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As production manager the single biggest requirement for any piece of equipment is productivity. In short, will this help me and my people get the job done better, quicker or more efficiently? Several smaller themes such as performance specifications, reliability, payback periods, service and support, dimensions and simplicity of operation become important factors. |
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Performance
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The IQ has been thoroughly designed and built to meet the variable demands of a dynamic work environment. Every business is unique, as is their operations and subsequent air demands. Even within plants, demand for air can fluctuate over hours, days, weeks and months. With this in mind, Gardner Denver designed multiple package sizes that cover an extensive air (or vacuum) map. Packages can be combined in any way to meet your specific requirements. Individual package sizes range from 7.5hp to 100hp, individual package air flow can go up to 1400 ICFM (vacuum applications go up to 15 Hg”).
All Gardner Denver IQ packages are fitted with an Air Smart controller that amongst another things, allow machines to be turned on and off as air requirements peak and trough throughout the day. In addition to this, the controller can rotate the designated lead machine, equalizing the overall workload and subsequently improving both performance and reliability.
In addition to sequencing machines, the Air Smart controller can also operate our variable speed drives, turning each blower up or down to precisely match air requirements. Even when not feeding air into your system, fixed speed blowers can continue to consume up to 90% of the energy used when running at full capacity. All of this means increased utilities for no real production gains. Variable speed drives combined with Air Smart controllers ensure that air is only ever being produced at the levels you require thus increasing productivity while reducing costs. From a capital investment standpoint, these efficiency gains can mean paybacks in one year or less depending on use.
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Installation and Turn Key Capability
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The singular aim for Gardner Denver with regard to installation is simplicity and a belief that anyone that uses the IQ package should be able to install and operate the unit with minimum fuss. In response to this aim, we feel that we produced genuine plug and play system that saves our customers from any additional hidden complications and or costs.
| Feature |
Problem Solved |
| Fully programmed VFD |
The VFD comes pre-programmed eliminating the need to program on site at the time of installation. |
| VFD integrated inside IQ frame |
Because the IQ VFD comes inside the existing enclosure, there is no extra space required to wall mount any drives and no need for external wiring between the package and the drive. |
| Integrated wiring |
The VFD, controller and motor are pre-wired and set eliminating the need to wire between systems. |
| Vibration Isolators |
The IQ comes with vibration isolators negating the need for any special housing pads or bolting to the floor. The IQ simply requires a flat surface that will bear its weight. |
| Structural rigidity |
The strengthened base and frame reduce the risk of damage with placing the blower package in a facility. |
Pre- wired, pre-engineered, pre-programmed features mean much faster cheaper and simpler installation without needing extra space, wiring or additional manpower to complete the installation.
The IQ is pre-programmed upfront. Should anything arise, you don’t need to deal with multiple vendors; your Gardner Denver distributor should be able to take care of it all.
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Energy Efficiency and ROI
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Total cost of ownership includes everything from initial investment, installation, maintenance and utility costs. The initial package cost forms a small part of the cost of ownership equation. Over a five year period, up to 78% of the total cost of ownership of a rotary lobe blower package will be energy costs.
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Operational efficiency is key to overall productivity and raises questions such as: How does my equipment perform in terms of utility consumption and how much more important will utility consumption become in future periods?
Sizing equipment to efficiently meet demand is therefore crucial, a fixed speed blower running idle (blowing off to atmosphere) typically consumes up to 90% of the energy required to run at full load. Paying for more machine than you need to meet worst case air demands could mean significant periods of energy waste when demand is not at peak.
Similarly under sizing a blower package that runs outside its optimal operating parameters increases energy utilization. Variable speed technology is therefore critical in allowing a blower to be turned up during peak demand times and turned down during off peak times. Gardner Denver rotary lobe packages have been designed extensively with energy efficiency in mind. Our goal is to deliver maximum operational efficiency, reducing costs and improving the carbon footprint of your business.
The IQ Blower package can incorporate many energy saving features including:
- TEFC EPAct Premium Efficiency Motor
- Integrated Variable Frequency Drives (inside the package) that turn individual blowers up and down in conjunction with demand
- Gardner Denver Air Smart control systems for optimal control and efficiency
- Remote monitoring capabilities
- Package sequencing capabilities that allow blowers to be turn on and off in sequence as dictated by overall facility demand avoiding the need to oversize systems for ‘worst case’ high demand scenarios Gardner Denver is an Energy Star Partner and is committed to developing products and introducing technologies that help conserve energy and protect the environment.
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Air Smart Controller and Cost Avoidance
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The goal of any business is to be as productive as possible. While energy optimization is key, reliability is also a must. When considering the fact that many of today’s operational costs such as facilities, utilities and personnel are fixed, any time production is down or even constrained, costs to business can be significant. Costs avoidance and the ability to minimize or even eliminate unplanned stoppages helps to manage one of the most costly risks to a business. All Gardner Denver blower packages are fitted with an Air Smart control system with these very issues in mind.
Air Smart Controller Capabilities include:
- Measurement of inlet and outlet air pressure
- Measurement of inlet and outlet air temperatures
- Measurement of blower oil temperatures
- Measurement of blower oil levels
- Ongoing performance monitoring and reports show how the package is operating even when inside normal parameters
- Pre set operating parameters can be programmed with warning levels. If a warning level is reached, an advisory is sent before a unit reaches critical thresholds and shuts down thus maintaining run time
- In-built shut down protection should the blower reach pre programmed shut down thresholds
- In the event of a shut down of any kind a diagnostic report is prepared to show exactly how the package was operating prior to shutdown. This speeds up trouble shooting, diagnosis and maintenance and reduces downtime
- Pre programmable scheduled maintenance counters for filter changes, oil changes etc. allow you to proactively maintain your asset and be sure that your package(s) are running as efficiently and effectively as possible
- Ability to pre program run times and sequence packages for efficient operation that matches facility demand and spread the work between units for reliability.
- Ability to send information out and monitor the blower (or blowers) remotely
- Ability to control the and change the speed of variable drives to match demand
All of this data is held in one easy to read control panel that can be clicked through and reviewed very quickly and easily. The Air Smart controller helps to manage your assets in a meaningful manner. Should anything happen to the blower, pre-cursory advisories should allow an opportunity to head any problems off before they occur. If there is a shutdown, the diagnostic history should point the service engineer to the trouble spot quickly to allow and service work to be conducted and the blower to come back online.
In short, the Air Smart controller moves blower management from a reactive state into proactive management. This in turn, helps to support ongoing cost avoidance. Furthermore, ongoing self monitoring reduces the time (and manpower) required to monitor each blower package and allows personnel to engage in other activities.
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Smart Made Simple: Easy Access Maintenance and Monitoring
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The goal of the maintenance group is to ensure that equipment runs as efficiently as possible for as long as possible. At different stages this will involve routine checks, minor maintenance (changing air filters etc) and scheduled maintenance or larger service work. One of the goals with the IQ blower package was to carefully design a package that would to allow easy monitoring in conjunction with fast and easy access to all of its internal components. The end result is a package that is as service friendly as possible. Some of the key features for fast easy access include:
- Auto self tensioning belt to optimize belt load, reduce belt wear, regulate overhung loads and minimize bearing wear.
- Multiple internal monitoring sensors regulating internal heat, pressures, oil levels and run times allows the service person to easily monitor what is happening at all times.
- Data can be sent through the web to your computer allowing you to monitor performance remotely without having to constantly visit the package.
- Vibration isolators, no need for special construction pads. The installation surface needs only to be level and to bear the weight of the package.
- All performance data being recorded in the controller providing one easy access point for monitoring and negating the need to crawl in and around the package to monitor it.
- Setting advisory thresholds and receiving notices ahead of problems occurring allows for proactive intervention rather than shutdown.
- All the enclosure panels are easily removable with quarter turn fasteners making all components accessible very quickly and easily.
- The IQ package has a hinged lid (like a car bonnet) allowing instant visibility to all the internal components.
- Easy access oil fill reservoirs and oil drain system
- All minor components (filters, thermometers, sensors) are all easily access and can be replaced in a few minutes.
- Inspecting the IQ does not require a lot of tools. A quarter turn fastener key and a screw driver is enough to inspect the whole machine.
- If required, all of the whole blower, motor and components can be removed from the enclosure in one piece to allow total access for major service making access quicker and reducing downtime.
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Manufacturing and Quality Assurance
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Over the last 150 years Gardner Denver has developed an unparalleled reputation in industrial manufacturing. This hard won reputation has been achieved through an ongoing commitment to excellence and continuous improvement over this period. The attention to engineering design is matched by a commitment to quality in manufacturing in assembly. Gardner Denver blowers are proudly manufactured in our ISO 9001: 2008 certified Sedalia, MO facility. The professionals based there have a collective goal to simply make the highest quality product available.
They have built blowers for decades that have developed an exceptional reputation for reliability and performance. This comes down to four factors, extensive training and development, continuous process improvement, industry leading equipment and rigorous quality testing.
Material entering the facility is subjected to a first pass quality inspection. Once the material is approved, it is milled on finest manufacturing equipment available using digital measurement and testing to ensure precision and exact tolerances. The blowers are then assembled and tested again before being passed for use in a package.
The package is assembled and then further tested again for performance standards. Only after every performance specification has been met will a package be approved for shipment.
When purchasing a Gardner Denver blower package, you are not simply getting industrial equipment. You are getting over 150 years of commitment to design, manufacturing, quality, service and delivery that sets Gardner Denver apart as a world class business partner. |
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Downloads
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Download the IQ Brochure to see what IQ can do for you! |