eHydroCOM - Electric Stepless Capacity Control System

eHydroCOM - Electric Stepless Capacity Control System

Solve stepless control tasks now in seconds

Many reciprocating compressors need to deliver less than their rated capacity for much or all of the time. Traditionally, this requires excess compressed gas to be returned to the suction side via a recycle valve. The energy used to compress this recycled gas is wasted. HOERBIGER’s eHydroCOM is the most compact and all-electric stepless volume control system available today for reciprocating compressors. The 100 % oilfree and fully standardized system is the ideal way to achieve stable capacity control of dynamic processes.

The eHydroCOM continuously adjusts the compressor’s delivery rate to match the amount required by the downstream process. Precise control of the suction valves eliminates the need for a bypass. This not only saves you energy and reduces CO2 emissions, but also improves your process controls at the same time.

eHydroCOM Sytem
One system – many possibilities

Conventional systems, such as step or bypass controls, do not work efficiently, are often slow and can only be adjusted with great effort and not accurate to the required delivery rate. The eHydroCOM system allows you a wide control range: Stepless from (0...)10* to 100 %. Due to the reverse flow control, the delivery rate is adjusted fully automatically and, above all, continuously. Thanks to the large control range and the possibility to operate your compressors more flexibly, you can cover requirements even with a smaller fleet, react extremely quickly and avoid overcapacities.

Test your energy savings here.

Failure prevention through real-time monitoring of the actuator

eHydroCOM offers a wide range of control: stepless turn down from 10–100% allows for rapid, automatic capacity adjustments. Thanks to the broad control range and the ability to run your compressors more flexibly, you can meet demand with a smaller fleet and avoid overcapacity.Digital networking allows you to monitor your actuator in real time and can thus detect failures at an early stage and avoid these in the best case. But not only that: Any problem that may arise can be can be solved with temporary access via remote maintenance. If spare parts are required, HOERBIGER always has semi-finished products ready for you – eliminating unnecessary storage costs for you.

Benefits at a glance

Saves energy and CO2 emission costs, while improving process control
Feature

Reverse flow control: The delivery rate of the compressor adjusts continuously to the requirements of the process

Advantage
Smaller fleet footprint, fast response to changes, and no overcapacity
Feature

Reverse flow control: Wide control range, and ability to assign new duties to individual compressors

Advantage
Better economics (ROI): Lower lifetime costs and sustainable production over a long service life
Feature

100% oil-free and all-electric operating principle

Advantage
Improved reliability, less shutdown of the compressor and less waste due to less spare parts (reduced OPEX)
Feature

Automatic wear compensation while compressor runs

Advantage
Reduced energy losses and minimal emissions, because you can quickly resume to normal operation
Feature

Standardized system: “One size fits all”

Advantage
Emergency orders are possible and there are less storage (areas) necessary/ less storage costs
Feature

Standardized system: “One size fits all”

Advantage
Failure avoidance through real-time monitoring of the actuator
Feature

Connectivity

Advantage
Minimizes energy use and cuts air pollution
Feature

Remote support

Advantage
eHydrocom
eHydroCOM
  • For medium force and medium speed​ applications​
  • Rugged and cost effective​
  • Low maintenance due to obsolete hydraulics​
  • Actuator​
  • Field Power Supply Unit (FPSU)​
  • Digital Compressor Interface (DCI)​
  • Bus & power cables​
  • Top Dead Center (TDC sensor)​
eHydrocom system layout
 eHydroCOM at a glance:
Technical data
Unloading force:
Medium, single stack actuator
Max. compressor speed:
800 rpm
Max. suction pressure:
70 bar a
Automatic clearance compensation:
yes
Automatic wear compensation while compressor runs:
yes
IP
Actuator: IP65
FPSU: IP65
EX-certificates:
ATEX Zone 1 IIC
Electrical connection:
Terminals
Height/ weight:
267 mm/ 20.5 kg (NACE 23.5 kg)
Power supply:
Actuator: 60 VDC
FPSU input: 3 x 400 VAC
HydroCOM replacement:
Partially (low pressure,
low
 speedlow force)
Separate enclosure required for FPSU/ ePU:
No
Maintenance intervals at 400 rpm:
32,000 operating hours
Gas 
sealsDepending on gas quality
Standardization:
Same actuator for all stagescompressors
eHydrocom X
eHydroCOM X
  • For high force, high speed and critical​ applications​
  • Most powerful and compact in size​
  • Efficiency made simple: Thanks to​ plug connectors and missing hydraulics​
  • Actuator​
  • Power Supply Unit (ePU)​
  • Compressor Interface Unit (eCIU)​
  • Bus & power cables​
  • Top Dead Center (TDC sensor)​
eHydrocom X system layout
 eHydroCOM X at a glance:
Technical data
Unloading force:
High, double stack actuator
Max. compressor speed:
1,200 rpm
Max. suction pressure:
160 bar a
Automatic clearance compensation:
yes
Automatic wear compensation while compressor runs:
yes
IP
Actuator: IP65
ePU: IP67
EX-certificates:
ATEX/ IECx Zone 1 IIC, CSA, TIS, KOSHA
Electrical connection:
Ex-connector
Height/ weight:
232 mm/ 20.0 kg (NACE 23.0 kg)
Power supply:
Actuator: 560 VDC
ePU input: 3 x 400 VAC
HydroCOM replacement:
All applications incl. Dia 17 mm high force
Separate enclosure required for FPSU/ ePU:
No
Maintenance intervals at 400 rpm:
32,000 operating hours
Gas 
sealsDepending on gas quality
Standardization:
Same actuator for all stagescompressors
eHydroCOM in the field
eHydroCOM

Brochure A4

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eHydroCOM

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Components for reciprocating compressors