Introduction
Thermal Energy Recovery From Industrial Compressors needs a strong controller. The Moduline IV delivers stable, safe and efficient control in demanding industrial sites.
Smarter heat recovery with modular control
Thermal Energy Recovery From Industrial Compressors helps companies save energy by using compressor waste heat. This waste heat is often large and steady, so capturing it can support hot-water systems, heating loops or process heat. Because these systems run every day, the controller must be reliable and flexible.
The GOcontroll Moduline IV fits this task very well. It offers a strong aluminium housing, broad IO options and a fast processor for real-time control. With its modular design, the controller supports a wide range of sensors, valves and pumps inside heat-recovery units. Additionally, its rugged form ensures long service life even when installed close to hot pipes and vibrating machines.
Why the Moduline IV suits compressor heat recovery
Industrial compressor rooms are hot, dusty and full of vibration. The Moduline IV was built for such harsh environments. Its CNC-milled EN-AW5083 aluminium enclosure protects the electronics from shocks and from outside damage. The controller also uses a pressure-vent plug that lowers the risk of condensation inside the unit, which is helpful in humid compressor rooms.
Additionally, it works from −20 to 85 °C, so it handles heat from compressors and heat-exchanger pipes without trouble. Because supply voltages in industrial buildings can vary, the Moduline IV accepts 8–32 VDC input and includes load-dump protection designed according to ISO 7637-2. As a result, it stays stable even when powered by shared industrial lines.
Flexible IO for pumps, valves and sensors
Thermal Energy Recovery From Industrial Compressors needs many signals. Common elements include temperature sensors on oil circuits, pressure sensors on heat exchangers, flow sensors on water loops and digital alarms from the compressor.
The Moduline IV supports up to eight Moduline IO modules. These modules allow you to mix inputs and outputs based on system needs.
For example:
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Temperature and pressure sensors can connect to analog inputs.
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Flow meters can connect through frequency inputs.
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Pumps and valves can be switched or modulated using output modules.
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Safety loops can be read via digital inputs.
All modules use automotive-grade SUPERSEAL connectors for a secure and sealed fit, which helps in dusty mechanical rooms. This modular approach makes it easy to change or expand the control system later.
Real-time logic with Simulink and Node-RED
Stable heat recovery depends on quick control decisions. The Moduline IV uses an NXP i.MX 8M Mini processor with four Cortex-A53 cores running at 1.6 GHz. Because of this, it can run real-time models from MATLAB Simulink. Engineers can design logic for pump speed control, valve switching or heat-exchanger monitoring without writing low-level code.
Node-RED comes preinstalled. It is a simple way to build dashboards, local HMIs or data pipelines. You can show system temperatures, flow levels or compressor conditions on a small screen or remote device. This makes troubleshooting easier for service staff, especially in busy compressor rooms where quick checks are needed.
Strong communication for industrial sites
Industrial sites often use several communication systems. The Moduline IV supports this with:
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4 CAN 2.0B interfaces
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1 LIN interface
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Ethernet (10/100 Mbps)
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USB for local connections
Optional wireless features such as Wi-Fi, Bluetooth, cellular and GNSS expand the setup when remote access is needed. GOcontroll’s remote services include secure cloud communication, software updates, controller state monitoring and predictive maintenance support. These options help plant operators keep track of heat-recovery performance and prevent downtime.
Example workflow for compressor heat-recovery control
Below is a simple workflow for using the Moduline IV in a Thermal Energy Recovery From Industrial Compressors setup:
Sensor reading
Temperature, flow and pressure sensors send signals to the input modules. The controller reads them at a steady rate.
Control logic
A Simulink model calculates heat input, flow demand and target temperature. It then adjusts pumps or valves to match system needs.
Safety handling
The controller checks pressure limits, flow status and compressor alarms. If something goes wrong, it shuts down parts of the process.
Monitoring
Node-RED shows the system state on a local dashboard. Operators can see compressor heat, water temperature and pump activity.
Remote support
When wireless options are installed, the controller sends logs to the cloud. This helps teams track long-term energy savings.
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