Neuron II Manual
Index 1.0 2.0 3.0 4.0 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.4 4.4.1 4.4.2 4.4.3 4.5 5.0 5.1 5.2 6.0 7.0 8.0
Technical Features Controller terminal configuration Main Menu Screen Menu Structure View Operator Fault Report Day Report Service Time Cumulative Time VFD Operator Machine Schedule Maintenance Language Change Password Service Calibration Relay Change Password Maintenance Clock Self Test Change Password Factory menu Machine Change Password Integrator Dryer Customer care Data Interface Analog output DCS Port Construction & Dimension Drawing Controller Identification Revision Details APPENDIX A: Mimic LED Table APPENDIX B: Short Cut Key Functions APPENDIX C APPENDIX-D 21.0
23.0 24.0 25.0 26.0 26.0 26.1 26.1 26.2 26.2 26.3 26.3 26.4 26.5 26.7 26.7 26.8 26.8 26.9 26.9 26.10 26.10 26.10 26.11 26.11 26.11 26.12 26.13 26.14 26.14 26.14 27.0 27.0 27.0 28.0 29.0 29.0 30.0 31.0 32.0 33.0
21.1
Technical Features
8 no’s of Optically Isolated Digital Inputs of 24VDC 01 02 03 04 05 06 07 08
= = = = = = = =
Emergency Stop Differential Pressure Oil Filter - DPOF Reverse Rotation Differential Pressure Air Filter - DPAF Remote Start/Stop High Sump Pressure Cooler Main Motor Overload
8 no’s of Output Relay (SPDT 250V AC 10A, 1,00,000 cycle electric life) 01 02 03 04 05 06 07
= = = = = = =
08
=
Main contactor Star contactor Delta contactor Load Valve Fan Auto Drain Valve Dryer (if Dryer is Connected- else Programmable -Load, Service, Standby, Warn, Trip, Remote, Ready) Programmable [Load, Service, Standby, Warn, Trip, Remote, Ready]
22.0
Technical Features 4 no’s of Analog Input Channels 1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure 1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature 1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure 1 no of RTD (Pt-100) channel, -50 to +90 degree C for Drier Dew Point or Ambient Temperature 2 no’s of Analog Output Channels 1 to 5 VDC, One for Discharge Pressure and One Programmable (Sump Pressure, Discharge temp, Dew point/Ambient) 9 no’s of Function keys Up, Down, Left, Right, Enter, Escape, Start, Stop and Reset. 1 no of Display 128X64 White Backlight Graphical LCD 9 no’s of LED’s for Visualization Alarm & Machine Status Auto Air Filter Main Motor Overload Reverse Rotation Cooler Pressure Temperature Differential Pressure Oil Filter Differential Pressure Separator Element 1 no. of Dual LED for Start/Stop Indication Green for start and Red for stop 1 no. of Non – Volatile Memory For storage of 30 Day’s reports & 99 Fault Reports 1 no. of Real Time Clock With Battery life of about 10 years
22.1
Technical Features 4 no’s of Communication Port (RS485, 2 wire) Serial Port 1: MODBUS-RTU or SCADA Port Serial Port 2: Dedicated FPD Port (For future use) Serial Port 3: Add-On I/O Interface Port (expansion possibility) Serial Port 4: VFD Interface Port 1 no. of In System Programming (ISP) Port –For program / Data down loading and data uploading Power Supply Input: 24VAC +/- 25%, 50Hz / 60Hz, 1A (In built Protection present for Surge, Over Current)
22.2
Controller Terminals Configuration X01: Power supply Connector type: 3 pole combicon Pin 1 2 3
Function 24V AC Phase Earth 24V AC Neutral
Id 24 VAC P Earth 24 VAC N
Active state -
X02: Relays Connector type: 10 pole combicon Pin 1 2
Function Common - Load Relay Load Relay
Id Common L / UL
3 4 5 6 7 8 9 10
Common - Fan Relay Fan Relay Common - Auto Drain Valve Relay Auto Drain Valve Relay Common – Dryer Relay Dryer Relay/ programmable relay Common - Programmable Relay Programmable Relay
Common Fan Common ADV Common Dryer / Pr2 Common Pr1
Active state Load when Energised Energised Energised Energised Energised
X03: Main Motor Relays Connector type: 4 pole combicon Pin
Function
Id
Active state
1
Common for Main, Star and Delta contactors
Common
-
2
Main Contactor
Main
Energised
3
Star Contactor
Star
Energised
4
Delta Contactor
Delta
Energised
23.0
Controller Terminals Configuration X04: Digital Inputs Connector type: 11 pole combicon Pin 1 2 3 4 5 6
Function Digital Inputs Common – 24VDC Emergency Stop Differential Pressure Oil Filter Reverse Rotation Differential Pressure Air Filter Remote Start Stop Control
Id 24VDC Emergency DPOF Rev. Rot DPAF Remote
7 8 9 10
High Sump Pressure Cooler Fault Input Main Motor Overload 24V Supply Ground
HSP Cooler MMOL -24V DC
No Connection
voltage) -
11
Active state Fault if open Fault if open Fault if closed Fault if open Stop if open/ start on Closure Fault if open Fault if open Fault if open (provision for check DI -
X05: Analog Inputs Connector type: 8 pole combicon Pin 1 2 3 4 5 6 7 8
Function Discharge pressure 15 to 24VDC Discharge Temperature Discharge Temperature Sump Pressure 15 to 24VDC Dryer or Ambient temperature Dryer or Ambient temperature
23.1
Id Type Dis. Pr 4-20 ma 18V Dis. Tr + KTY10 Dis. Tr Sump Pr 4-20 ma 18V Pt100 + Pt100 Pt100 -
Range 0 to 16 bar 0 to 150°C 0 to 16 bar -50 to +90°C
Controller Terminals Configuration X06: Analog Outputs and VFD Connector type: 5 pole combicon Pin 1 2 3 4
Function VFD Interface VFD Interface Supply Ground For 5V Dis. Pressure Output
Id VFD A VFD B 0VDC AO1
Type Protocol/Range RS485A FC Protocol RS485 B Voltage(1-5V) 0 to 16 bar
5
Programmable Analog Output
AO2
Voltage (1-5V)
0 to 160C / 0 to 16 bar /65 to 95C
X07: Communication Connector type: 6 pole combicon Pin
Id
Type
Protocol/Range
DCS Interface-Modbus RTU
DCS A
RS485 A
Modbus-RTU
DCS Interface –Modbus RTU
DCS B
RS485 B
3
FPD Interface
FPD A
RS485 A
4
FPD Interface
FPD B
RS485 B
5
Add On Interface
Add-On A
RS485 A
6
Add On Interface
Add-On B
RS485 B
1 2
Function
23.2
ASCII Modbus
Main Menu Screen Dis. Pr Dis. Tr Message 1 Message 2 Warning HH:MM:SS 1
: :
6.0 bar 32°C
2 DD/MM
Message 1: Based on the short cut keys pressed (refer APPENDIX B) Message 2: Compressor Status or fault message 1 - Pressure schedule - If Blank → Pressure schedule is disabled - If “PS” → Pressure schedule is enabled - If “PS” blinking → Waiting for pressure schedule acknowledgement 2 - Control Mode (*/$) - *L → Local, ON/OFF control from local keypad - *R → Remote, ON/OFF control from remote input - *D → DCS, Control is from DCS System - $M → Manual, Start command given after power failure - $A → Auto, Compressor will automatically restart after power failure
24.0
Main Menu Screen Message 2 - Compressor Status or Fault message Status Ready Star Run Run load Run unload Stop busy Idle Emergency stop Start inhibit xx.x
Description Ready for start Motor running in Star Motor running in Delta Compressor in load Compressor in unload Stop sequence in progress When the controller is in idle, User interface will not function during this period for 5 seconds Emergency Stop Push Switch is ON During the start, if sump pressure is higher than the set sump pressure value for starting, this message is displayed XX.X denotes the live sump pressure value. The compressor starts only if the pump pressure value is below the set value.
Start inhibit “seconds”
If the sump pressure is not used (Disabled) then the controller will ensure a minimum of 60 seconds delay between the stop and the start. Count stops if “STOP” key is pressed
Auto restart “seconds”
If the compressor is in Auto Mode, the controller will ensure a minimum delay (user set, e.g. 90 sec) between the stop and the start operations. Count stops if “STOP” key is pressed This message is displayed when the compressor waits for user acknowledgement, after fault clearance. By pressing “START” key user can acknowledge
Start ack wait
24.1
Main Menu Screen Status Pr. Probe failure Tp. Probe failure Sump Pr. probe HSP (A)
HSP (D) Cooler Main motor Rev Rot / Ph fail Trip temperature Sump pressure not developing
Power failure Low voltage
Description Discharge pressure sensor probe failure Temperature sensor probe failure Sump pressure sensor probe failure Failure Case 1: Sump pressure is enabled when the sump pressure exceeds the set high sump pressure value. Case 2: Sump pressure is disabled when the discharge pressure exceeds the set high sump pressure value. HSP digital input opens due to high sump pressure Cooler digital input opens due to cooler fault MMOL digital input opens due to main motor overload overload. If the Rev Rot input closes, when the motor is running, due to motor reverse rotation or phase failure. Discharge temperature exceeds the set trip temperature value This function is displayed when the sump pr sensor is activated. After the Start, the sump pressure should be at least 1.0 bar in 10 seconds. If this is not achieved fault may occurs. Mains supply is interrupted for more than 30 msec Mains supply voltage is less than the 67% of rated voltage, compressor is tripped and the controller operation is stopped until the Mains supply returns to normal (at least 75% of the rated)
24.2
Menu Structure From the default screen, press shortcut keys to view the following (Refer Appendix B) S Set load, unload, start sump & maximum differential pressure values T Current day report W Warning messages (All warning messages can be viewed) X Current sump pressure, diff pressure & ambient temperature or dew point Press “Enter” Key to display main menu Main Menu Dis. Pr : 6.0 bar Dis. Tr : 32°C Status X View Operator Service Factory Customer Care Scroll up or down by using up and down keys to select the menu. Then press Enter to enter the selected menu.
View
Operator
Fault Report
Day Report
Service Time
Cumulative Time
VFD
4.1 View No password required. On view parameters, the preset parameters like mode, pressure values, temperature values, timer settings, DCS parameters, last 99 fault reports, last 30days report, remaining service hrs due, cumulative time details and VFD parameters can be viewed. The values cannot be altered through this menu.
25.0
Menu Structure 4.1.1 Operator LEVEL 1
LEVEL 2
View
Operator
LEVEL 3 Mode
Pressure
Delay
DCS port
Temperature
LEVEL 4 Control mode Unload mode Auto restart Pressure unit Temperature unit Unload pressure
Local / Remote / DCS Enable / Disable ON/ OFF PSI / Bar Fahren / Centi X X . X b or p (bar or psi) Load pressure X X . X b or p Pr. schedule ON/ OFF Start sump pressure X X . X b or p Max .diff pressure X X . X b or p Warn RST delay X X X s(second) Star delay XXs DTR delay XXs RTS delay XXs Standby time Sby X X m minute) St/Sp PH X X Type Modbus / SCADA Compr. ID XX Baud rate 9600/19200 Parity None / Even Length 8/7 Stop bit 2/1 Trip temperature X X X C or F Warn temperature X X X C or F Fan temperature X X X C or F Low dew Pt X X C or F High dew Pt X X C or F
4.1.2 Fault Report Use S ,T to select the Fault record number (1 to 99). LEVEL 1 View
LEVEL 2 Fault report
LEVEL 3 Fault code: XX, Message Time:
25.1
HH:MM:SS
Date:
DD/MM/YY
Dis.Pr:
X X .X
Dis.Tr:
XXX
Status:
Load/ UnLoad /OFF
Menu Structure Fault Code: 01 & 09 – Reserved 02-Main motor overload, 03-Cooler, 04-HSP(Analog), 05–Trip temperature, 06Reverse rotation, 07-Pressure probe failure, 08-Temperature probe failure, 0A-HSP(Digital), 0B-Power failure( Short Power Interrupt), 0CSump pressure not developing , 0D-Sump pressure probe failure. On the fault report, parameters such as line pressure, discharge temperature and status of compressor will be displayed. This will help to troubleshoot the failure. 4.1.3 Day Report Use S ,T to select the Record number (1 to 30). LEVEL 1
LEVEL 2
View
LEVEL 3
Day report
Date:
DD/MM/YY
L:
X X Hours
St:
X X Hours
UL:
X X Hours
F:
X X Hours
R:
X X Hours
Sby:
X X Hours
STC: X X X
LDC: X X X X X
L- Load, St – Stop, UL – Unload, F- Fault, R- Run, Sby- Standby, STC – Start Count, LDC Load Count On the fault report, parameters such as line pressure, discharge temperature and status of compressor will be displayed. This will help to troubleshoot the failure.
4.1.4 Service Time LEVEL 1
LEVEL 2
View
Service time
LEVEL 3 Remaining AFCT:
X X X X X X hours
Remaining OFCT:
X X X X X X hours
Remaining OSCT:
X X X X X X hours
Remaining OCT:
X X X X X X hours
Remaining RGT:
X X X X X X hours
The remaining service hours for the consumable parts can be viewed and the service due is completed. The countdown then will be shown in negative (- hrs).
25.2
Menu Structure 4.1.5 Cumulative Time LEVEL 1 View
LEVEL 2 Cumulative time
LEVEL 3 Load
X X X X X X hrs: X X Min
Unload
X X X X X X hrs: X X Min
Run
X X X X X X hrs: X X Min
Stop
X X X X X X hrs: X X Min
Fault
X X X X X X hrs: X X Min
Standby
X X X X X X hrs: X X Min
Start Count
XXXXXX
Load Count
XXXXXXXXX
Utilisation
XX%
On this menu, the cumulative hours including number of start/stops, number of load/unloads and percentage of utilization can be viewed. With this Cumulative Time feature, the Emergency stop hours will be accounted in stop hours, and not under fault hours. This enables the user to view the real fault hours. These details will further guide for energy savings in compressed air. 4.1.6 VFD When the VFD is connected to the compressor, user can view the following parameters of VFD on Neuron II. 1. Voltage in V 2. Current in A 3. Frequency in Hz 4. Power in KW 5. Run Hours 6. Kilowatt Hour (Multiply the value shown by 100 to get the real KWH) 7. Status of the VFD
25.3
Menu Structure 4.2 Operator Password protected. The operator has to receive the password from the compressor commissioning engineer Operator
Machine
Mode
Schedule
Pressure
Maintenance
Set Delay
DCS Port
Language
Auto Drain Valve
Change Password
Set Dew Point
With this menu, the operator parameters can be adjusted to match the requirement. Minimum and maximum limits are fixed for all the value adjustment parameters. When the setting exceeds these values, there will be an indication of ‘out of range’.
25.4
Menu Structure 4.2.1 Machine # 1 2 3 4 5 6
Item Auto restart Pr unit Tr unit Control mode Unload mode Analog output 2
7 Unload pressure +0.5 (bar) 8 Load pressure
Min -
Max Option on / off bar / psi cen / fah loc/rem/dcs en/dis Tmp / Sp / Pt / off off Pressure > load < max pressure unload pressure according (bar) to pr model) 4.0 (bar) < unload pressure0.5 (bar) according to pr
Default off bar cen loc dis
Unit -
7.5 bar (Varied
bar/psi
5.5 bar (Varied
bar/psi
model) 9 10 11 12 13 14
Warn RST Star DTR RTS Standby St/Sp per hr
15
Type
16 17 18 19 20
ID Baud rate Parity Length Stop bit
21 22
Off time On time
23 24
Low dew point High dew point
90 6 10 5 1 3 -
Set Delay 300 10 60 30 99 10 DCS Port -
-
90 6 10 5 5 5
second second second second minute -
Modbus / modbus SCADA 01 99 01 9600/19200 9600 bps None /Even None 8/7 8 2/1 2 Auto Drain Valve 1 150 4 minute 1 15 5 Second Set Dew Point -6 C +2 C -2 C C/F 6C 12 C 8C C/F 25.5
Menu Structure Important Function Keys: Auto restart ON: Switches On the compressor automatically after a power failure. The internal timer counts the power Off period and the period when power resumes. The compressor starts after elapsing the set time by this function, ensuring the compressor availability immediately after a power failure. On the screen A will be displayed and the Auto lamp is On, indicating that the compressor can be automatically started. If it doesn’t, M (manual) will be displayed. This mode indicates that a manual start is required after power failure. Local: The compressor is switched On/ Off through the start and stop buttons in the controller. Remote: The compressor is switched On/Off only through Digital input (Remote), and cannot be operated through the controller push buttons. DCS : The compressor is operated only through modbus. In Remote and DCS modes, the compressor can be stopped through the Emergency stop. The Auto LED will glow, in both these modes, indicating that the compressor can be automatically started. Unload mode: This key verifies the functions of the compressor with out loading. If this mode is selected, the relay out put (load / unload) will be de energized. During this mode, the compressor runs continuously in Unload mode. If the function is disabled, then the compressor operates as per the pressure set in the controller. Load pressure & unload pressure: The user can adjust these values within the limits of the factory. The value is set at a minimum load pressure of 4 bar. The maximum unload pressure is set as per the indication on the compressor name plate. The minimum differential is 0.5 bar.
25.6
Menu Structure 4.2.2 Schedule Enable Pressure Schedule, and use ²%, ¼% to select the schedule number (1 to 32). Then Press “Enter” to set the following # 1
Item Day
2 3 4 5
Action Time HH Time MM Unload Pressure
6
Min -
Max -
00 23 00 59 > Load < Max Pressure Unload +0.5 Pressure (bar) (bar) Load Pressure 4.0 bar < Unload Pressure – 0.5 (bar)
Option
Default Unit Sun to Sat / -- (means no schedule) on / off ——Hour —Minute bar/psi
-
—-
bar/psi
Once the pressure scheduler is selected, PS blinks on the screen. To acknowledge this, press “START” button. When pressed, the compressor starts and stops as per the pressure scheduler. The start / stop keys are not activated in this mode, after the user acknowledges it. The controller is designed to accommodate changes in the schedule in between periods. It avoids the necessity of marking changes in schedules in an order. For example, consider the two periods: Monday schedule (1-4) and Tuesday schedule (5-8). If the user wants to make changes to the Monday schedule, he can enter the changes in the 9 schedule (that follows after the Tuesday schedule). 4.2.3 Maintenance #
Item
1
AF changed
Min
Max
Option
Default
Unit
-
-
no/yes
no
-
2
OF changed
-
-
no/yes
no
-
3
OS changed
-
-
no/yes
no
-
4
Oil changed
-
-
no/yes
no
-
5
Re Grease
-
-
no/yes
no
-
Once the consumable part is replaced, enter in to the maintenance menu. Type the changed part as Yes. Set the remaining service hours as per the 100% service hours.
25.7
Menu Structure 4.2.4 Language # 1 2 3
Item English Hindi Portuguese
The user language can be selected, Default is in English. 4.2.5 Change Password Procedure for changing the password 1. 2.
Enter the old password If old password is correct, next screen is displayed. If wrong, the control comes out of the ‘change password’ screen 3. When the ‘next’ screen is displayed, enter the new password 4. Re-enter new password 5. If new password matches both the entries, the password will be updated. If mismatch occurs, the control goes back to step 3. Pressing Esc will bring the control back to the main menu screen
25.8
Menu Structure 4.3 Service Password protected. Only Elgi Service engineers are authorized to change the menu. Service
Calibration
Relay
Fan Temp
Maintenance
Clock
Self Test
4.3.1 Calibration Select the parameter needed for calibration using the ²%, ¼%keys. Then Press “Enter” to calibrate. Discharge Pressure/ Discharge Temperature/ Sump Pressure Calibration Run the compressor. Measure the value using a standard and recently calibrated meter, when the value is stable. Enter the meter reading in the set value field displayed on the Neuron II. Set Value should not exceed +/- 1 bar and +/- 10 C the actual value. Pt 100 Calibration Measure the value using a standard and recently calibrated meter, when the dew point/ ambient temperature is stable. Enter the meter reading in the set value field displayed on the Neuron II. Set Value should not exceed +/- 3 C the actual value. Note: Calibration should be done when the compressor is switched Off , and ensure the digital outputs (relay terminals) are disconnected from the controller. Calibration for pressure should be done for the pressure sensor at 8 bar (in bar only), and at 100 Deg C (in Centigrade only). (3.3k resistor=100Deg C) Analog Output 1 & 2 Calibration for analog output is done for two values: one at zero and the other at 8.0 bar / 80 degree C. These values are set by connecting a Variable Resistor (TRIM POT) to the analog input channel. Measure the analog output value (can be viewed in the DCS/VFD / or any master unit where this output is connected). Enter this value in “set pressure:”
25.9
,
Menu Structure 4.3.2 Relay Select the Programmable Relay 1 or 2 using the S,Tkeys. Then Press “Enter” to assign any of the following functions for the relay. # 1 2 3 4 5 6 7
Item Warn Load Service Standby Trip Remote Ready
Default: Relay 1 = Warn Relay 2 = Trip Note: If Dryer is enabled, the Programmable Relay 2 is not user programmable. It is used for automatic dryer control.
4.3.3 Change Password The fan temperature set point is used to start the fan when set temperature is reached. Stop the fan when the temperature reaches 10 Deg C or lesser than the set temperature. This setting is used to control On / Off settings of the fan, based on the discharge oil temperature. #
Item
Min
Max
Option
Default
Unit
1
Fan temperature
60 C
85 C
-
85 C
C/F
Max
Option
Default
4.3.4 Maintenance #
Item
Min
Unit
1
Set AFCT
000000
999999
-
001500H
Hour
2
Set OFCT
000000
999999
-
001000H
Hour
3
Set OSCT
000000
999999
-
004000H
Hour
4
Set OCT
000000
999999
-
001000H
Hour
5
Set RGT
000000
999999
-
001500H
Hour
The maintenance due is fixed by Elgi Service Engineer based on the spare parts used.
25.10
Menu Structure 4.3.5 Clock #
Item
Min
Max
1
Hour
00
23
2
Minute
00
59
3
Second
00
59
4
Date
01
31
5
Month
01
12
6
Year
00
99
7
Day
Sun/Mon/Tue/Wed/Thu/Fri/Sat
The clock setting of the controller is not changed, if used in India. When used overseas, the time is set according to the local timings, at the time of commissioning 4.3.6 Self Test Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output, Memory & Communication Ports working. Follow the instructions displayed on the screen.
Warning Self-Test should be conducted only after disconnecting the compressor from the controller. (Use connect power supply X01 3 pin connector) DO NOT perform self-test when the controller is connected to the compressor. Doing so will cause severe damage to the compressor. 4.3.7 Change Password 1.
Enter the old password
1. 2.
Enter the old password If old password is correct, next screen is displayed. If wrong, the control comes out of the ‘change password’ screen When the ‘next’ screen is displayed, enter the new password Re-enter new password If new password matches both the entries, the password will be updated. If mismatch occurs, the control goes back to step 3. Pressing Esc will bring the control back to the main menu screen
3. 4. 5.
25.11
Menu Structure 4.4 Factory menu Password protected. Only Elgi authorized persons are allowed to change the setting.
Factory
Change Password
Machine
Compressor Info
DPAF
DPOF
Dryer
Max. Pressure Settings
25.12
Temperature Settings
Menu Structure 4.4.1 Machine #
Item
Min
Max
1
Rating
-
-
2
Pressure
-
-
3
Fab no (10 digit)
Alpha:A num:0
Alpha:Z num:9
4
DPAF
-
-
5
DPOF
6
Max UL Pressure
> Unload <13.5bar Pressure
7
High sump pressure
> Max < Max Unload Unload pressure pressure +0.5 +3
8
Sump pressure
9
Option
Default
Unit
11 to 315
22
KW
LP/ 7.0to12.5
LP
bar
-
AAAA 000000
-
on/off
off
-
on/off Max. Pressure Settings
off
-
-
7.5 bar
bar /psi
-
10.5 bar
bar /psi
-
-
enable/ disable
disable
-
Start sump pressure
0.0 bar
16.0 bar
-
1.0 bar
bar /psi
10 Max. differential pressure
0.0 bar
2.0 bar
-
1.5 bar
bar /psi
Temperature Settings 11 Trip temperature
80 C
120 C
-
110 C
C/F
12 Warn temperature
70 C
110 C
-
105 C
C/F
If the sump pressure sensor is enabled, the Star sump pressure and the maximum differential pressure values will function. In this mode, the high sump pressure is activated based on the sump pressure in the Air oil sump.
25.13
Menu Structure 4.4.2 Change Password 1. Enter the old password 2. If old password is correct, next screen is displayed. If wrong, the control comes out of the ‘change password’ screen 3. When the ‘next’ screen is displayed, enter the new password 4. Re-enter new password 5. If new password matches both the entries, the password will be updated. If mismatch occurs, the control goes back to step 3. Pressing Esc will bring the control back to the main menu screen 4.4.3 Dryer #
Item
Min
Max
Option
Default
Unit
1
Dryer mode
-
-
on/off
off
-
2
Dryer Delay
2
10
-
3
Minute
This mode is enabled, if dryer is part of the compressor. The dryer is switched on and off through the controller, provided the compressor is switched On. When the compressor is On, dryer is switched On; and the dryer is switched Off when the compressor is on Off mode. The time interval between the stop and start operations is decided by dryer delay time setting, which enables the safe operation of dryer and compressor. 4.5 Customer Care Dis. Pr
:
6.0 bar
Dis. Tr
:
32 C
o
Status Toll Free No 1800-425-3544 e-mail
[email protected]
25.14
Data Interface Neuron II has two types of Data Interface N
Analog output
N
DCS Port
5.1 Analog output Two channels are available for analog output. The first channel will output the current discharge pressure value from 0.0 -16.0 bar, converted from 1 - 5V. The Second channel is programmable. User can select any one of the following menu: “Operator/ Machine/ Mode/ Analog output” a. Dis. Temperature
0 -160 C, converted from 1 - 5V
b. Sump Pressure
0 - 16.0 bar, converted from 1 - 5V
c. Pt100 Temperature
-65 - 95 C, converted from 1 - 5V
Note: Analog output will be 0V, in case of probe failure. 5.2 DCS Port DCS port can be of Modbus RTU type to interface to Generic DCS system or SCADA type to interface to ELGI SCADA software. User can select the Port type in menu “Operator/ Machine/ DCS Port”. The ID, Baud Rate, Parity, data Length, Stop Bit are also user settable. The Modbus data table will be provided based on the request (A CD contains address table and activation key)
26.0
Construction N
Corrosion & dust protected back cover
N
IP65 polyethylene front keypad
N
Inputs and outputs through terminal block, board to wires, disconnect able, screw terminals
N
Front plate dimensions 260 x 145mm
N
Enclosure dimensions 235 X 120 X 70 mm
N
Operating temperature - 0ºC to +75ºC
N
Relative humidity <85% RH non-condensing @ 40ºC
6.1 Dimension Drawing
Panel Front Plate
260 100
145
133
Panel Cut out Dimension 70
235
X01
X05
X07 ISP
X03
All dimensions are in mm 27.0
X02
120
120
X04
X06
Controller Identification While Communicating to Elgi, please mention the following: Type of controller SL no Batch NO
Revision Details Version
Date
Changes
1.0
2 April 2009
Initial Draft
1.1
13 July 2009
Pilot Batch S/W Version 1.1
1.2
01.02.2010
Pilot batch SW version 1.1D
For any other clarification in the controller please contact ELGI
Toll Free No : 1800-425-3544 e-mail
[email protected]
28.0
Appendix A Mimic Led Table # 1
LED Auto
2
Air Filter
3
Main Motor Overload
4
Reverse Rotation
5
Cooler fault
6
Pressure
7
Temperature
8
Differential Pressure
9
Differential Pressure
10
Start & Stop
Description Indicates the machine is in Automatic on/off mode. LED glows in Amber Colour when 1. Pressure Schedule is enabled (or) Auto Restart is enabled Glows in Amber colour when 1. Air Filter Service is due based on service hours2. Air Filter Digital Input (DPAF) is Open & DPAF is enabled Glows in Red when the Main Motor Overload Digital Input is Open. Glows in Red when the Reverse Rotation Digital Input is Closed Glows in Red when the cooler Digital Input is Open Glows in Red when 1. HSP Digital Input is Open 2. Analog Pressure Input is Open (Probe Failure) Dis. Pressure is higher than set HSP Glows in Red when 1. Analog Temperature Input is Open (Probe Failure) 2. Dis. Temperature is higher than set Trip temp. Glows in Amber when 1. DPOF Digital Input is Open & DPOF is enabled Oil Filter Service is due Glows in Amber when 1. Oil Separator Filter Service is due 2. On High Differential Pressure (Only if Sump Pressure enabled) 1. Glows in Red when machine is stopped / idle 2. Glows in Green when machine is running
29.0
Appendix B APPENDIX B: Short Cut Key Functions Note1: All shortcut key functions only when the display is on Main Screen. Note2: On every press of the key NEXT message is displayed. W“LEFT” – Warning messages Warning DPAF
Description Differential Pressure Air Filter Due For Service DPOF Differential Pressure Oil Filter Due For Service Dryer Probe Failure Pt100 Sensor Probe Failure Low Dew Point Live Dew Point less than the Set Low Dew Point High Dew Point Live Dew Point greater than the Set High Dew Point High Differential pressure Difference Between the Sump & Discharge Pressure is greater than the set max Differential Pressure value. Warn Temperature Discharge Temperature exceeds the set Warn value Change Air Filter Air Filter Due For Service Change Oil Filter Oil Filter Due For Service Change Oil Separator Oil Separator Due For Service Change Oil Oil Change Due For Service Change Grease Re Grease Due For Service Start Stop Exceeded No. of Start and Stop per hour exceeded
30.0
Appendix B X“RIGHT” - Live analog values 1. Live differential pressure 2. Live sump pressure 3. Live Pt100 temperature S “UP” – Set analog values 1. Set load pressure 2. Set unload pressure 3. Set start sump pressure 4. Max differential pressure
d“DOWN” – Today report 1. 2. 3. 4. 5.
Date Load and stop hours Unload and fault hours Run and standby hours Start count and load count
30.1
Appendix C APPENDIX C: Modbus Table [Function Code: 0x03(Read) & 0x10(Write)] #
Data Description
Address
Type Bytes
Example/ Format
Access
Cumulative Time & Count Registers 1
Load Hours
1010
BCD
4
HHHHHH:MM
R
2
Unload Hours
1012
BCD
4
HHHHHH:MM
R
3
Run Hours
1014
BCD
4
HHHHHH:MM
R
4
Stop Hours
1016
BCD
4
HHHHHH:MM
R
5
Fault Hours
1018
BCD
4
HHHHHH:MM
R
6
Standby Hours
101A
BCD
4
HHHHHH:MM
R
7
No of Start
101C
BCD
4
NNNNNNNN
R
8
Load Count
101E
BCD
6
NNNNNNNNNNNN
R
9
Utilization %
1022
BCD
2
10
Rem AFCT Minutes
11
Rem OFCT Minutes
XXXX
R
Service Remaining Time Registers 1029
ULong
4
H800927BF = -599999
R
102C
ULong
4
H800927BF = -599999
R
12
Rem OSCT Minutes
102F
ULong
4
H800927BF = -599999
R
13
Rem OCT Minutes
1032
ULong
4
H800927BF = -599999
R
14
Rem RGT Minutes
1035
ULong
4
H800927BF = -599999
R
Mode Registers
15 Control Mode
16 Unload Mode 17 Auto Restart
1040
1041 1042
18 Pr Unit
1043
31.0
BCD
BCD BCD BCD
2
2 2 2
0001-DCS 0002-Local 0003-Remote
R/W
0001-Disabled 0002-Enabled
R/W
0001-OFF 0002-ON
R/W
0001-BAR 0002-PSI
R/W
Appendix C
#
Data Description
19 Tr unit 20 Pr. Schdl (on/off)
Address
1044 1045
Type Bytes
BCD BCD
2 2
Example/ Format
Access
0001-Centi 0002-Farhen
R/W
0001-OFF 0002-ON
R
1200 (/100) = 12.0 bar
R
1100 (/10) = 110 C
R
MSB 01 = + MSB 02 = LSB = 30
R
1200 (/100) = 12.0 bar
R
0100 (/100) =1.0 bar
R
0120 (/10) = 12.0 bar
R/W
0080 (/10) = 8.0 bar
R/W
Analog Registers
27 Dis. Pressure 28 Dis. Temperature 29 Dew Point / Ambient Temperature
30 Sump Pressure 31 Diff Pressure
104A 104B
104C
104D 104E
BCD BCD
BCD
BCD BCD
2
2
2 2
32 Set Unload Pressure
104F
33 Set Load Pressure
1050
34 Set Diff Pressure
1051
BCD
2
0010 (/10) = 1.0 bar
R/W
35 Trip Temp
1052
BCD
2
0110 = 110 C
R
36 Warn Temp
1053
BCD
2
0105 = 105 C
R/W
37 Low Dew Point
1054
BCD
2
MSB 01 = + MSB 02 = LSB = 30
R/W
MSB 01 = + MSB 02 = LSB = 30
R/W
0070 = 70 C
R/W
38 High Dew Point
39 Fan Temp
1055
1056
BCD
2
BCD
BCD
BCD
2 2
2
2
31.1
Appendix C #
Data Description
Address
Type Bytes
Example/ Format
Access
21 Auto Restart Delay (Sec)
1060
BCD
2
0100
R/W
22 Star Delay (Sec)
1061
BCD
2
0005
R/W
23 DTR Delay (Sec)
1062
BCD
2
0010
R/W
24 RTS Delay (Sec)
1063
BCD
2
0010
R/W
25 Standby Time (Min)
1064
BCD
2
0005
R/W
26 Max. No of Start per hour
1065
BCD
2
0005
R/W
RTC Registers
40 Hour
106A
BCD
2
0023
R
41 Minutes
106B
BCD
2
0059
R
42 Seconds
106C
BCD
2
0059
R
43 Date
106D
BCD
2
0031
R
44 Month
106E
BCD
2
0012
R
45 Year
106F
BCD
2
0009
R
46 Day
1070
BCD
2
0001Sunday -1
R
Status Registers
47 General Status
1071
UInt
2
Refer table
R
48 Warning Status
1072
UInt
2
Refer table
R
49 Fault Status
1073
UInt
2
Refer table
R
31.2
Appendix C Function Code: 0x01(Read Coil) & 0x05(Write Coil) 0x01 Read Coil (Start / Stop) Frame Type
ID
Function Address Code
Request
XX
01
Response
XX
01
Quantity of coils
Data
2000
0001
—
—
Byte count: 01
ON Æ 0x01 OFF Æ0x00
Quantity of coils
Data
0x05 Write Coil (Start / Stop) Frame Type
ID
Function Address Code
Request
XX
01
2000
0xFF00 Æ Start 0x0000 Æ Stop
Response
XX
01
2000
0xFF00 Æ Start 0x0000 Æ Stop
31.3
Appendix C Note: Function Code 0x10 (Write), 0x05 (Start/Stop) and 0x01 (read Start/Stop) will function only if “Control Mode” is set to “DCS”. Refer: Operator/Machine/ Mode (Chapter 5.2.1) On improper master request, any one of the following exception response is sent Code 01: Illegal function Code 02: Illegal data address Code 03: Illegal data value Status Register Bit Definition:
Bit Position
General
Warning
Fault
0
Ready
DPAF
HSP
1
Star
DPOF
Cooler
2
Run
Dryer probe failure
Main motor overload
3
Run load
Low dew point
Reverse rotation
4
Run unload
High dew point
Pressure probe failure
5
Stop busy
High differential pressure
Temperature probe Failure
6
Idle
Warn temperature
Trip temperature
7
Emergency stop
Change air filter
Sump pressure not developing
8
Start inhibit filter
Change oil
Sump pressure probe failure
9
Start ack wait
Change oil separator
Power failure
10
Standby
Change oil
Reserved
11
Reserved
Change grease
Reserved
12
Reserved
Reserved
Reserved
13
Reserved
Reserved
Reserved
14
Reserved
Reserved
Reserved
15
Reserved
Reserved
Reserved
31.4
Appendix D Appendix-D Flow charts (Start, Stop, Load /unload /standby sequence) Start Sequence: Start Sequence
STAR ON
Delay for 100msecs (Fixed)
MAIN
‘ON’
NO. OF. START INCREMENT
STAR TO DELTA delay ‘x’ sec (Star delay)
STAR OFF
DELTA ON
Delta to run delay ‘x’ sec (DTR)
Return
32.0
Appendix D Stop Sequence: Stop
Is STAR ON?
Yes
No
Is MAIN ON?
No
Return
Yes
LOAD “OFF”
(RTS delay) Run to stop ‘x’ sec
DELTA & MAIN OFF
“IDLE” delay for 5 secs Fixed delay
READY
32.1
Appendix D RUN LOAD/UNLOAD/STANDBY
Is Delta ON?
Return NO
Yes
Is DIS Pr < Load pr
NO
Is DIS pr. >UL pr
No Return
Yes
Yes Load ‘ON’
Load ‘OFF’
Increment Load Count
Standby mode: In unload mode, if the pressure exceeds the set load pressure in the preset standby time, and is less than number of start/stop cycles during that time, the compressor goes into the standby mode ( or the compressor stops as per the stop sequence). In standby mode, if the pressure drops below the set load pressure, the compressor starts automatically as per the start sequence.
32.2