Steady-Mix is the intelligent buffer tank filling for Gasyco gas mixers. It continuously adjusts the mixing output to your actual gas consumption. And the mixer stays ready for operation, even when the gas supply runs short.
Where conventional filling reaches its limits
The tank drops to the switch-on pressure, the mixer runs at a fixed output up to the switch-off pressure and stops. That means many starts, and every start is a settling phase in which the composition can fluctuate. The controllers often operate far from their ideal operating point, and the gas supply is loaded in bursts with high peaks.
The principle: mixing output follows demand
Steady-Mix recognises how much gas you really need and sets the mixing output so that the tank is filled slowly but surely. The mixer runs long and steadily, ideally continuously.
Fewer starts mean fewer settling phases – and therefore a more consistent mixture.
Mixing exactly as much as you need right now
- Consumption-led mixing output: Current consumption is estimated continuously and the mixing output follows it. If withdrawal rises, Steady-Mix follows; if it falls, Steady-Mix reduces the output.
- Gets to know your system: Steady-Mix approximates the actual volume of the buffer tank and connected pipework itself during operation. The tank size entered once serves as a starting aid and fallback value.
- Fast response to load peaks: If the tank pressure falls despite ongoing filling, Steady-Mix increases the mixing output immediately – targeted to actual demand rather than simply to maximum.
- Always within the control range: The limits follow automatically from the recipe and the controllers fitted. No controller is driven below its minimum controllable flow or above its maximum – mixing accuracy is maintained across the entire output range.
Staying ready for operation, even when the gas supply runs short
- Early warning: Steady-Mix monitors the supply pressure of every gas line involved. If the pressure reserve runs low, a warning appears. The mixer keeps running as long as it can hold the mixture reliably – and you know in good time that, for example, a cylinder bundle will soon need changing.
- Controlled stop instead of lockout: If the supply pressure is no longer sufficient, Steady-Mix ends the filling itself before a controller leaves its control range and an incorrect mixture can occur. No hard shutdown, no manual intervention on site. The message shows which gas line is affected.
- Standby mode: If the supply pressure is too low, the controllers receive no setpoint and no gas flows. The inlet valves open briefly at intervals to check the line pressure – the coils stay cool. When the pressure returns, for example after a bundle change, the mixer resumes operation by itself.
- Automatic restart: As soon as conditions are right again, filling restarts quite normally. An integrated restart lock prevents constant switching on and off at the limit.
Every state – normal operation, early warning, filling ended, standby, restart – is clearly shown on the operator panel. You can see at any time what the mixer is doing and why.
Your benefits
- More constant gas composition thanks to fewer start-ups
- Higher availability – no downtime requiring manual intervention when supply is short
- Fewer service call-outs – the mixer recovers by itself after a fault
- Less wear on controllers and valves thanks to fewer switching operations
- Relieved gas supply – even withdrawal instead of high peaks
- Simple commissioning – enter the tank size as a starting value, Steady-Mix learns the rest by itself
- Clear messages show what is going on and where
Technical data
| Feature | Version |
|---|---|
| Mixing output | automatic, consumption-led |
| Tank volume | approximated automatically incl. pipework, starting value on the operator panel |
| Switching pressures | adjustable on the operator panel |
| Supply pressure monitoring | per gas line |
| In case of undersupply | warning · controlled stop · standby · automatic restart |
| Redundant operation | supported |
| Availability | for new systems; retrofit as a software update for a one-off fee or as part of the Connect Plus subscription |
New or as a retrofit
Steady-Mix is available for new gas mixers. Existing gas mixers can be retrofitted via a software update for a one-off fee – or as part of the Connect Plus subscription. We would be happy to show you what Steady-Mix can do in your system: office@gasyco.com.
