An air compressor is a pneumatic device that generates potential energy stored in pressurized air (i.e., compressed air). By one of several methods, an air compressor forces more and more air into a storage tank, increasing the pressure. When the tank's pressure reaches its engineered upper limit, the air compressor shuts off. The compressed air, then, is held in the tank until called into use. The energy contained in the compressed air can be used for a variety of applications, utilizing the kinetic energy of the air as it is released and the tank depressurizes.

1. LOW PRESSURE AIR COMPRESSOR PLANT AUTOMATION
WITH MESSUNG'S NX-ERA SERIES
An air compressor is a pneumatic device that generates potential
energy stored in pressurized air (i.e., compressed air). By one of several
methods, an air compressor forces more and more air into a storage tank,
increasing the pressure.
When the tank's pressure reaches its engineered upper limit, the air
compressor shuts off. The compressed air, then, is held in the tank until called
into use. The energy contained in the compressed air can be used for a variety
of applications, utilizing the kinetic energy of the air as it is released and the
tank depressurizes.
APPLICATION WHERE LP COMPRESSOR IS USED: Food and Beverage
Industry
Low pressure, oil-free blowers play an integral role in the food and beverage
industry. The main sub segments that use low-pressure air for numerous
applications in this industry include meat processing, poultry, dairy product
manufacturing, preserved fruits and vegetables, as well as brewing and
beverage processes. The primary use of low-pressure air in this market is
pneumatic conveying in both vacuum and pressure. Many food manufacturers
also operate wastewater treatment facilities independent from their
municipalities to decontaminate process or sewage water and to treat organic
waste.

2. THE CUSTOMER
Our customer is a key player in the beverage industry and one of the largest
franchisees of a reputable SOFTDRINK PRODUCER in the world (outside USA).
The Company produces and distributes a wide range of carbonated soft drinks
(CSDs), as well as a large selection of non-carbonated beverages (NCBs),
including packaged drinking water.
KEY FEATURES OF THE COMPRESSERPLANT
• Filtering out contaminated air is essential to creating sanitary food
products, helping to preserve customer health and avoid liability.
• Because of the wide range of pressures that air compressors can
generate, they can be used in many different places on product line.
• Easy to maintain.
• It is perfect for high-pressure requirements.
• It has a low noise.
• The compressed air outlet temperature is not very high.
THE SOLUTION
Messung engineers studied the plant and its requirements, and came up with a
solution consisting of
• NX-ERA XPRESS XP300 PLC controller
• 4.3 inches HMI
Programmable Logic Controllers (PLCs) have been used in various control
systems in order to increase efficiency, to reduce the initial investment and to
minimize the long-term maintenance costs. Every industrial plant requires
compressed air to perform various operations. This can be obtained by the air
compressor. Air compressors have high capacity and stable flow in varying
conditions, but this requires a sophisticated control algorithm.
In this work, we have designed and implemented a PLC-based air compressor
for industrial applications. HMI display is used to indicate different conditions
of the air compressor, such as, over load, no load, full load, cooling fan's
on/off, vent valve's open/close or oil level low/high conditions etc. Besides, to
show different error messages, such as, oil level error signal, over temperature
error, over air pressure error, over motor current error signals etc.
Manual and automatic modes of operations have been incorporated in the
system. Besides, reset system has been included in case of emergency. In
practice, it is found that the developed control system works very well for
different types of input signals from the sensors and provides appropriate
output.

3. THE BRAIN OF THE SYSTEM: NX-ERA XPRESS
NX-ERA Xpress is a powerful mini PLC (Programmable Logic Controller)
developed by Messung, leading micro PLC manufacturer. NX-ERA Xpress brings
you world-class technology at a cost-effective price - for entry-level
applications.
NX-ERA Xpress Highlights:
• High density I/O both Digital & Analog
• Programming by Codesys® - IEC 61131 based software
• Ethernet Port - TCP/IP, Modbus TCP/IP
• Inbuilt Webserver
• Industry 4.0 ready - OPC-UA, MQTT features
• RS-485 port with Modbus RTU Master protocol
• CANopen Master/Slave protocol
• SCADA and HMI interfaces available
• Built in HTML web server
Packed with advanced features, NX-ERA Xpress micro PLC delivers high-speed
processing power in a compact design with embedded I/O. The micro PLC
system can be easily expanded through CANopen using the Remote I/O
Modules - a great advantage for OEMs with needs of small, scalable
applications.
BENEFITS FOR THE CUSTOMER
Latest Industry 4.0 enabled PLC System: provides access to sensor-level data
in difficult-to-reach areas. This ensures smoother operation of system
components while streamlining device replacement and machine maintenance
– again saving costs and improving efficiency.
Cloud connectivity
Conformal Coating: ensures integrity even in harsh environments
Programming and configuration environment based on IEC 61131-3 standard:
the global standard in programming languages for programmable controllers
THE OUTCOME:
• Due to Automation, all systems are designed for un-attended operation
and automatic Pneumatic demand adjustment

4. • The design and Instrumentation make the plant very compact; assembly
on skids, prefabricated supplied from factory
• Air purity is achieved in a very short time. Hence the compressor can be
switched ON & OFF as per air demand changes
• High reliability: Very reliable for continuous and steady operation with
constant air purity. Plant availability time is better than 90 - 95% always
• The only utilities required is electrical power. Smart control of
compressor ensures energy savings.
For automation system components such as PLCs, HMIs, Remote I/Os, etc. or
for customised yet cost-effective industrial automation solutions tailored for
your specific application – talk to Messung, leading Top PLC manufacturer in
India. Messung Industrial Automation & Control division also offers the latest
SCADA applications, Variable Frequency Drives (VFDs) and servo drives.
Our Process Automation, Servo & Motion Control Automation, and General
Purpose Automation solutions have proven themselves across the gamut of
industries with their flexibility, efficiency and long service life. We can offer a
long list of successful case studies and satisfied customers to justify their
claims.
MESSUNG SYSTEMS PVT. LTD.
PUNE (HO),501, 502, 503, Lunkad Sky Vista,Viman Nagar, Pune - 411014, India.
Tel: +91 20 66492800 www.messungautomation.co.in Email:info@messung.com