Compressed Air Monitoring

The problem

Compressors run on local pressure switches, leaks and idle running go unnoticed, and nobody knows the energy cost of a cubic metre of compressed air.

Solution overview

MILESGO gateways collect data from air compressor controllers, flow meters, pressure transmitters, dew point sensors, electricity meters over Modbus RTU / Modbus TCP, and deliver it to the energy management system, WEB HMI panels, a cloud platform (MQTT) as MQTT / OPC UA / BACnet/IP. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

air compressor controllers
flow meters
pressure transmitters
dew point sensors
electricity meters

Protocol path

Modbus RTU / Modbus TCP → MQTT / OPC UA / BACnet/IP

Implementation checklist for the project manager

Collect register maps and protocol documents from every equipment vendor early; a missing map is the most common delay.
For hard-wired signals, list each DI/DO/AI/AO with its type (dry contact, 4–20 mA, 0–10 V, PT1000) and choose I/O modules accordingly.
Record CT ratios, meter IDs and multipliers in the point table; wrong multipliers are the usual cause of billing errors.
Agree KPI definitions (for example OEE components or kWh per unit) with operations before building dashboards.
Commission in read-only mode first; enable write / control points only after the client approves each one.
Hand over configuration backups, point table, IP plan and as-built drawings, with a short operator training.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: air compressor controllers, flow meters, pressure transmitters, dew point sensors, electricity meters, connected over Modbus RTU / Modbus TCP. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: the energy management system, WEB HMI panels, a cloud platform (MQTT), which receives the data as MQTT / OPC UA / BACnet/IP. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: air compressor controllers, flow meters, pressure transmitters, dew point sensors, electricity meters
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: the energy management system, WEB HMI panels, a cloud platform (MQTT) (MQTT / OPC UA / BACnet/IP)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Consumption baseline and deviation alertsPilot
Anomaly detection on trend dataRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

Consumption visible by area, system and time period
Abnormal conditions seen early, before they become failures
Reliable trend data for optimisation and fault diagnosis
Consumption attributable by tenant, department or cost centre

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

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