding a regulator with Return stroke backflow function on the Return stroke 0.

5 MPa Regulator with backflow function Circuit Reduced air Circuit Bore size: ø50 Stroke: 200 mm Pressure on the extension

7 Regulator with Backflow Function Series AR K Series ARM10/11 Series ARJ210 (X209) Series ARM5 Series ARJ1020F Lowering of the pressure of a non-operating stroke for the entire cylinder Reduction of the air by regulating the non-operating return-stroke side When the retraction side is on the non-operating side that does not require power Operating stroke Operating stroke 0.5 MPa 0.5 MPa Pressure regulation by adding a regulator with Return stroke backflow function on the Return stroke 0.2 MPa retraction side piping 0.5 MPa Regulator with backflow function Circuit Reduced air Circuit Bore size: ø50 Stroke: 200 mm Pressure on the extension side: 0.5 MPa Pressure on the retraction side: 0.2 MPa Bore size: ø50 Stroke: 200 mm Pressure: 0.5 MPa 3.3 l 4.3 l When it is operated 900,000 times/year 25% When it is operated 900,000 times/year 3,011 m 3 /year ( 4,520/year) product product 3,902 m 3 /year ( 5,850/year) ( 1,330/year reduction) Corresponding value: Air unit 1.5/m 3 5

Direct Operated Precision Regulator Series ARP20 to 40 Greatly reducing the bleed air flow compared with the conventional (ARP3000) Constantly bleeding a small amount of air in order to make precise

8 Direct Operated Precision Regulator Series ARP20 to 40 Greatly reducing the bleed air flow compared with the conventional (ARP3000) Constantly bleeding a small amount of air in order to make precise pressure adjustment possible Interchangeable mounting available ARP3000 ARP30 (No equivalent s for APR20 and 40 are available since they are newly added ones.) Model When setting 0.3 MPa 0.8 l/min or less When air supplying time is 24 hours/day, 250 days/year Reduced air Model When setting 0.3 MPa 4 to 6 l/min When air supplying time is 24 hours/day, 250 days/year 288 m 3 or less/year ( 430/year) ( 1,730/year to 2,810/year reduction) 80% Corresponding value: Air unit 1.5/m 3 1,440 to 2,160 m 3 /year ( 2,160 to 3,240/year) 6

flow between a cylinder and a valve Piping

necessary Piping Model CVQ Bore size: ø32

9 Compact Cylinder with Solenoid Valve Series CVQ Series CVQM Reduction of the flow between a cylinder and a valve Piping between a cylinder and a valve not necessary Piping Model CVQ Bore size: ø32 Stroke: 50 mm No piping between a valve and a cylinder Supply pressure: 0.5 MPa Reduced air Model CQ2 Bore size: ø32 Stroke: 50 mm Piping bore: 4 mm Piping length: 2 m Supply pressure: 0.5 MPa l When it is operated 900,000 times/year 37% 0.67 l When it is operated 900,000 times/year 380 m 3 /year ( 570/year) ( 340/year reduction) 606 m 3 /year ( 910/year) Corresponding value: Air unit 1.5/m 3 7

Double Power Cylinder Series MGZ Reduction of the air by reducing the cylinder size Possible to reduce air in the retracting direction, compared with a standard cylinder with equivalent output in the

10 Double Power Cylinder Series MGZ Reduction of the air by reducing the cylinder size Possible to reduce air in the retracting direction, compared with a standard cylinder with equivalent output in the extending direction, thanks to a doubled piston area for the extending direction. Double extension output power!! SMC s unique construction doubles the piston area for the extending direction. An ideal air cylinder for lifting and press applications. Air pressure supplied from A operates on both surfaces q and w. (Extension) q w A B Air pressure supplied from B operates on surfaces e. (Retraction) e A B More energy-saving and compact cylinder through reducing the cylinder size ø63 Piston area Extension: 5,945 mm 2 Retraction: 2,313 mm 2 Size reduction ø63 ø80 ø80 Piston area Extension: 5,030 mm 2 Retraction: 4,540 mm 2 Circuit Bore size: ø63 Stroke: 200 mm Pressure on the extension side: 0.5 MPa Theoretical output (Extension side): 2,973 N 14% Reduced air Circuit Bore size: ø80 Stroke: 200 mm Pressure: 0.5 MPa Theoretical output (Extension side): 2,520 N 9.9 l 11.5 l When it is operated 900,000 times/year When it is operated 900,000 times/year 8,910 m 3 /year ( 13,370/year) ( 2,160/year reduction) product product 10,350 m 3 /year ( 15,530/year) Corresponding value: Air unit 1.5/m 3 8

11 Booster Circuit Series VBA Boost an insufficiently powered portion with a booster regulator Optimizing the booster circuit: Replacing it with a minimum sized booster circuit Example of one-side booster circuit (Boosting pressure on the operating stroke only) Operating stroke 0.8 MPa (boosting pressure) Example of two-side booster circuit Operating stroke 0.8 MPa Return stroke 0.4 MPa Return stroke 0.8 MPa Booster regulator Booster regulator Circuit When boosting pressure on the extension side only Retraction: 0.4 MPa Extension: 0.8 MPa (Boosting pressure) Reduced air Circuit Bore size: ø50 Stroke: 200 mm Pressure: 0.4 MPa Boosting pressure: 0.8 MPa 8.7 l When it is operated 900,000 times/year 33% 13 l When it is operated 900,000 times/year 7,830 m 3 /year ( 11,750/year) ( 5,800/year reduction) 11,700 m 3 /year ( 17,550/year) Corresponding value: Air unit 1.5/m 3 9

S Couplers Lower Pressure in the Piping Line MPa Series KK130 Since pressure loss is smaller than the conventional (Series KK13), even if inlet pressure is reduced, equivalent outlet pressure and

12 S Couplers Lower Pressure in the Piping Line MPa Series KK130 Since pressure loss is smaller than the conventional (Series KK13), even if inlet pressure is reduced, equivalent outlet pressure and flow rate can be achieved when it is used for air blow. Enables lower compressor discharge pressure. It is possible to reduce the cost with lower air and energy of compressors. Inlet pressure Outlet pressure 0.5 MPa Compressor S coupler Constantly used between 0 and 2 m 3 /min Reduced Pressure Loss Circuit Operating pressure at the outlet: 0.5 MPa Compressor efficiency: 0.7 Annual operating time: 2500 hours Flow rate: 1.2 m 3 /min Inlet pressure 0.54 MPa 7% Circuit Operating pressure at the outlet: 0.5 MPa Compressor efficiency: 0.7 Annual operating time: 2500 hours Flow rate: 1.2 m 3 /min Inlet pressure 0.58 MPa Power by compressor 262,000/year ( 11,000/year reduction) Power by compressor 273,000/year Corresponding value: Electricity unit 15/kWh Refer to the energy saving program and catalog for details. 10

3/4/5 Port Solenoid Valve Low Power Consumption W Series SY Series VQ Series VF Series S0700 Reduction of the power when

1/3 by reducing the wattage required to hold the valve in an energized state.

Electrical power waveform with power saving circuit Applied voltage 24 V 0 V 0.4 W 1 0.

With DC light Model SJ2000 SJ3000 SY3000/5000/7000/9000 SYJ3000/5000/7000 VQZ1000/3000/5000 VF1000/3000/5000 S0700

4 0.15 0.4 0.1 0.4 0.1 0.4 1.55 0.55 0.35 0.4 0.4 0.1 0.4 1.55 0.55 0.35 0.1 0.35 Product Power W 2 Standard 0.55 0.55 1 2 1 0.

13 3/4/5 Port Solenoid Valve Low Power Consumption W Series SY Series VQ Series VF Series S0700 Reduction of the power when energized Power is reduced by power saving circuit. Power is decreased by approx. 1/3 by reducing the wattage required to hold the valve in an energized state. (Effective energizing time is over 62 ms 1 at 24 VDC.) Refer to electrical power waveform as shown below. Electrical power waveform with power saving circuit Applied voltage 24 V 0 V 0.4 W W 1 0 W 62 ms 1 Standard Energy saving With power saving circuit Low Power Consumption Valve Product Type 4/5 port 3 port 2 With DC light Model SJ2000 SJ3000 SY3000/5000/7000/9000 SYJ3000/5000/7000 VQZ1000/3000/5000 VF1000/3000/5000 S0700 VQ/VQC1000/2000 SYJ300/500/700 VQZ100/200/300 VP300/500/700 V100 S070 Power W 2 With power Standard saving circuit Product Power W 2 Standard Series SY/SYJ Model SY: 0.1 W (With power-saving circuit) When the energizing time is 5 hours/day, 250 days/year Reduced power Model SY: 0.55 W When the energizing time is 5 hours/day, 250 days/year 0.13 kwh/year ( 2/year) 81% 0.69 kwh/year ( 10/year) ( 8/year reduction) Corresponding value: Electricity unit 15/kWh 11

Energy Saving Type 2 Port Solenoid Valve Low Power Consumption W Direct Operated Pilot Operated Zero Differential Pressure Type Pilot Operated

1/3 during holding compared with a conventional (New Series VX).

of conventional s. Replaceable coil Possible to change the solenoid coil assembly for the VX2, VXD and VXZ with the energy saving coil type.

0 W Reduced power Replacement for conventional s (24 DCV

14 Energy Saving Type 2 Port Solenoid Valve Low Power Consumption W Direct Operated Pilot Operated Zero Differential Pressure Type Pilot Operated Series VXE21/22/23 Series VXED21/22/23 Series VXEZ22/23 Built-in energy saving circuit. Electrical reduced by approx. 1/3 during holding compared with a conventional (New Series VX). Built-in energy saving circuit Coil heat reduction Interchangeable The mounting dimensions and its basic specifications are equivalent to those of conventional s. Replaceable coil Possible to change the solenoid coil assembly for the VX2, VXD and VXZ with the energy saving coil type. (Restricted for the rated voltage 12, 24 VDC) Model VXE21: 1.5 W VXE22: 2.3 W VXE23: 3.0 W Reduced power Replacement for conventional s (24 DCV, N.C. valve only) No energy saving effect when the energizing time is 200 ms or less per operation Model New VX21: 4.5 W New VX22: 7.0 W New VX23: 10.5 W Series VXE23 Energizing time: 5 hours/ day, 250 days/year 3.8 kwh/year ( 57/year) 70% Series VX23 Energizing time: 5 hours/ day, 250 days/year 13.1 kwh/year ( 197/year) ( 140/year reduction) Corresponding value: Electricity unit 15/kWh 12

58 W (With light) SGC (Without light) Energizing time: 5 hours/day, 250 days/year 0.4 kwh/year ( 6/year) 68 to 88% Reduced power Model VNC1: 1.

15 Series SGC Coolant Valve Low Power Consumption Reduction of the power when energized Flow rate: Av factor (In case of 0.5 MPa specification) SGC2: 155 SGC3: 284 SGC4: 440 Service life: 5 million cycles or more (Based on SMC s test condition) W Model SGC: 0.35 W (Without light) (24 VDC)0.58 W (With light) SGC (Without light) Energizing time: 5 hours/day, 250 days/year 0.4 kwh/year ( 6/year) 68 to 88% Reduced power Model VNC1: 1.8 W (Without light) (24 VDC) 2 W (With light) VNC2 to 9: 4.8 W (Without light) (24 VDC) 5 W (With light) VNC2 to 9 (Without light) Energizing time: 5 hours/day, 250 days/year 6 kwh/year ( 90/year) ( 84/year reduction) Corresponding value: Electricity unit 15/kWh Series IDF E Refrigerated Air Dryer Reduction of the power consumpsion using a high-performance heat exchanger Low Power Consumption Improved air flow capacity (by an average of 17% as measured in 12 s) W Model IDF15E: 620 W Air flow capacity: 3100 l/min Operating time: 24 hours/day, 250 days/year 3,720 kwh/year ( 55,800/year) 6% Reduced power Model IDF15C: 662W Air flow capacity: 2400 l/min Operating time: 24 hours/day, 250 days/year 3,972 kwh/year ( 59,580/year) ( 3,780/year reduction) Corresponding value: Electricity unit 15/kWh 13

OUT PRESSURE kpa Double Inverter Type Refrigerated Thermo-chiller Low Power Consumption W Series HRZ Reduction of the power by using a DC inverter refrigerator and inverter pump. Model HRZ010-WS: 1.

16 OUT PRESSURE kpa Double Inverter Type Refrigerated Thermo-chiller Low Power Consumption W Series HRZ Reduction of the power by using a DC inverter refrigerator and inverter pump. Model HRZ010-WS: 1.1 kwh/h Reduced power Model 6.2 kwh/h Operating conditions: 10 C 0 kw with 50% load 2 kw with 50% load Operating time: 24 hours/day, 250 days/year 6,600 kwh/year ( 99,000/year) 82% Operating conditions: 10 C 0 kw with 50% load 2 kw with 50% load Operating time: 24 hours/day, 250 days/year 37,200 kwh/year ( 558,000/year) ( 459,000/year reduction) Corresponding value: Electricity unit 15/kWh Digital Switches Improve control and visibility of pressure and flow rate. Pressure, flow control of the main line and equipment line. Measuring instruments are used effectively. Flow rate is numerically controlled, and targets and effects are clearly shown. Digital Flow Switches Digital Flow Switch for Air Series PF2A Digital Pressure Switches 2-Color Display High-Precision Digital Pressure Switch Air Line Maintenance SET Series ISE30A Digital Flow Switch for Water Series PF2W Compact Digital Pressure Switch Series ISE10 2-Color Display Digital Flow Switch Series PFM 2-Color Display Digital Pressure Switch Series ISE80 Akihabara UDX 15F, , Sotokanda, Chiyoda-ku, Tokyo , JAPAN Phone: Fax: URL SMC Corporation All Rights Reserved Specifications are subject to change without prior notice and any obligation on the part of the manufacturer. D-DN 1st printing OR printing OR 12200SZ Printed in Japan. This catalog is printed on recycled paper with concern for the global environment.

Pilot Check Valve: Metal Body Type

INFORMATION Pilot Check Valve: Metal Body Type The use of a metal body improves strength and environmental resistance. Temporary intermediate stops are possible. *1 *1 Precise intermediate stops are not