When a compressed air system has more than one compressor or dryer, it is hard to decide when and which machine should run. This is especially true in applications with large, frequent fluctuations in compressed air demand. If the system is not properly controlled, the risk is producing air across a wide pressure band – which means spending more money.
The solution for such situations is a central controller. Here are 6 reasons why every compressor station with several compressors benefits from one:
011. A narrower working pressure band
With a central controller installed, compressors can operate within a narrower, predefined pressure band. This ensures the system fully meets air demand while optimising energy efficiency.
022. Fast response to breakdowns and planned maintenance
If one compressor suddenly breaks down, there is no stoppage: the other compressors connected to the central controller are set to take over automatically, so production downtime is avoided. The controller also lets operators plan regular maintenance in a way that avoids the costs that would otherwise arise while a compressor is out of service.
033. Flexible machine sequencing from a single monitor
Controllers let machines work in groups and adjust to demand. In a fixed system, machines have to run in a set order. In a flexible system with a central controller, the best combination of machines is used for each level of demand, and the operator can follow the status of every compressor on one central monitor.
044. Balanced operating hours
By simply setting the controller parameters, the operator can schedule the running time of individual compressors so they are used equally, without two or three compressors installed in the same year ending up with very different operating hours. This is particularly useful for regular maintenance.
055. Fewer service visits
A central controller makes it possible to prioritise older and newer machines so that preventive maintenance is synchronised and the number of service interventions reduced. Planned compressor shutdowns should be a mandatory part of every predictable maintenance plan.
066. Continuous operation of variable-speed compressors for higher efficiency
With a central controller, variable-speed compressors can be given priority over fixed-speed ones. Variable-speed compressors work more efficiently, taking each compressor’s flow into account and reducing total electricity consumption.
