Compressed air is the utility a plant notices only when the pressure falls and a line stops. A controller in the compressor room reports receiver pressure, motor load and discharge temperature, and the record shows what nobody sees on a walk-round: the compressor running all weekend to feed leaks.
Demand outgrows supply, or a compressor trips, and the first alarm is a machine stopping on the line.
A system that loads all weekend with the plant closed is feeding leaks, and nothing on a weekday shows it.
A blocked cooler or a hot room raises discharge temperature for days before the compressor shuts itself down.
| Signal | How it is read | What it tells you |
|---|---|---|
| Receiver and line pressure | Analogue pressure transducers | Whether supply keeps up with demand |
| Motor current | Clamp-on current sensor over RS485 | Loaded, unloaded and stopped time |
| Discharge temperature | PT1000 probe | Overheating before a trip |
| Room temperature | 1-Wire probe | A compressor room too hot to run in |
| Compressor controller | RS485 Modbus RTU, from its register map | Hours, service counters and alarm codes |
Four ports on one Genesis controller, and RS485 devices share a bus, so most sites need one unit.
Minimum and maximum on each sensor, with alerts to the people on the list. Acknowledgement is recorded against the alarm, so a handover shows what was already seen.
Readings are stored on the controller with their time and sent in order when coverage returns, so the record has no gap where the incident was.
Full-resolution history, exported to Excel for a report, an insurer or a contractor, or pulled into your own system through the REST API.
A device can be shared with a service company without sharing a login, and they see nothing else on your account.
Through load out of hours. With production stopped, the time the compressor spends loaded is almost entirely leakage, and the record shows it night after night.
Yes. Current sensors and controllers share the RS485 bus, and each is filed against its own compressor.
Neither. The controller connects over 4G-LTE and runs on its rechargeable battery, with solar or a 6 to 32 V DC supply where readings need to be frequent.
Usually, yes. Over fifty sensor types are supported today and more are added on request, including RS485 Modbus instruments from their register map.
What needs watching, which instruments are already there, and whether the site has power and coverage. We come back with what a Genesis would read and what the installation involves.
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