Continuously reassess network dynamics
8 time windowsThe self-learning calculation continuously adjusts the network volume, pressure development and required flow capacity to the real operation.
+49 7044 911 100Products · Features
Detect demand. Select the right combination. Maintain pressure.
Airleader evaluates consumption and network dynamics in several time windows. In this way, not only the next compressor is switched, but also the economically suitable available combination.
8-foldCalculation depth
±0,15 barMinimum possible pressure band
allcommon brands
Control algorithm · included with every Airleader
A station is more than the sum of its individual controls.
The self-learning control algorithm is standard in every Airleader model. It continuously builds a station model from pressure, pressure gradient, flow capacities, availability and network behaviour. Calculations across multiple time windows reveal short-term demand spikes as clearly as the stable base load.
Do not just start the next compressor
Airleader compares the available combinations, taking into account flow capacities, hysteresis, starts, runtimes, rankings and faults.
Cover requirements with as little idling as possible
Die passende Kombination läuft überwiegend unter Last. Der kleinste geeignete Kompressor übernimmt die verbleibende Anpassung im gemeinsamen Druckband.
Feature · VSD Pro
Operate VSD compressors in their optimal range.
A variable-speed screw compressor is not equally efficient across its entire speed range. Like a combustion engine, it has an optimum operating range. For a screw compressor, the curve is determined by the air end design, internal leakage, pressure ratio, and losses in the motor and frequency converter.
Schematic specific power curve.
Same nominal pressure, different speeds
Several VSD compressors initially regulate independently to the same pressure. This allows one machine to turn very high and another very low – both outside the favorable range.
Dynamically displace pressure specification
VSD Pro constantly monitors the operating points. The integrated actual pressure specification brakes a compressor that is too fast and accelerates it too slower without intervening in the internal controller or frequency converter.
Working together in the economic sphere
ca. 6,5 %The VSD compressors are run as synchronously as possible and close to the most favorable working area. For its published 200 kW example, Airleader cites an improvement in the specific mode of operation of around 6.5 percent.
Effizienzgewinn in Jahreskosten übersetzen
7.020 €/aAnlagenleistung (kW) × Betriebsstunden (h/a) × Lastanteil im optimierten Bereich × Effizienzgewinn (%) × Strompreis (€/kWh). Beispiel: 200 kW × 6.000 h × 50 % × 6,5 % × 0,18 €/kWh.
Manufacturer independent retrofittable
The prerequisite is the actual pressure integration on the compressor. The modular bus structure enables active speed intervention without rebuilding the internal machine control.
Feature · FIX-Speed whenever possible
FIX-Speed und VSD wirtschaftlich kombinieren.
Sobald ein Fixed Kompressor in den Regelbereich eines oder mehrerer drehzahlgeregelter Kompressoren passt, kann dieser Betriebspunkt mit FIX-Speed wirtschaftlicher sein. Da VSD-Kompressoren jedoch immer wirtschaftlicher werden, ist dieses Feature frei einzustellen.
Additional speed control losses
≈ 6 %For the same flow capacity, Airleader typically expects the VSD compressor to require around six percent more than a suitable speed-fixed machine. This is due to additional losses in the frequency converter, in the motor control and in the controlled drive train. The specific value remains dependent on the machine and operating point.
FIX-Speed im Regelbereich der VSD-Kombination
Die Funktion bewertet den Betriebspunkt aus drehzahlfestem und drehzahlgeregeltem Kompressor als Alternative zu zwei parallel regelnden VSD-Kompressoren. Die Priorisierung lässt sich frei an die tatsächliche Wirtschaftlichkeit der vorhandenen Maschinen anpassen.
Full load for fixed speed, fine control with VSD
The fixed-speed compressor supplies its efficient full-load share. A VSD compressor covers only the remaining, genuinely fluctuating demand.
Feature · Multiple pressure sensors
Take pressure into account where it is needed in production.
In widely branched or hydraulically unfavorable networks, the pressure at the station may be sufficient, while a pressure sink already arises at a remote consumer. Several control pressure sensors make these differences visible to Airleader systems.
Up to three locations in the control pressure
1 + 2 sensorsIn addition to the reference pressure sensor, two further system pressure sensors can be selected. Airleader thus forms a common control pressure and reacts earlier to local pressure drops.
Hiding defective sensors
If a sensor exceeds an adjustable deviation from the reference pressure, it is taken from the averaging. This prevents wrong decisions by blocked or defective measuring points.
Less surcharge
0,1 bar ≈ 1 %A more sensitive network model can reduce unnecessarily high pressure reserves. As an Airleader guide value, a 0.1 bar reduction saves about one percent of energy.
Feature · Distributed compressors
Connect distributed stations over the existing network.
Compressors don’t have to be in the same room to run as a station. Airleader can classically integrate remote machines via RS-485 or optionally via the Ethernet network.
Bridging large distances directly
up to 1200 mAccording to Airleader, the bus technology is suitable for cable routes up to about 1,200 meters and connects connection modules from compressor to compressor.
Bus über Netzwerk praktisch unbegrenzt weiterführen
bis unendlichBei weit verteilten Gebäuden überbrücken COM-Server den RS-485-Bus über TCP/IP. Innerhalb einer geeigneten, stabilen Netzwerkinfrastruktur ist die räumliche Entfernung damit nicht durch die Busleitung begrenzt.
An algorithm despite distributed locations
Pressure, availability and flow capacities of the decentralized compressors are included in the same combination determination.
Feature · Priorities and profiles
Betriebliche Prioritäten abbilden.
Not always the most energy-efficient machine should run first. Heat recovery, reserve concepts, layers or different pressure requirements require specific priorities.
Prefer heat recovery, protect reserve
Compressors with usable heat recovery can be prioritized higher, pure reserve machines lower. Airleader continues to select machines of the same rank depending on consumption.
Change pressure and ranking depending on time
Up to four pressure profiles and four rankings can be activated via the weekly timer or external signals suitable for shift, production or special operation.
Balancing runtimes of comparable machines
At the same output, Airleader replaces compressors within the pressure band as soon as the defined run time offset is reached.
Feature · Auxiliary equipment and sensors
Not only monitor compressors.
The efficiency and operational safety of the station also depend on drying, filtration, condensate discharge, cooling and compressed air quality. Airleader combines their signals in the same system.
continuously record quality and condition
Pressure, dew point, temperature, volume flow, differential pressure, power and vibration can be recorded and evaluated together depending on the expansion.
Reporting limit values and failures early
Digital operating messages and analog limit values show conspicuous dryers, filters, condensate drains, pumps or vents before a supply problem arises.
Determine operational values
Because compressor states and sensor signals are on the same time axis, pressure loss, quality deviation and energy input can be traced together.
Feature · Alarm and service management
Detect faults. Plan servicing.
Compressor and auxiliary equipment faults appear as on-screen warnings and in the monthly alarm and service report, revealing recurring issues early.
Monthly alarm and service report from Airleader web visualisation.
Separate collective fault signals
Depending on the controller, separate contacts for compressors and accessories provide two alarm channels to building management or telephone systems.
Email, fax or SMS
Optional alarm and service management sends notifications from web visualisation, including service alerts and exceeded sensor limits.
Features for existing Airleader systems
More features for your existing Airleader.
Ihnen fehlt ein Feature? Je nach Gerät schalten wir es per Software frei oder bringen Ihren Airleader mit einem gezielten Hardwareupgrade auf den aktuellen Stand. Sprechen Sie mit uns über den passenden Weg.