No communication between Airleader control and compressors.

Check the wiring. Check the bus addresses on communication modules. If the communication is bridged over the Ethernet network (FL-COM Server) check and increase the response time (Code 111111).

Can we have more than 2 FU Compressors on one Airleader control?

The Airleader Mastermodul / CN can handle up to 4 FU compressors with additional software. Contact our technician for more information and costs.

How can I compensate for pressure differences?

With Airleader Mastermodul / CN it is possible to handle up to 3 pressure sensors, mounted on different places inside the system, to get an average of all sensors as pressure value to control the Airleader. For every pressure sensor, a divergence value can be set. If the pressure exceeded the divergence value, this sensor will not be included in the calculation.

Actual pressure on system and FU differ. Can i get the system pressure for the FU compressor?

With Airleader Mastermodul / CN it is possible to send the system pressure to the FU compressors. The system pressure can get from the AO connector of the communication module as 4-20mA signal. Offsets can be programmed in the controller.

New compressor installed but not visible in OPC Server.

With such changes, it is necessary to restart the OPC server, because the OPC Server reads it’s configuration only on startup. Please disconnect all client connections before restarting the OPC Server.

Webbrowser shows other website after installation of WebServer.

The cause for this issue is the security setting of Windows 7, which does not allow script-based installation of windows services. For the installation, it is necessary to turn off the UAC (user account control). In some cases, you have to reboot your machine. After turning off the UAC, the installation process should run correctly.

Panel shows up communiation error

This issue can have many causes. First, you should check the availability of the control in the network through a PING. This can be done in the “Diagnostics” area. If the PING is successful, it should be checked whether the IP address of the controller may have been assigned more than once. If this is not the case, the issue can be triggered by the internal memory card of the controller. For that, the SD card should be initialized. The procedure for initializing is described in the operating manual.

Airleader doesn’t store the values sending from WebServer?

Key switch “Prog” must be set to “Off”. Have you entered the correct WebServer Plus code?

Why is the web server accessible only on the server machine?

Maybe the incoming requests are blocked by the servers firewall. Make sure that the firewall is passing incoming traffic on port 80.

Old software version after updating

Before installing a new software version, you have to deinstall the previous version. Take care that you remember the controllers ip-adress and the data path. As from Version 3.000 or higher, there is an online updater included, which can be used to update the system on the fly. For the online update, an internet connection must be available.

Common Challenges and Solutions in Compressed Air Distribution System Design

Designing an efficient and reliable compressed air distribution system is crucial for ensuring optimal performance and productivity in industrial operations. However, this process comes with its own set of challenges that require careful consideration and strategic solutions. In this blog post, we’ll explore some of the common challenges encountered in compressed air distribution system design and provide actionable solutions to address them.

Challenge 1: Pressure Drop

Pressure drop is one of the most prevalent challenges in compressed air distribution systems. As air travels through the piping network, friction and obstructions can cause a decrease in pressure, resulting in reduced efficiency and performance at the point of use.

Solution: To mitigate pressure drop, it’s essential to design the system with proper pipe sizing, layout optimization, and the use of smooth, corrosion-resistant piping materials. Additionally, installing strategically placed pressure regulators and ensuring regular maintenance can help maintain consistent pressure levels throughout the system.

Challenge 2: Air Leaks

Air leaks are a common source of inefficiency in compressed air systems designs, leading to wasted energy and increased operating costs. Leaks can occur at connections, joints, valves, and fittings, often going unnoticed but contributing significantly to air loss.

Solution: Conducting regular leak detection audits and implementing a proactive maintenance program are essential steps in addressing air leaks. Utilize ultrasonic leak detection technology to identify and repair leaks promptly. Additionally, investing in quality fittings and components and ensuring proper installation can help minimize the occurrence of leaks.

Challenge 3: Moisture and Contaminants

Moisture and contaminants present in compressed air can cause corrosion, damage to equipment, and compromise product quality in sensitive applications. Proper filtration and moisture removal are essential for maintaining air quality and preventing system issues.

Solution: Integrate effective filtration and moisture removal equipment into the compressed air distribution system. This includes installing high-quality filters, separators, and dryers at strategic points in the system to remove moisture, oil, and particulate matter. Regular maintenance of these components is also crucial to ensure their continued effectiveness.

Challenge 4: Uneven Air Distribution

Uneven air distribution can result in some areas receiving insufficient airflow while others experience excessive pressure, leading to inefficiencies and compromised performance in certain processes or equipment.

Solution: Design the distribution system with careful consideration of airflow requirements and balance the system using appropriate pipe sizing, layout optimization, and the installation of flow control valves or regulators where necessary. Conduct regular airflow measurements and adjustments to ensure uniform distribution throughout the system.

Challenge 5: Space Constraints

In some industrial settings, space constraints may limit the options for installing and configuring the compressed air distribution system, making it challenging to design an efficient layout.

Solution: Utilize space-saving design strategies such as vertical piping runs, compact components, and routing piping through existing infrastructure or overhead spaces. Consider customizing system components or utilizing modular piping solutions to maximize space utilization while maintaining system functionality.

Optimizing Compressed Air Systems with AirLeader’s Intelligent Monitoring Solutions

Unlock the power of your compressed air system with AirLeader. Our suite of products, including the intelligent Compressor Master Controller, captures vital system performance and air quality data. With AirLeader, you can enhance system reliability and efficiency while gaining valuable insights into your operations. Maximize uptime, optimize performance, and stay ahead of maintenance needs with AirLeader’s advanced monitoring and control solutions. Elevate your compressed air system to new heights with AirLeader.