Air compressor monitoring software Hardware integrated solution

As a professional provider of IoT data acquisition solutions and an expert in industrial IoT data acquisition, the editor of Shanghai Data Acquisition IOT Technology Co., Ltd， (daq-iot) hereby presents the following introduction, and sincerely welcomes discussions and exchanges. Supported Communication Interfaces: CAN, RS485, Mbus, 4–20mA, Profibus, CC-Link, HART, digital I/O, etc. Industrial Protocols: Modbus RTU/TCP, HJ212, IEC104, DLT645, DLMS, IEC61850, MQTT, etc. Mail:export@daq-iot.com

1、 Overview of the Plan

This solution addresses the pain points of air compressor equipment in industrial scenarios, providing a software integrated solution that combinesHardwarewithsolutionconversion, centralized monitoring, intelligent control, and energy efficiency analysis. The plan adopts the conversion fromProtocoltoGateway+Wireless Communication Management Machine/Layered architecture of intelligent terminal+self-developed Zhihu platform+configuration visualization software: converting Protocol from Protocol to Gateway to achieve private Protocol of all brand air compressors to standardModbusRTUThe conversion of data is completed by a wireless communication management machine/intelligent terminal, which wirelessly reports data and connects with the cloud platform. Combined with a self-developed monitoring platform, it helps enterprises achieve digital and intelligent management of air compressor equipment, reduce costs, improve equipment operating efficiency, and achieve energy conservation and consumption reduction.

The plan has the following core values:

●Full brand access:Covering mainstream air compressors, centrifuges, and supporting equipment at home and abroad, theProtocollibrary has over 190 types of controller models built-in, which are plug and play.

●Protocol Conversion:Convert fromProtocoltoGateway, and unify the privateProtocolof each brand into a standard Modbus RTU. The upper computer/PLC/DCS can be connected with one click.

●Wireless reporting:By supporting wireless communication management machines/intelligent terminals, Modbus RTU data can be reported to any public cloud platform via 4G/Ethernet, supportingMQTT/TCP/UDP/HTTP and various other Protocol.

●Centralized monitoring:Real-time collects operational status and process parameters, displays them on a large configuration screen for visualization, and bids farewell to manual inspection and meter reading.

●Intelligent Joint Control:Automatic rotation, on-demand start stop, fault isolation, achieving group control and energy-saving operation of air compressors.

●Data driven:Historical data storage and energy efficiency analysis support preventive maintenance and operational optimization decisions.

2、 Supported air compressor brands and model types

This solution supports mainstream global air compressor brands, covering various types of air compressors such as screw, centrifugal, and vortex compressors, as well as supporting equipment such as dryers, filters, and waste heat recovery machines. As of now, theProtocollibrary has been adapted to over 190 controller models, with core supported brands including:

2.1 Core Support Brands

●International mainstream brands:Ingersoll Rand, Atlas Copco, Sullair, Hitachi, Kobelco, Boge, CompAir, Gardner Denver, Orion, etc.

●Domestic brands:Prudential, Fusheng, Yunaites, SaZhen, Baos, LinggeFeng, DeMan, BaoDe, Jaguar, AiGao, Qiangshi, JiaDe, Elide, etc.

●General supporting equipment:General supporting equipment such as refrigerated dryers, waste heat recovery machines, filters, dryers, vacuum pumps, blowers, and dry contact air compressors.

●Communication Protocol supports:Protocol conversionGatewaymainstream support RS-485ModbusRTU Protocol output (some Atlas models are compatible with CAN bus), and a singleGatewaycan be connected to at most 10 air compressor equipment at the same time; The data reporting to the cloud platform is undertaken by the supporting wireless communication management machine/intelligent terminal, which supports communication methods such as Ethernet and MQTT.

2.2 Adaptation Model Statistics

The following table shows the distribution of controller models and brands that have been adapted to theProtocollibrary in this scheme (a total of 156 air compressors and 37 centrifuges):

brand	Number of compatible models for air compressors	Number of centrifuge compatible models	total
Ingersoll Rand	56	16	72
Erlide	15	—	15
Sullair	10	3	13
Kobelco	12	—	12
Hitachi	9	—	9
Plext	8	—	8
Atlas	3	5	8
Fusheng	6	1	7
Yunaites	5	—	5
Berg	3	—	3
Dengfu	2	1	3
Strong Time	2	—	2
Bao Si	1	1	2
DeMan air compressor	2	—	2
Zhongfu Shenying Filter	2	—	2
Compair	2	—	2
pioneer	—	2	2
Alfred	—	2	2
Hanwha	—	2	2
ENC frequency converter	1	—	1
Yuan Yi refrigerated dryer	1	—	1
Inovance	1	—	1
Sa Zhen	1	—	1
Omron	1	—	1
Jierong heat recovery machine	1	—	1
Huanneng Phoenix Waste Heat Recovery Machine	1	—	1
Ailide medium press machine	1	—	1
Universal dry contact air compressor 1	1	—	1
Universal dry contact air compressor 2	1	—	1
linguaphone	1	—	1
Haituobin	1	—	1
Aigle	1	—	1
Orion	1	—	1
Carter	1	—	1

Jaguar	1	—	1
Jiade	1	—	1
Baldor	1	—	1
heroic	—	1	1
Wancong Thermal Heat Recovery Machine	—	1	1
Lingyu	—	1	1
Magnetic Valley	—	1	1
total	156	37	193

Note: Please refer to Section 2.3 for the complete list of controller communication models; The new model is continuously adapting, and non-standard Protocol supports customized development.

2.3 List of Controller Communication Models

The following is a complete list of communication models of air compressors and centrifuge controllers that have been adapted to this scheme Gateway. When connected on site, the corresponding Gateway model can be selected according to the brand and controller model to achieve debugging free docking.

(1) Communication list of air compressor controller

serial number	brand	Air compressor series	Controller Model	Communication bus
1	Ingersoll Rand	VSD	KT	RS-485
2	Ingersoll Rand	V	KT	RS-485
3	Ingersoll Rand	SG		RS-485
4	Ingersoll Rand	M、R	XE70M	RS-485
5	Ingersoll Rand	M、R	XE90M	RS-485
6	Ingersoll Rand	V	fierce tiger	RS-485
7	Ingersoll Rand	KOS400		RS-485
8	Ingersoll Rand	SE	IRLAN to 485	RS-485
9	Ingersoll Rand	VSD	KT frequency conversion new model 1	RS-485
10	Ingersoll Rand	VSD	XE90M/XE145M	RS-485
11	Ingersoll Rand	VSD	SGVSD	RS-485
12	Ingersoll Rand	M、R	XE145M	RS-485
13	Ingersoll Rand	SMxxVSD	KT frequency conversion new model 2	RS-485
14	Ingersoll Rand	SMxxV	KT power frequency new model 1	RS-485
15	Ingersoll Rand	M、RVSD	XE90MVSD	RS-485
16	Ingersoll Rand	SG		RS-485
17	Ingersoll Rand		XE145M Model 2	RS-485
18	Ingersoll Rand	KOS500		RS-485
19	Ingersoll Rand	VSD	VSD-XE145M	RS-485
20	Ingersoll Rand	VSD	XE145M	RS-485
21	Plext		MAM_KY	RS-485
22	Plext		MAM_200	RS-485
23	Plext		MAM_6090	RS-485
24	Plext		MAM_KY12S	RS-485
25	Plext	Variable frequency type	MAM_VSD_1	RS-485
26	Plext		MAM_YL	RS-485
27	Plext		MAM6080/6090_2	RS-485
28	Plext		MAM8070	RS-485

29	Atlas	MK4、MK5	Shenzhen module	CAN/RS-485
30	Atlas	MK4	MK4	CAN
31	Atlas	MK5	MK5	CAN
32	Sullair		Standard Type 1	RS-485
33	Sullair		Type 4	RS-485
34	Sullair	oil-free machine		RS-485
35	Sullair		Luxury Type 2	RS-485
36	Sullair		EC2000	RS-485
37	Sullair		SDS	RS-485
38	Sullair		STS	RS-485
39	Sullair		DS series	RS-485
40	Sullair	vacuum pump	Luxury Type 4	RS-485
41	Sullair	oil-free machine	Luxury Type 6	RS-485
42	Hitachi	N2 micro oil	HC_1	RS-485
43	Hitachi	N2 oil-free	HC_2	RS-485
44	Hitachi	N1 oil-free (using transfer PLC)	HC_3	RS-485
45	Hitachi	4G	HC_4	RS-485
46	Hitachi	TH series power frequency	EPC-2000	RS-485
47	Hitachi	TH series frequency converter	EPC-2000	RS-485
48	Hitachi	Micro oil single-stage compression	HC-5	RS-485
49	Hitachi	Micro oil single-stage compression	HC-CP650	RS-485
50	Hitachi	Micro oil single-stage compression - Envision	HC-INVT	RS-485
51	Berg		V120	RS-485
52	Berg		BOGE_DC_1	RS-485
53	Berg		BOGE_1	RS-485
54	Kobelco	ALE/FE	KB_1	RS-485
55	Kobelco	Kobelion	KB_2	RS-485
56	Kobelco	AG75	KB_3	RS-485
57	Kobelco	AG75	KB_4	RS-485
58	Kobelco		KB_5	RS-485
59	Kobelco	ALE_2	KB_6	RS-485
60	Kobelco		KB_7	RS-485
61	Kobelco		KB_8	RS-485
62	Kobelco		KB_9	RS-485
63	Kobelco		KB_10	RS-485
64	Strong Time		QS_1	RS-485
65	Strong Time	E75	Hailipu inverter direct control	RS-485
66	ENC frequency converter		EN600	RS-485
67	Yuan Yi refrigerated dryer		YY_RD_1	RS-485
68	Fusheng	SA	FS_SA	RS-485
69	Fusheng		FS_MAM	RS-485
70	Fusheng		FS_1200	RS-485
71	Fusheng		FS_MAM_2	RS-485
72	Fusheng	SA	FS_SA250	RS-485
73	Fusheng		FS_MAM_3	RS-485
74	Ingersoll Rand		XE145M	RS-485
75	Ingersoll Rand		SE	RS-485
76	Ingersoll Rand		XE145M_5	RS-485
77	Ingersoll Rand		XE145M_6	RS-485
78	Ingersoll Rand		XE145M_7	RS-485
79	Ingersoll Rand		SG_3	RS-485
80	Ingersoll Rand		S3	RS-485
81	Ingersoll Rand		XE145M_VSD_2	RS-485
82	Ingersoll Rand		XE145M_8	RS-485
83	Ingersoll Rand		S1	RS-485
84	Inovance	frequency converter	cp700	RS-485
85	Yunaites		EPC-2000	RS-485
86	Yunaites		EPC-2000_2	RS-485
87	Yunaites		EPC-2000 frequency converter	RS-485
88	Yunaites		EPC-2000_3	RS-485
89	Yunaites	container	EPC-2000PX	RS-485
90	Sa Zhen		VK070	RS-485
91	Bao Si		ZMF02	RS-485
92	Ingersoll Rand		KT_VSD	RS-485
93	Ingersoll Rand		XE70M_2	RS-485
94	Ingersoll Rand		CMC_V3_SH300W	RS-485
95	Ingersoll Rand	E200ie oil-free machine	XE145M_9	RS-485
96	Ingersoll Rand		XE90M_VSD_4	RS-485
97	Erlide	dual motor	AIR_TSFC	RS-485
98	Erlide	Terry oxygen concentrator	AIR_OXY	RS-485
99	Erlide	Power frequency machine	AIR_TSFC	RS-485
100	Erlide	Single stage frequency converter	AIR_TSA	RS-485
101	Erlide	Cold dry integrated machine	AIR_VSD	RS-485
102	Erlide	Dual motor (new program)	AIR_TSFC_2	RS-485
103	Erlide	Single container	AIR_IES_1	RS-485
104	Erlide	Single stage frequency converter with integrated display and control	AIR_VSD_2	RS-485
105	Erlide	Single container (new program)	AIR_IES_2	RS-485
106	Omron		E5CC	RS-485
107	Jierong heat recovery machine		JR_1	RS-485
108	DeMan air compressor		MD8500	RS-485
109	Huanneng Phoenix Waste Heat Recovery Machine			RS-485
110	Zhongfu Shenying Filter		ZF_1	RS-485
111	Zhongfu Shenying Filter		ZF_2	RS-485
112	DeMan air compressor		MD8500_TCP	RS-485
113	Ailide medium press machine	EBV_8_40	Huichuan H2u	RS-485
114	Universal dry contact air compressor 1
115	Universal dry contact air compressor 2
116	Ingersoll Rand		XE145M_VSD_3	RS-485
117	Ingersoll Rand		LM_1	RS-485
118	Ingersoll Rand		LM_VSD_1	RS-485
119	Ingersoll Rand		KT_VSD_2	RS-485
120	Ingersoll Rand		XE145M_VSD_4	RS-485
121	Ingersoll Rand		LM_VSD_2	RS-485
122	Ingersoll Rand		LM_2	RS-485
123	Ingersoll Rand		XE90M_VSD_3	RS-485
124	Ingersoll Rand		V100T	RS-485
125	Ingersoll Rand		LM_VSD_3	RS-485
126	Ingersoll Rand		LM_3	RS-485
127	Ingersoll Rand		LM_VSD_4	RS-485
128	Ingersoll Rand		LM_VSD_5	RS-485
129	Ingersoll Rand		LM_VSD_6	RS-485
130	Ingersoll Rand		KT_VSD_3	RS-485
131	Ingersoll Rand		SG_4	RS-485
132	Ingersoll Rand		XE145M_10	RS-485
133	Ingersoll Rand		LM_VSD_7	RS-485
134	Ingersoll Rand		LM_4	RS-485
135	linguaphone		HD37	RS-485
136	Compair		DelcosTs power frequency	RS-485
137	Compair		DelcosTs frequency converter	RS-485
138	Haituobin		blower	RS-485
139	Aigle	BPM110	Huichuan PLC	RS-485
140	Orion		Omron CVs	RS-485
141	Dengfu	SAV250		RS-485
142	Dengfu	DH55VSD		RS-485
143	Erlide	Single container with heat recovery	AIR_IES_3	RS-485
144	Erlide	Container dual main controller	AIR_IES2_M	RS-485
145	Erlide	Container Double Unit 1 #	AIR_IES2_1	RS-485
146	Erlide	Container Double Unit 2 #	AIR_IES2_2	RS-485
147	Erlide	Container unit (Nvidian GD300)	AIR_IES_4	RS-485
148	Erlide	Container unit (Nvidian GD350)	AIR_IES_5	RS-485
149	Carter		KT_VSD_1	RS-485
150	Jaguar		JB_1	RS-485
151	Jiade	container	JD_1	RS-485
152	Kobelco	AG75	KB_11	RS-485
153	Kobelco	VS160+AR	KB_12	RS-485
154	Baldor	BD-30GS	BD_30GS	RS-485
155	Ingersoll Rand		SVT vacuum pump	RS-485
156	Ingersoll Rand		VS680 vacuum pump	RS-485

(2) Communication list of centrifuge controller

serial number	brand	Air compressor series	Controller Model	Communication bus
1	pioneer			RS-485
2	Ingersoll Rand	C700，C1000	Xe145m	RS-485
3	Ingersoll Rand	C700，C1000	Xe145DCU	RS-485

4	Sullair	SL400		RS-485
5	Atlas		MK4	RS-485
6	Atlas		MK5	RS-485
7	Atlas		MK5	RS-485
8	Ingersoll Rand		CMCBCM2.x	RS-485
9	Fusheng		EDC-PLC	RS-485
10	pioneer		S7-1215	RS-485
11	Atlas		MK5	CAN
12	Atlas	ZH630	MK5	CAN
13	Alfred		EDC	RS-485
14	Alfred		R150	RS-485
15	Hanwha	SM4100		RS-485
16	Hanwha	SM4000		RS-485
17	Ingersoll Rand	C700	Xe145DCU	RS-485
18	Ingersoll Rand	NX8000		RS-485
19	Ingersoll Rand	NX8000_2		RS-485
20	Ingersoll Rand	TA6000		RS-485
21	Ingersoll Rand	TA6000_2		RS-485
22	Ingersoll Rand	TA6000_3		RS-485
23	Ingersoll Rand	NX5000		RS-485
24	Ingersoll Rand	TA6000_4		RS-485
25	Ingersoll Rand	TA6000_5		RS-485
26	Ingersoll Rand	C700_2	Xe145DCU	RS-485
27	Sullair	SL400		RS-485
28	Sullair	TRE		RS-485
29	Bao Si	VT		RS-485
30	Dengfu	VB1200		RS-485
31	heroic	HM850		RS-485
32	Wancong Thermal Heat Recovery Machine		CTY600	RS-485
33	Lingyu		LY_DB600	RS-485
34	Magnetic Valley	CG400	CG/A400	RS-485
35	Ingersoll Rand	TA6000_6		RS-485
36	Ingersoll Rand	NX8000_3		RS-485
37	Ingersoll Rand	TA3000		RS-485

3、 Hardware Scheme Design

3.1 Hardware Architecture Overview

The scheme Hardware adopts a clear hierarchical architecture, with clear responsibilities and each layer performing its own duties, ensuring the decoupling of Protocol conversion and data reporting functions, facilitating on-site deployment and maintenance:

Hardware hierarchy	core equipment	Main Responsibilities	communication interface
Protocol Conversion Layer	Air compressor Protocol conversion acquisition Gateway（DAQ-GP-AMmodbus）	Connect to the privateProtocolair compressor controller and convert it to standard Modbus RTU output	Downward: MKLAN connected to air compressor; Upstream: RS485 Modbus RTU
Data reporting layer	Wireless communication management machine/wireless intelligent terminal	Collect Modbus RTU data output fromGatewayand report it to the cloud platform via 4G/Ethernet	Downstream: RS485 acquisition; Upstream: 4G/Ethernet (MQTT/TCP/HTTP, etc.)
Application Display Layer	Industrial computer/cloud monitoring platform	Data storage, configuration visualization, intelligent control, alarm and reporting	Local or cloud deployment, browser access

Explanation: The air compressor Protocol conversion Gateway is only responsible for converting the private Protocol of the air compressor into standard Modbus RTU output, and does not directly have wireless reporting and cloud platform integration capabilities; If data needs to be reported to the public cloud platform orRemote Monitoringcenter, a supporting wireless communication management machine or wireless intelligent terminal needs to be added on the upstream side ofGatewayto complete the collection, encapsulation, and wireless reporting of Modbus RTU data.

3.2 Conversion and acquisition of air compressor Protocol Gateway (DAQ-GP AMmodbus)

The DAQ-GP AMmodbus series air compressor Protocol conversion Gateway is a Gateway device launched by Shanghai DAQ-IoT Network Technology Co., Ltd. for the conversion and reverse control of [TERM0042TTOKEN] and Protocol for air compressors. It can be used for mainstream air compressor equipment [TERM0033TTOKEN] to quickly connect air compressor data to third-party systems such as PLC or DCS.

Through this Gateway, the operating status and parameters of the air compressor can be monitored, and the start, stop, loading, and unloading of the air compressor can also be controlled through serial communication. ThisGatewaycan connect 5 Atlas/Ingersoll Rand and other air compressors (up to 10) at the same time without additional configuration to form an air compressor group control network. The upper computer software or PLC can be connected to the networkReal-timeusing Modbus RTU via RS485 interface.

3.2.1 Core parameter specifications

project	Parameter Specifications
model	DAQ-GP AMmodbus (customizable brand specific models)
core functionality	Air compressor Data Acquisition, private Protocol converted to standard Modbus RTU, remote start stop/load unload reverse control, multi device cluster access

interface configuration	MKLAN air compressor dedicated interface (DB9), A/B-RS485 Modbus interface
working power supply	220VAC，60mA
Dimensions	122×84×24（mm）
working environment	Temperature -30 ℃~75 ℃, humidity 0~95%
Output Protocol	RS485 Modbus RTU (standard) for upper computer/PLC/wireless terminal to read
Supporting attachments	Power adapter, air compressor communication connector

3.2.2 Gateway Selection Instructions

model	Feature Description
DAQ-GP-AMmodbus-Atlas	Connect Atlas Copco MK2, MK4 and MK5 computer controllers
DAQ-GP-AMmodbus-Ingersoll	Connect Ingersoll air compressor
DAQ-GP-AMmodbus-XX	Other brands of air compressors, such as Sullair, Fusheng, Kaishan, Shengang, etc
……	Customization (developed specifically for the non-standard controllerProtocolmodelGateway)

3.2.3 Product Features

●Electrical characteristics:Working power supply 220VAC, 60mA, suitable for industrial site power supply environment.

●Communication characteristics:Standard RS485 Modbus RTU output, the upper computer/PLC/wireless terminal reads data from Modbus slave addresses 1-10; The MKLAN interface is connected to the air compressor controller in a one to many manner, and the A/B terminals are Modbus (485) interfaces.

●Structural characteristics:Size specification 122 × 84 × 24 (mm), rail/wall mounted, compact structure.

●Work environment:Working temperature -30 ℃~75 ℃, humidity 0~95%, suitable for various industrial site environments.

●Ability boundary:Note: Gateway itself only outputs Modbus RTU and does not directly support wireless reporting such as 4G/MQTT; The wireless reporting and cloud platform integration capability is provided by the supporting wireless communication management machine/intelligent terminal (see section 3.3).

3.3 Wireless Communication Management Machine/Wireless Intelligent Terminal

When on-site data needs to be reported to the public cloud platform orRemote Monitoringcenter, a supporting wireless communication management machine or wireless intelligent terminal needs to be added on the upstream side of theProtocolconversion. This device serves as the core of the data reporting layer Hardware, responsible for collecting Modbus RTU data output by Gateway, and reporting it to any public network server or cloud platform via 4G/Ethernet via MQTT/TCP/UDP/HTTP, etc. Protocol.

3.3.1 Core parameter specifications

project	Parameter Specifications
Device Type	Industrial grade wireless communication management machine/wireless intelligent terminal
core functionality	Modbus RTU Data Acquisition, Protocol encapsulation, 4G/Ethernet wireless reporting, cloud platform docking, breakpoint resume transmission
Downstream acquisition interface	RS485 Modbus RTU master station, capable of polling and collecting multiple Protocol conversion Gateway output data
Upstream communication method	4G LTE full network/Ethernet (RJ45)
Support Protocol	MQTT/TCP/UDP/HTTP/SSL， Customizable for other communications Protocol
data forwarding	Any public network server/cloud platform
working power supply	220VAC or DC wide voltage power supply
working environment	Industrial grade, temperature range of -30 ℃ to 75 ℃, suitable for various industrial sites

3.3.2 Functional Characteristics

●Data Acquisition：As a Modbus RTU master station, collect air compressor data from Protocol converted to Gateway by polling from slave addresses 1 to 10, aggregate and report it uniformly.

●Wireless uplink:Supports 4G LTE full network and Ethernet uplink, suitable for various on-site environments with or without network.

●Multiple Protocol reports:Support MQTT/TCP/UDP/HTTP/SSL multiple reporting Protocol, can interface with any public network server and mainstream cloud platforms.

●Resume from breakpoint:Capable of local data caching and breakpoint retransmission, data is not lost during network interruption, and automatic retransmission is performed after recovery.

●Platform docking:Support platform customization and integration, such as the Alibaba Cloud IoT platformChina Mobile OneNet PlatformHua Weiyun, etc. (see Chapter 6 for details).

3.4 On site installation plan

●Installation location:Protocol conversion Gateway is installed near the air compressor control cabinet, and the wireless communication management machine/intelligent terminal is installed near Gateway or in the weak current box, all using DIN rail installation or wall mounted installation to ensure good ventilation and stay away from strong electromagnetic interference sources.

●Network topology:The air compressor controller "hand-in-hand" is connected in series to the Gateway MKLAN interface; Gateway A/B terminals are connected to wireless communication management machines/smart terminals via RS485; The wireless terminal reports to the cloud platform or local industrial computer via 4G/Ethernet.

●Address configuration:Each air compressor controller is set with a unique address (1-10), corresponding to Gateway Modbus slave addresses 1-10. Wireless terminals distinguish different devices based on their addresses.

Standard installation process:

1.Disconnect the power supply of the air compressor controller and confirm that there is no risk of live operation.

2.Connect the DB9 plug to the "LAN" plug of the air compressor controller, and use a dedicated communication cable to connect the controller communication port to the Protocol conversion Gateway MKLAN interface.

3.Connect the Gateway 220VAC power supply and confirm that the power indicator light is on normally.

4.Configure the address of the air compressor controller panel to be 1-10, ensuring consistency with the Modbus slave address mapping of Gateway.

5.The Gateway A/B terminals are connected to the RS485 acquisition port of the wireless communication management machine/intelligent terminal (or directly connected to the local industrial control computer/PLC) through an RS485 cable.

6.Connect power to wireless communication management machine/intelligent terminal, configure 4G/Ethernet and report platform parameters.

7.Test the End-to-End data link: air compressor → Gateway → wireless terminal → cloud platform, confirm that data is collected and reported normally.

3.5 Wiring scheme

3.5.1 Core Wiring Terminal Description

Equipment	Terminal/Interface	Functional Description	Wiring specifications
Protocol ConversionGateway	MKLAN interface	Communication interface for air compressor controller, DB9 connector	Standard DB9 pin connector, corresponding to the LAN/communication port of the air compressor controller, supports one-to-one or hand-in-hand connection
Protocol ConversionGateway	A/B terminals	Modbus RTU output, connected to wireless terminal/upper computer/PLC	Connect A to RS485+, B to RS485-, GND to shielded ground, communication distance ≤ 1200m
Protocol ConversionGateway	power terminal	220VAC power input	L is connected to the live wire, N is connected to the neutral wire, and PE is connected to the protective ground to ensure reliable grounding
Wireless communication management machine/intelligent terminal	RS485 acquisition port	Downward acquisition of Gateway Modbus RTU data	A/B corresponds to Gateway A/B terminals, GND is common ground
Wireless communication management machine/intelligent terminal	4G antenna/network port	Upstream wireless reporting	Connect 4G antenna or RJ45 network cable to access the Internet
Wireless communication management machine/intelligent terminal	power terminal	Equipment power supply	Connect 220VAC or DC wide voltage power supply according to device specifications

3.5.2 Typical Wiring Topology

Single air compressor wiring (including wireless reporting): air compressor controller communication interface → Protocol conversionGatewayMKLAN interface →GatewayA/B terminal → wireless communication management machine/intelligent terminal RS485 interface → 4G/EthernetGateway→ cloud platform/upper computer software (take Atlas air compressor as an example).

Multiple air compressor cluster wiring: Communication port of compressor controller 1 → Communication port of compressor controller 2 →... → Protocol Convert Gateway MKLAN interface → Gateway A/B terminals → Wireless communication management machine/intelligent terminal → 4G/Ethernet → Cloud platform/work control machine. Multiple AC air compressors form a "hand-in-hand" network, which is ultimately connected to the MKLAN interface of DAQ-GP AMmodbus. Gateway then sends Modbus RTU data to the wireless communication management machine/intelligent terminal via RS485 for wireless reporting.

3.5.3 Wiring precautions

The communication cable adopts shielded twisted pair, with the shielding layer grounded at one end to avoid forming a grounding loop.

Communication cables and power cables should be laid separately with a spacing of ≥ 30cm to avoid electromagnetic interference.

When multiple devices are connected in series, 120 Ω terminal resistors need to be connected at both ends of the bus to improve communication stability.

After the wiring is completed, all terminals should be checked for tightness and no looseness or short circuits.

The maximum length of the CAN bus cannot exceed 80 meters, and signals exceeding the recommended length will be accompanied by attenuation.

4、 Software functional solution

The air compressor monitoring platform supporting this scheme adopts a layered architecture design, which is divided into Data Acquisition layer, data storage layer, and application display layer. The core functions are as follows:

4.1 Data Acquisition and Storage

●Second level Real-time collection:Support the collection of all core operating parameters of the air compressor usingReal-time, with a maximum collection frequency of 1 second per time. The core collection parameters include:

Operating status: Run/Stop, Load/Unload, Manual/Automatic mode, Local/Remote control;

Process parameters: exhaust pressure, exhaust temperature, oil temperature, oil pressure, oil separator pressure difference, cooler pressure;

Equipment operation data: running time, loading time, startup times, loading times, motor speed;

Alarm fault information: comprehensive alarm, fault shutdown, emergency shutdown, motor overload, maintenance prompt;

Control instructions: Support remote start/stop, load/unload, pressure upper and lower limit settings, and other reverse control operations.

Data storage:Supports dual storage of local and cloud databases, with traceable historical data and customizable storage periods. It can store historical data for up to 5 years or more.

●Protocol Adaptation:Built in full brand air compressor library Protocol, device integration can be achieved without secondary development, supporting customized development of non-standard Protocol.

4.2 Centralized monitoring and visualization

●Overview of Equipment Status:The large screen displays the operation/stop/fault status of all air compressors, and the total number of devices, online numbers, running numbers, and fault numbers are clear at a glance.

●Real-time Data Dashboard:The details page of a single device displays all operational parameters ofReal-timein a centralized manner, supporting red alerts for parameter exceeding limits, and customizable data refresh rates.

●Configuration visualization:Support customized operating process diagrams, simulate the actual operation process of air compressors, and visually display the equipment's operating status.

4.3 Intelligent Joint Control and Automation Control

●Automatic rotation operation:Multiple air compressors can be set with an automatic rotation strategy, running alternately at set time intervals (such as 6 hours/time) to balance equipment losses and extend the overall service life of the equipment.

●On demand intelligent start stop:Automatically control the start and stop of equipment based on pipeline pressure. When the pipeline pressure is below the set lower limit, the standby machine will be automatically started to supplement the pressure; After reaching the target pressure, the standby machine will automatically stop to achieve energy-saving operation.

●Automatic fault isolation:When a running device fails, the system automatically isolates it from the running queue and seamlessly switches to a backup device to ensure uninterrupted gas supply.

●Flexible control mode:Support seamless switching between manual/automatic modes. In manual mode, individual control of the start stop, loading and unloading of a single device can be achieved to meet special working conditions.

●Customization of joint control parameters:Parameters such as rotation time, upper and lower limits of pressure, and equipment priority can be flexibly configured to adapt to different on-site working conditions.

4.4 Alarm and Warning Management

●Real-time Alarm push:When the device experiences parameter overload, malfunction, shutdown, and other situations, the system immediately triggers an alarm and supports multiple alarm methods such as pop ups, sound, SMS, and WeChat push notifications.

●Alarm grading management:Support custom alarm levels, divided into general warnings, important alarms, and emergency faults according to urgency, with differentiated push strategies.

●Alarm history tracing:All alarm records are fully stored, including alarm time, alarm content, alarm level, and processing status, supporting alarm statistics and analysis.

●Preventive maintenance warning:Based on the running time and status of the equipment, maintenance reminders are automatically triggered, and the maintenance cycle can be customized, changing from "repair after failure" to "warning based maintenance".

4.5 Energy Efficiency Analysis and Report Management

●Energy efficiency analysis:Based on historical operational data, analyze the equipment's no-load rate, loading rate, and unit gas production energy consumption, identify energy-saving space, and optimize operational strategies.

●Run report:Automatically generate daily, weekly, and monthly reports, including core indicators such as device operating time, loading time, start stop frequency, energy consumption data, etc., supporting Excel/PDF format export.

●Data traceability:Support historical data trend curve query, generate trend charts by time range and parameter type for fault analysis and operation optimization.

●Third party system integration:Support integration with existing PLC, DCS, MES, ERP and other systems of users, and provide standard Modbus RTU Protocol output to achieve data interoperability.

5、 Collecting parameters and Modbus address table

Protocol Convert Gateway to open the standard register address table to the upper computer/wireless communication management computer through Modbus RTU Protocol, covering the full collection and control points of air compressor control instructions, process parameters, switch inputs, operating status, operating statistics, and pressure band settings. The upper computer/PLC/wireless terminal accesses the corresponding air compressor according to Modbus slave addresses 1-10, and the address table is uniformly applicable. The specific register address is subject to the point table document delivered with Gateway. The core acquisition parameters are described as follows:

serial number	parameter name	visit	explanation
1	control command	RW	1: Start up; 2: Stop; 3: Loading; 4: Uninstall
2	Reset instruction	R	1: Fault shutdown; 2: Start up malfunction

5.2 Process parameter category (pressure)

The data type of pressure parameters is Int16, with the unit of Bar, and the actual value is equal to the reading value multiplied by 0.001.

serial number	parameter name	data type	explanation
3	Exhaust pressure	Int16	Unit Bar, value x 0.001
4	Dp oil separator	Int16	Ditto.
5	oil pressure	Int16	Ditto.
6	Pressure of intercooler	Int16	Ditto.

5.3 Process parameter category (temperature)

The unit of temperature parameters is ℃, and the actual value is equal to the reading value multiplied by 0.1.

serial number	parameter name	data type	explanation
7	exhaust gas temperature	Int16	Unit ℃, value × 0.1
8	1 # rotor exhaust temperature	Int16	Ditto.
9	2 # rotor inlet temperature	Int16	Ditto.
10	2 # rotor exhaust temperature	Int16	Ditto.
11~13	Reserve	Int16	Reserved extension (value x 0.1)
14	oil temperature	Int16	Unit ℃, value × 0.1

5.4 Switching input category

serial number	parameter name	explanation
15	Emergency stop input	0: Emergency stop; 1: Normal
16	Remote start stop input	0: Shutdown; 1: Start up
17	Remote loading and unloading input	0: Uninstall; 1: Loading
18	Remote pressure control input	0: On site; 1: Remote
19	Main motor overload	0: Overload; 1: Normal
20	Fan motor overload	0: Overload; 1: Normal
21	Motor operation feedback	0: Stop; 1: Run

5.5 Operating Status Category

serial number	parameter name	explanation
22	Operating status	1: Operation; 0: Stop
23	Add/unload status	1: Loading; 0: Uninstall
24	Integrated Alarm	1: Alarm; 0: Normal
25	Comprehensive fault shutdown alarm	1: Alarm; 0: Normal
26	Comprehensive fault shutdown	1: Shutdown; 0: Normal
27	Maintenance Tips	1: Maintenance; 0: Normal
28	Startup failure	1: Fault; 0: Normal
29	Emergency shutdown	1: Emergency stop; 0: Normal
30	Hand/Automatic Adjustment	1: Automatic; 0: Manual
31	Local/remote control	1: Remote; 0: On site

5.6 Running time statistics

The following parameters are stored in 32-bit dual word format, with actual values=high word x 65536+low word.

serial number	parameter name	visit	explanation
32	Running time (high+low)	R	High character x 65536+low character, in hours
33	Loading time (high+low)	R	High character x 65536+low character
34	Number of motor starts (high+low)	R	High character x 65536+low character
35	Module communication time (high+low)	R	High character x 65536+low character
36	Loading times (high+low)	R	High character x 65536+low character

5.7 Pressure band setting category

serial number	parameter name	explanation
37	Pressure band selection	1 or 2
38	Load pressure band 1	Unit Bar, value x 0.001
39	Unload pressure band 1	Ditto.
40	Load pressure band 2	Ditto.
41	Unload pressure band 2	Ditto.

Note: The above point table is a general acquisition point for mainstream air compressors such as Atlas, and the specific register addresses of different brands/controller models are subject to theGatewaydocument delivered with Protocol; Non standard Protocol supports customized development.

6、 Project Implementation Case

Project Name: Atlas Air Compressor Cluster Intelligent Joint Control and Data Visualization System Project Date: January 2026

6.1 Project Background and Pain Points

There are 4 ATLAS brand air compressors in the customer's factory area (currently 2 on site, with 2 to be added later), providing a stable gas source for the production line. There are the following pain points before the renovation:

Each air compressor operates independently and relies on manual inspection to record operating parameters (pressure, temperature, etc.). The data is scattered and cannot be centrally monitored.

The start stop and rotation of equipment rely on manual labor, which poses a risk of forgetting to switch and uneven load, affecting the lifespan of the equipment.

When a device malfunctions and cannot automatically adjust its operating strategy in a timely manner, it may affect the supply of production gas sources.

Lack of historical data traceability makes it difficult to conduct energy efficiency analysis and preventive maintenance.

6.2 Project Objectives and Customization Requirements

The customer wishes to build a centralized monitoring and intelligent control system to achieve the following functions:

●Visualization in dataset:The operating status display of each unit Real-time includes operating time, inlet temperature, outlet temperature, inlet pressure, outlet pressure, oil pressure, oil temperature, etc. of the low-pressure and high-pressure engines. The controller Real-time collects and displays them on a unified large screen.

●Intelligent rotation control:Realize automatic sequential rotation operation of 4 devices, rotating every 6 hours (adjustable), with 1 device running and the other 3 turned off, balancing equipment wear and extending overall lifespan. The rotation time can be flexibly set.

●On demand intelligent start stop:Automatically control the start and stop of equipment based on pipeline pressure. When the end pressure is lower than the set lower limit (pressure can be set), the backup machine will be automatically started for replenishment; After reaching the target pressure, the original host continues to run and the backup host stops; After the main equipment malfunctions and shuts down, it will automatically kick out, while other equipment will continue to be automatically controlled in sequence to achieve energy-saving operation.

●High Availability sexual protection:When a running host fails, the system needs to be able to automatically isolate it safely from the running queue and automatically activate backup equipment to ensure uninterrupted gas supply.

●Flexible control mode:Retain manual control function, can switch between "automatic" and "manual" modes, both upper and lower pressure can be set to meet special operating needs.

6.3solution

We provide customers with a set of software Hardware integrated customization solution based on "Protocol conversion Gateway+wireless communication management machine/intelligent terminal+self-developed Data Acquisition platform+configuration visualization software":

(1) Hardware docking layer

Use Atlas air compressor Protocol to convertGateway(DAQ-GP AMmodbus), and conduct stable communication with the controller of each air compressor through the standard ModbusRTU Protocol.Gatewayis connected to the air compressor panel through the DB nine pin air compressor interface for one to many conversion and preliminary data processing. The data is then output through Modbus RTU for localData Acquisitionsystem and wireless communication management machine/intelligent terminal to read and report.

(2) Data and Logic Core Layer

Deploy the self-developed universal industrial Data Acquisition system, accurately parse equipment point tables, and achieve second level Real-time collection and storage of all air compressor parameters (while supporting various databases). The system is equipped with a custom developed integrated control logic engine, which reliably executes core control strategies such as "automatic rotation", "on-demand start stop", and "removal of faulty devices", ensuring the stability and accuracy of the logic.

(3) Application Display Layer

Tailored industrial configuration monitoring screens for customers, with intuitive design including:

●Equipment status overview:The operation/stop/fault status of the four devices is clear at a glance.

●Real-time Data Panel:Display all key temperature and pressure parameters in a centralized manner.

●Intelligent control panel:Rotation time, upper and lower pressure limits can be set, and the current host and queue order can be displayed.

●Manual control panel:Provide independent device start stop buttons and manual/automatic mode switching.

●Historical trend curve:The trend of key parameter changes can be queried at any time for fault analysis and energy efficiency management.

●Automatic alarm system:When the device is abnormal, an alarm message will pop up and be recorded.

6.4 Project Achievements

●Management visualization:The on duty personnel have a comprehensive understanding of the operation status of each air compressor at the industrial computer, bidding farewell to manual inspection and meter reading, and improving management efficiency.

●Control automation:Fully automatic rotation and on-demand start stop have been achieved, avoiding human operational errors, achieving more balanced equipment utilization, and extending the overall lifespan of the equipment.

●Energy saving operation:Accurate on-demand start stop control avoids ineffective operation and achieves significant energy-saving effects.

●System High Availability:The rapid isolation of faulty equipment and seamless replacement of backup equipment greatly ensure the stability of production gas sources and reduce the risk of unplanned shutdowns.

●Maintain digitalization:The complete operation history data provides accurate data support for preventive maintenance of equipment, transforming "repair after failure" into "warning based maintenance".

7、 Application value and benefits

This plan has been implemented and verified on multiple industry sites, with significant comprehensive benefits. The core application value is shown in the table below:

value dimension	Pain points before renovation	Empowering the plan	expected benefits
Management Efficiency	Manual inspection and meter reading, scattered data, unable to centrally grasp equipment status	Centralized visualization of the configuration screen, Real-time displays the operating status of all air compressors in the factory	Significant improvement in management efficiency, bidding farewell to manual meter reading
Equipment lifespan	Start stop rotation relies on manual labor, resulting in uneven load and imbalanced equipment wear and tear	Automatic sequential rotation, balanced equipment operating time, automatic isolation of faulty equipment	More balanced utilization of equipment, extending overall service life
energy conservation and consumption reduction	Invalid operation of equipment, mismatch between gas supply and demand, high energy consumption	On demand intelligent start stop, precise control of pipeline pressure, avoiding empty load waste	Achieve significant energy-saving effects and reduce energy consumption per unit of gas production
stable operation	The malfunction cannot be adjusted in a timely manner, affecting the supply of production gas source	Fault automatic isolation+seamless replacement of backup equipment, guaranteed byHigh Availability	Reduce the risk of unplanned shutdowns and ensure stable gas supply
Maintenance Method	Repair after malfunction, lack of data support, passive maintenance	Complete storage of historical data during operation, triggering preventive maintenance reminders	Change from 'repair after malfunction' to 'early warning maintenance'
data asset	Without historical data traceability, it is difficult to conduct energy efficiency analysis	Historical data can be traced back more than 5 years, supporting energy efficiency analysis and reporting	Data driven operation optimization and decision-making
system integration	The data islands of each system make it difficult to interconnect and communicate with each other	Standard Modbus RTU output+wireless terminal multi Protocol reporting, compatible with PLC/DCS/cloud platform	Realize data interoperability and support digital transformation

8、 About Us

Shanghai DAQ-IoTNetwork Technology Co., Ltd. is a professional service provider in the industrial field ofData Acquisition, focusing on the research and implementation ofData AcquisitionandProtocolconversion, centralized monitoring, and intelligent control of industrial equipment such as air compressors. The company's mission is to make every industrial equipment intelligent and controllable. It has independently developed a series of air compressors Protocol conversion and acquisition Gateway, wireless communication management machines/intelligent terminals, and a general industrial Data Acquisition platform. TheProtocollibrary has been adapted to more than 190 controller models, covering mainstream air compressor, centrifuge, and supporting equipment brands at home and abroad.

We solemnly promise that you are not only purchasing products, but also providing meticulous and thoughtful technical support services. The conversion fromProtocoltoGatewayonly requires ordinary workers to connect and install it on site, without the need for debugging; We provide free remote guidance, remote configuration and debugging services, and send data to the user's designated cloud platform. As an industrial expert inData Acquisition, Shucai IoT provides free consulting services forIoTsolutions.