Master controller
The AirLeader controller allows you to control compressors produced by different manufacturers, of different sizes, in different locations of compressor rooms supplying the same network, with constant speed screw compressors and several variable speed compressors at the same time!
The first AirLeader compressor controller was developed more than 30 years ago in Germany by Werner Weidner, the founder of WF Steuerungstechnik GmbH. The company's main objective is to continuously improve the energy efficiency of compressed air production systems by controlling their self-learning intelligent master control system. Today, the AirLeader family of products includes continuously improved compressor master controllers, monitoring and visualization systems and audit analysers to determine the performance of the compressed air production system. The unquestionable success in Europe - more than 7000 installed AirLeader master controllers - contributed to the expansion of the business in 2008 to the American market, where AirLeader products are very popular. Our company can boast that it is a distributor of a worldwide recognized German master control system for compressors in Poland.
"Don't ask which plant in Germany has an AirLeader controller - ask which one doesn't."
Werner Weidner
WHY THIS IS IMPORTANT
Usually, a group of cooperating compressors is controlled by the mechanism of pressure cascade or constant pressure hysteresis. Such solutions often lead to unnecessary extension of compressor operation time at idling speed. In such cases, the compressors consume approx. 30% of the power without producing compressed air. This results in many engine starts and a higher cost of idle running. The Air Leader master controller demonstrates the ability to create combinations of available machines with a narrow pressure range to optimally meet the needs of compressed air consumers. The use of a master control system enables optimum values for the most important indicators to be achieved:
- Idling rate of less than 2%.
- Reducing the number of start-ups and load cycles and compensating for almost the same number of load cycles.
- A unit energy consumption of less than 0.11 kW/m3 despite the average of more than 400 compressors measured at 0.123 kWh/m3.
- The unit air cost index often even significantly below 0.04 PLN/m3.
BENEFITS
The master controller allows to reduce the number of start-up cycles and compressor loads, which has a positive impact on the reduction of their mechanical wear and tear as well as the frequency and cost of maintenance and service.
How to estimate the profitability of a master controller installation?
To check whether the AirLeader master controller used in compressor plants can optimize your system for you, it is worth starting to record the total hours of operation of machines and hours of operation under load from compressor displays at specific intervals, and then using the form provided by us via e-mail. This allows you to calculate the current compressed air production efficiency index and the energy consumed at idling speed. By obtaining this data, we can determine the profitability of installing a master controller for AirLeader compressors and predict the estimated time of the return on this investment.
How does the AirLeader driver work?
The 8-step, self-learning trend analyser ensures that air production is dynamically adjusted to meet air demand. The compressors are connected serially with the controller via connection modules mounted in the machines. The compressor sends signals concerning the compressor operation to the module. Therefore, there is no need to worry about the loss of warranty. This is confirmed by thousands of AirLeader system applications in leading compressor brands around the world and in Poland. Once the pressure transmitter is connected to the network, the controller is ready for operation. AirLeader controller allows you to control compressors of different brands, different sizes, constant-rotary and even 3 variable-rotary at the same time in different locations of compressor stations supplying the same network!
UNIQUE FEATURES
Controller characteristics
- Management of 1 to 16 displacement compressors of different capacities and brands.
- Up to 16 additional analog sensors (flow meter, pressure transmitter, dew point, etc.) and 24 digital inputs can be connected, e.g. for signalling external equipment failure.
- Key switches allowing only authorized personnel to intervene.
- Up to 4 different pressure profiles selected by the timer or digital inputs (e.g. possible pressure reduction e.g. for weekends).
- Up to 4 different operation sequences (priority setting of compressors, e.g. keeping the compressor in reserve or setting it as the basic compressor).
- Communication with the user via Ethernet, the information can be transferred to an existing visualization system.
- Control clock for sequencing the order, pressure profiles and 2 digital outputs for controlling relays (external devices can also be controlled).
- Visualization software on CD.
- Internal memory of 1 GB allowing for more than two years of recording of measurements.
- Backlit display 240x128 pixels.
- Programming via numeric keypad
- Power supply 90-250 V AC.
- Symbolic compressor status display (pumping, idling, fault, availability, readiness) and display of compressed air consumption, pressure, dew point and room temperature sensor, if such sensors are connected.
IMPLEMENTATION
- The decision to install the controller should be preceded by measurements of the operation of existing compressors with the AirLeader MK analyser. The MK analyser software has the same built-in algorithm as the AirLeader controller. The measurements allow to simulate the operation of the tested system with the AirLeader controller, as well as to obtain information on how the system would work at a different air intake, with different compressors, with a different tank, at a lower pressure, and to estimate the time of return on investment and the selection of appropriate configuration of machines.
- Compressors do not have to be located in one room, our company is able to perform control of compressors located in several different rooms.
- Our company, in addition to the delivery of the controller and its start-up, can take care of the installation of signal lines between the compressors and the controller.
- Check if the controller can save something for you - contact a specialist today!