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Programmable sequencer for up to 4 air compressors
Pro-Master 4
A system solution offering
optimised pressure control,
reduced energy consumption,
lowered carbon footprint and
decreased costs.
Pro-Master 4. Balances output and saves power
The Hydrovane Pro-Master 4 sequencer uses narrow band pressure
control with flexible functionality for the central management and control
of air compressors in multiple compressor installations.
In most compressed air systems the demand for air will fluctuate and the air main pressure will
consequently decay or rise in response to the changes in demand. To cope with the unpredictability
of changes in demand it is usual to operate all of the compressors all of the time. While this ensures
an adequate flow rate of air for all demand profiles in most cases the air flow rate will be excessive.
Hence it is an inefficient method of control that results in unnecessarily increased energy consumption,
higher running costs and larger carbon footprint.
A decrease of 0.5 bar in the
operating pressure of an air
main will typically produce
around a 5% reduction in the
overall cost of electricity
consumed by the compressors.
In single compressor installations compressors are available with their own individual controllers that
provide an individual capability to switch on or off based on air main pressure. In a multiple compressor
installation individual compressors cannot have their controllers directly linked together to provide any
collective control. To control multiple compressors a discrete piece of ancillary equipment called a
sequencer is required.
The Hydrovane Pro-Master 4 sequencer is specifically designed for use with the Hydrovane Pro and
Pro RS controller using ModBus and the Hydrovane S1 controller using AirBus. It will also seamlessly
connect to any other Gardner Denver or CompAir compressor using Modbus.
Password
protected user
interface
Average systems
pay for themselves
within 12 months
Real time clock
allows automated time
scheduled tasking
Quick and easy
installation with pre-loaded
software for instant
savings
Controls
up to 4
compressors
Uses high
accuracy pressure
sensing
The Hydrovane Pro-Master 4
comes complete with pressure
sensor providing a digital output.
User benefits:
•
•
•
•
•
•
Optimised pressure control
Reduced energy consumption
Lowered carbon footprint
Decreased costs
Increased compressor life
Hydrovane’s guarantee of
worldwide technical support,
knowledge and service.
Optional Extra:
For connectivity with other brands of
positive displacement compressors
an input/output device called an
iPCB is available.
Universal application:
for use with most
positive displacement
compressors
Note that with Pro RS controllers the sequencer only
connects with the compressor and provides it with a
load signal: the sequencer does not control it.
Typical Application
Up to 4 air compressors can be sequenced
Hydrovane Pro-Master compressor sequencers automatically respond to changes in demand by optimising
the operation of each compressor in a multi compressor installation. The optimisation is achieved by controlling
the air main pressure within a narrow band and then managing the operation of each of the available compressors
in a pre defined sequence. This control strategy provides a total system solution offering an automatic and fast
response to changes in demand, reduced energy consumption, lowered carbon footprint and decreased costs.
They provide a low cost solution with a short return on investment (ROI).
Auxiliary Digital Input
Auxiliary Relay Output
Network
Pressure Sensor
iPCB (Max 100 metres)
RS485 2 (Max 1600 metres)
RS485 2 (Max 1600 metres)
RS485 1 (Max 1600 metres)
iPCB
By understanding the capability and operational requirements of a particular installation the selection of the most suitable sequence
combined with adjustment of the parameters will then achieve the highest level of efficiency.
Hydrovane Pro-Master 4 compressor sequencers have two different modes of control to suit the specific
characteristics of any installation:
Timer Rotation:
Fixed Cascade:
Used where all the compressors are sequenced based on a defined or pre-selected running order.
Used where the compressors are of all different capacity by sequencing all in an optimised manner
avoiding inefficient idle running by selecting the correct size of compressor for the demand based
on a reduction of pressure in the air main.
Within the Timer Rotation mode of control one of the following sequences may be selected:
Equal Hours:
Used where all compressors are the same size and there is preference to service all the
compressors at the same time by equalising the hours run.
First In First Out (FIFO): Used where the compressors are different sizes, typically for air systems where there is widely
fluctuating demand, and a particular compressor is prioritised.
Timer Rotation:
Used where the compressors are different sizes, typically for air systems where there is widely
fluctuating demand, and different compressors can be prioritised for different demand profiles.
To users
on the plant
Hydrovane Pro-Master compressor sequencers also have a number of adjustable parameters offering further flexibility
to modify the control mode to suit the installation as follows:
Pre-Fill:
Sequence Rotation:
Priority Settings:
Pressure Schedule:
This feature is used to select which compressor(s) will be used for start-up to eliminate the high power
demand and inefficient operation associated with conventional sequence control systems where all the
compressors are run at start up irrespective of the system fill time and initial demand.
This feature allows a change in sequence to occur at a pre-defined time when air demand may be
different e.g. at break times.
This feature allows the system to react to changes in pressure target levels in a smooth and
energy efficient manner without abrupt overreaction.
This feature provides settings that instruct the system to change from one target system
pressure to another or to put the system on standby at a pre-determined time.
Hydrovane Pro-Master compressor sequencers also have the capability to accept an auxiliary input
and provide an auxiliary output.
Auxiliary Digital Input:
Provides capability for auxiliary equipment to override the sequencer function
e.g. remote start/stop, remote trip, etc.
Auxiliary Relay Output: Used to control auxiliary equipment eg starting refrigerant dryers so that they can fully initialise
before the compressors start.
Auxiliary digital input – Function list
Auxiliary relay output – Function list
Override – standby
Remote start / stop
Remote alarm (always active)
Remote alarm (active only when Pro-Master 4 is running)
Remote trip (always active)
Remote trip (active only when Pro-Master 4 is running)
Any fault (alarm, trip, unavailable condition)
Any trip (trip, unavailable condition)
Compressor alarm (alarm)
Compressor trip (trip, unavailable)
System fault
System on
System active
System pressure control active
Low pressure alarm
High pressure alarm
Pressure control override
24mm
Outline Technical Information
Supply / Power:
Enclosure rating:
Approvals:
Dimensions:
Weight:
Mounting:
238mm
24mm
230Vac +/- 10%, 115Vac +/- 10%, 50VA
IP54 / NEMA12
CE, UL, cUL
Height: 236mm (9.45”) x Width: 286mm (11.45”) x Depth: 152mm (6”)
6.4kg (14lb)
Wall, 4 x screw fixing
188mm
236mm
8mm ø
286mm
Please contact your local authorised Hydrovane distributor to
discuss your needs and how we can reduce your energy costs with
a compressed air system energy audit.
Gardner Denver Ltd
Claybrook Drive, Washford Industrial Estate,
Redditch, Worcestershire B98 0DS, United Kingdom
T. +44 (0)1527 525522 / 838200
F. +44 (0)1527 521140
E. [email protected]
www.hydrovaneproducts.com
© Gardner Denver Ltd
Hydrovane is part of the Gardner Denver Group.
Gardner Denver policy is one of continuous improvement
and we therefore reserve the right to alter specifications
without prior notice. All products are sold subject to the
Company’s conditions of sale.
G609GB – 09/2011