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

info@jorc.nlwww.jorc.eu

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

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Air

sav

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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

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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

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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

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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.