Service unit combination MSE6-C2M

Intelligent use of energy

The energy efficiency module MSE6-C2M combines pressure regulator, on/off valve, sensors and fieldbus communication into a single unit. It monitors the compressed air consumption, shuts off the compressed air after production has stopped for a certain amount of time, and prevents the system pressure from falling below a specific stand-by pressure level.

Detecting stand-by states, automatic shut-off or stand-by pressure control
After entering machine-specific parameters, the module detects when a system is operating or idling. By shutting off the compressed air supply, air cannot be consumed unnecessarily and will not continue to be supplied to any leaks in the machine. Instead, the MSE6-C2M can maintain the output pressure at a previously defined stand-by pressure so that system availability is not impaired.

Control functions and process monitoring
The MSE6-C2M can be installed in new or existing systems, wherever the supply of compressed air is to be monitored and controlled.

Control functions:

• Adjustable regulated output pressure
• Automatic pressure reduction without exhausting the system during downtimes
• Detecting leaks by evaluating the pressure drop in stand-by mode
• Adjustable pressure increase (soft-start)
• Digital inputs and outputs
  
  

Process monitoring:

• Flow rate
• Air consumption
• Output pressure
• Pressure change

Return on investment after only 1 to 1.5 years

Let's assume that a machine is operational 250 days per year based on two shifts and has a compressed air consumption of 2,000 l/min at 6 bar and a leakage rate of 10%. If the compressed air is not shut off during the 4,000 hours of non-production time, 48,000 Nm³ is simply lost. This would be an expensive luxury that would cost you €912 and 3.2 tonnes of CO₂emissions. On the other hand, by simply reducing the pressure from 6 bar to 2.5 bar, you can save as much as €640 and 2.2 tonnes of CO₂emissions.
And since the energy efficiency modules incorporate additional functions such as those of the classic pressure regulators MS6-LR, on/off valves MS6-EE, pressure sensors SPAU and flow rate sensors SFAM , the amortisation period is further reduced. Especially if you consider the costs of regular manual leakage detection.
The bottom line is that a more conscious use of compressed air pays for itself in less than 1 to 1.5 years.

Sample calculation:

• Costs for compressed air: €0.019/Nm³
• Consumption of the machine: 2,000 l/min
• Production/day: 16 h
• Production/year: 250 d
• Leakage rate: 10%
• Working pressure: 6 bar
• Stand-by pressure: 2.5 bar

Leakage
10% at 2,000 l/min* = 2,000 l/min ( fi = 0.2 Nm³/min )

Production-free time:
(365 d · 24 h) - (250 · 16 h) = 4,760 h
4,760 h - 760 h** = 4,000 h (240,000 min)

Leakage during non-production time (at 6 bar)
0.2 Nm³/min - 240,000 min = 48,000 Nm³

Savings during non-production time
when reducing the pressure from 6 bar to 2.5 bar
48,000 Nm³ · 0.7 · €0.019/Nm³ = €639

1. * Depending on the type of leakage: based on a purely statistical worst-case scenario (hole in the tubing) = 70%
   * Assumption: 760 h repair/maintenance
   *** 1 kWh of electricity produces 0.5 kg CO2. These figures apply to Germany and may vary in other countries. Figures 2015: Source German Environment Agency