Diesel Air Compressor Controllers: Can they reduce your fuel costs?

The smarter you work, the more efficient you are. Same is true with our compressors; they’re more efficient and they’re smarter than most.

So, how does this intelligence translate into making you more efficient? Atlas Copco Intelligent controls enable you set pressure, check diagnostics and receive a notification when your compressor feels it needs some TLC, i.e., maintenance. Our compressor controllers are intuitive, intelligent, and IP 65 rated for dust and water resistance. In short, they’re built to reliably perform in even the harshest, toughest application conditions.

Fuel isn’t cheap. This is probably no late-breaking news flash, but 80% of your cost of ownership comes from fueling your air compressor. Imagine if your compressor was smart enough to know when to sip and when to guzzle; adding compressor fuel savings. Our digital controls can match engine speed to demand, drastically improving the machine’s fuel economy. Our most advanced controllers, running on our largest machines, have other built-in technology such as ECO-mode.

You don’t pay workers to lean on shovels. Why would you let your compressor suck up expensive fuel while it’s just sitting there, idle? Diesel compressors spend a lot of time “shovel leaning.” As a result, when in idling mode – during drill rod refills, while being transported, or simply while your crew is taking a lunch break – the compressor’s engine is still running, driving an element that works hard to keep the pressure up.

Thanks to ECO-mode, available on both our Xc2003 and Xc4004 controllers, Atlas Copco’s compressors switch from unload, the idling status, to no-load. During this no-load time, the compressor consumes 50% less fuel. When you’re ready to go back to work, the Atlas Copco air compressor is also ready. An air discharge pressure sensor detects the application’s air demand and the controller automatically triggers a re-load. We know that not only is fuel costly, but so is downtime. Thanks to the controller’s auto detection feature, the machine is always ready to go back to work as soon as you are.

You can customize ECO-mode’s parameters to meet each application’s needs. For instance, you can set the time after which ECO-mode takes over, set the minimum pressure, and using the compressor “auto stop” function, set the time period after which you want the compressor to shut down automatically. If you want a completely automated system, you can also activate the compressor “auto start” setting. This function starts your compressor automatically again if the pressure drops below a preset level. 

Another feature of the Xc2003 controller is our Pressure Adjusted through Cognitive Electronics or PACE technology. This electronic pressure regulation system enables you to define the pressure in the controller while the compressor regulates the flow. We talked earlier about bringing efficiencies to your application. Thanks to PACE and the ability to run one compressor at different pressure settings, just one machine can handle the job of three fixed-pressure machines, helping you tackle various applications at the same time.

For example, do you ever need to operate handheld air tools on a project? Set the machine to 7 bar. Tackling a shotcrete application an hour later? Switch to 12 bar, connect your tool, and away you go. Setting the pressure can be accomplished in just a few seconds with just three clicks. Presets can be saved for fast toggling, and the intuitive controller lets you set any pressure level within the pressure band of the machine, adjustable with increments of 0.1 bar.

Managing fleet locations and applications can be a time-consuming endeavor. The more time you spend and miles you drive, the less profitable your projects become. With FleetLink, our telematics monitoring system, you have the power to complete more jobs in fewer hours and with less time on the road.

What is telematics? Put simply, telematics is the joining of two sciences; one, telecommunications, a branch of technology including phone lines and cables, and two, informatics, such as computer systems. For compressed air, it's a control system for reporting usage and machine functions.

Through FleetLink, which is a standard feature on most of our air compressors, you can monitor your fleet remotely. You’ll have access to real-time performance insights, as well as the ability to send messages to your fleet and re-route your equipment quickly and easily when needed. The telematics system allows for geo-fencing, digitalizing the performance of your compressors, and more. In short, FleetLink provides you with up-to-date information on your fleet, wherever you are and whenever you need it.

Of course, it all comes back to efficiency. Real-time, FleetLink insights provide you with the information you need to make better, more informed decisions by maximizing operating times, minimizing downtime and optimizing the productivity of your fleet. 

Running the wrong compressors on a project can have a significantly negative impact on your profitability. Without an intelligent controller, it’s nearly impossible to maximize your compressor operating efficiencies and with those efficiencies, your profitability.

The last thing any business needs are out-of-control costs.  An Atlas Copco compressor with Intelligent Controls puts you in control; not just control of the compressor itself, but of your investment costs, utilization rate and ultimately, return on investment.  Looking for an air compressor with the intelligence to give you greater control over both the machine and your business? Look no further than Atlas Copco.