NEURON II

User Manual

Version 1.1 13 July 2009

INDEX #
1.0 2.0 3.0 4.0 5.0

Chapter
Salient Features Technical Features Input Output Description Main Screen Menu Structure 5.1 View 5.1.1Operator 5.1.2 Fault Report 5.1.3 Day Report 5.1.4 Service Time 5.1.5 Cumulative Time 5.1.6 VFD 5.2 Operator 5.2.1 Machine 5.2.2 Schedule 5.2.3 Maintenance 5.2.4 Language 5.2.5 Change Password 5.3 Service 5.3.1 Calibration 5.3.2 Relay 5.3.3 Change Password 5.3.4 Maintenance 5.3.5 Clock 5.3.6 Self Test 5.4 Factory menu 5.4.1 Machine 5.4.2 Change Password 5.4.3 Integrator Dryer 5.5 Customer care Controls 6.1 Start Sequence 6.2 Stop Sequence 6.3 Fan Control 6.4 ADV control 6.5 Dryer Control Data Interface 7.1 Analog output 7.2 DCS Port Construction & Dimension Drawing Revision Details Appendix APPENDIX A: MODBUS Table APPENDIX B: Mimic LED Table APPENDIX C: Short Cut Key Functions

Page
1 3 4 6 8 8 9 10 10 10 11 11 11 12 13 13 13 14 14 15 15 16 16 16 17 17 18 19 19 19 20 20 22 23 24 24 25 25 25 26 27 28 28 32 33

6.0

7.0

8.0 9.0 10.0

1.0 Salient features

Saves Money
The Smart Logic of NEURON II automatically decides the start delay required to ensure minimum wait time between successive starts of the compressor and dryer thereby increasing their lifetime. Start Inhibit till sump pressure is within safe limits to enhance the life of the compressor Low Voltage & Short time Power Interrupts detection to enhance the life of the contactors Automatic Display Back-light Control to increase the Display Lifetime Data validation of critical parameters for protecting the compressor from improper usage.

Saves Energy
Automatic Dryer ON/OFF Control to reduce power wastage Automatic Fan ON/OFF Control based on temperature to reduce power wastage Pressure Scheduling to allow user to plan for air requirements and avoid power wastage Dedicated VFD interface port for synchronized operation of integrated compressor with VFD

Saves Time
Easy User Interface thro 8 line Graphical Display and intuitive menu navigation keys Multi Language menu & message display: English, Hindi, Selective European Languages Mimic LED indication for fault diagnosis Easy to read Fault and Warning message display Cumulative Hours Display for Load, Unload, Run, Stop, Fault, Standby Total No of Start/Stop and Load/Unload Cycle Display Compressor Utilisation Display Service Remain Hours Display Dryer or Ambient Temperature (Pt100 sensor) Display Different Control Modes: Local, Remote & DCS Unload Mode for Service Pressure & Temperature Units Selectable PSI or Bar, Centigrade or Fahrenheit 30 Day Report includes Date, Load, Unload, Run, Stop, Standby, Fault hours 99 Fault Report includes Fault Code along with the Date, Time, Pressure, Temperature and Run Status MODBUS RTU protocol for monitoring the compressor through DCS interface (BAUD 9600 / 19200) Analog Output for Pressure (Channel1), Temperature/Sump Pressure, Pt100 (Programmable on Channel2) Programmable Relay for Load, Warn, Trip, Standby, Service, Ready, Remote Easy Firmware update using a handheld programming device or a laptop

Optional Features
Optional add-on Fault Predictive Device o o o Eliminate the need for the customer to call for service or repair Compressor life could be increased by regular monitoring for problems Production can be maximized due to the minimal downtime

Optional Add-on IO card further extends Input and Output o o o o 4 nos of Isolated Digital Input 4 nos of Relay Output 2 nos of Analog Input, 4-20ma 2 nos of Analog Input, RTD

2.0 Technical Features

8 nos of Optically Isolated Digital Inputs of 24VDC 01 = Emergency Stop 02 = Differential Pressure Oil Filter - DPOF 03 = Reverse Rotation 04 = Differential Pressure Air Filter - DPAF 05 = Remote Start/Stop 06 = High Sump Pressure 07 = Cooler 08 = Main Motor Overload 8 nos of Output Relay (SPDT 250V AC 10A, 1, 00,000 cycle electric life) 01 = Main contactor 02 = Star contactor 03 = Delta contactor 04 = Load Valve 05 = Fan 06 = Auto Drain Valve 07 = Dryer (if Dryer is Connected) else Programmable 08 = Programmable [Load, Service, Standby, Warn, Trip, Remote, Ready] 4 nos 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 +85 degree C for Drier or Ambient Temperature 2 nos of Analog Output Channels 0 to 5 VDC, One for Discharge Pressure and One Programmable 9 nos of Function keys Up, Down, Left, Right, Enter, Escape, Start, Stop and Reset. 1 no of Display 128X64 White Backlight Graphical LCD 11 nos of LEDs for visualization alarm & machine status Auto Air Filter Main Motor Overload Reverse Rotation Cooler Pressure Temperature Differential Pressure Oil Filter Differential Pressure Separator Element Start & Stop 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 & 99 Fault Reports 1 no. of Real Time Clock With Battery life of about 10 years 4 nos 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 (For future use) Serial Port 4: VFD Interface Port (For future use) 1 no. of In System Programming (ISP) port Power Supply Input: 24VAC +/- 25%, 50Hz, 1A (In built Protection present for Surge, Over Current)

3.0 Input Output Description

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 3 4 5 6 7 8 9 10 Function Common - Load Relay Load Relay Common - Fan Relay Fan Relay Common - Auto Drain Valve Relay Auto Drain Valve Relay Common Dryer Relay Dryer Relay Common - Programmable Relay Programmable Relay Id Common L / UL 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 1 2 3 4 Function Common for Main, Star and Delta contactors Main Contactor Star Contactor Delta Contactor Id Common Main Star Delta Active state Energised Energised Energised

X04: Digital inputs Connector type: 11 pole combicon Pin 1 2 3 4 5 6 7 8 9 10 11 Function Digital Inputs Common 24VDC Emergency Stop Differential Pressure Oil Filter Reverse Rotation Differential Pressure Air Filter Remote Start Stop Control High Sump Pressure Cooler Fault Input Main Motor Overload 24V supply ground No Connection Id 24VDC Emergency DPOF Rev. Rot DPAF Remote HSP Cooler MMOL GND24 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 -

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 Amb temperature Dryer or Amb temperature Id Dis. Pr 18V Dis. Tr + Dis. Tr Sump Pr 18V Pt100 + Pt100 Type 4-20 ma KTY10 4-20 ma Pt100 Range 0 to 16 bar 0 to 150 C 0 to 16 bar -50 to +85 C

X06: Analog outputs and VFD Connector type: 5 pole combicon Pin 1 2 3 4 5 Function VFD Interface VFD Interface Supply Ground For 5V Dis. Pressure Output Programmable Analog Output Id VFD A VFD B 0VDC AO1 AO2 Type RS485 A RS485 B Voltage Voltage Protocol / Range FC Protocol 0 to 16 bar Programmable

X07: Communication Connector type: 6 pole combicon Pin 1 2 3 4 5 6 Function DCS Interface DCS Interface FPD Interface FPD Interface Add On Interface Add On Interface Id DCS A DCS B FPD A FPD B Add-On A Add-On B Type RS485 A RS485 B RS485 A RS485 B RS485 A RS485 B Protocol Modbus ASCII Modbus

4.0 Main Screen

Dis. Pr Dis. Tr Message1 Message2 Warning HH:MM:SS : 6.0 bar : 32 C

DD/MM

Message1: Based on the short cut key pressed (refer APPENDIX C) Message2: Compressor Status or Fault message
1

Pressure schedule If Blank If PS Pressure Schedule is Disabled Pressure Schedule is Enabled Waiting for Pressure Schedule Acknowledgement

If PS blinking Control Mode L R D M A

Local, ON/OFF Control from Local Keypad Remote, ON/OFF Control from Remote Input DCS, Control is from DCS System Manual, Start need to given after Power failure Auto, Compressor will Automatically Restart after power failure

Message 2 - Compressor Status or Fault message Status Description Ready Ready for Start Star Motor Running in Star Run Motor Running in Delta Run Load Compressor in Load Run Unload Compressor in Unload Stop Busy Stop Sequence in Progress Idle Controller in Idle condition, User interface will not work for this period (5 Seconds) Emergency Stop Emergency Stop Push Switch is ON Start Inhibit xx.x During the Start, if the Sump Pressure is higher than the set start sump pressure value, you will see this message. XX.X denotes the live sump pressure value. The Compressor Starts only if the Sump Pressure value goes below the set value. Start Inhibit If Sump Pressure is Not used (Disabled) then the controller will ensure seconds minimum 60 seconds delay between the stop and the start. Count stops if STOP key is pressed Auto Restart If Compressor is in Auto Mode, seconds The controller will ensure minimum delay (user set, e.g. 90 sec) between stop and start. Count stops if STOP key is pressed Start ack wait This message is displayed after a fault is cleared and waiting for user acknowledgement. By pressing RESET key user can acknowledge. Fault Pr. Probe Failure Tp. Probe Failure Sump Pr. Probe Failure HSP (A) Description Discharge Pressure Sensor Probe Failure Temperature Sensor Probe Failure Sump Pressure Sensor Probe Failure Case 1: Sump Pressure is enabled If Sump Pressure exceeds the set high sump pressure value. Case 2: Sump Pressure is disabled If Discharge Pressure exceeds the set high sump pressure value. If the HSP Digital Input Opens due to High Sump Pressure If the Cooler Digital Input Opens due to Cooler fault IF the MMOL Digital Input Opens due to Main Motor Over Load. If the Rev Rot Input Closes when Motor Running due to motor reverse rotation or Phase failure. If the Discharge Temperature exceeds the set trip temperature value. After the Start, The Sump Pressure should be at least 1.0 bar in 10 seconds. If this is NOT achieved this Fault occurs If the Mains Supply is Interrupted for more than 50 msec If the Mains Supply Voltage is less than the 67% of rated Voltage. Compressor is tripped & All Controller Operation is Halted until the Mains Supply Comes back to normal (at least 75% of the rated)

HSP (D) Cooler Main Motor Overload Rev Rot / Ph Fail Trip Temperature Sump Pressure Not Developing Power failure Low Voltage

5.0 Menu Structure

Press any one of the following keys , , and to enter main menu Main Menu Dis. Pr Dis. Tr Status View Operator Service Factory Customer Care : 6.0 bar : 32 C

5.1 View

View

Operator

Fault Report

Day Report

Service Time

Cumulative Time

VFD

5.1.1 Operator
LEVEL 1 View LEVEL 2 Operator LEVEL 3 Mode LEVEL 4 Control mode Local / Remote / DCS Unload Mode Enable / Disable Auto Restart ON/ OFF Pressure Unit PSI / Bar Temperature Unit Fahren / Centi Unload pressure X X . X b or p (bar or psi) Load pressure X X . X b or p Pr. Schedule ON/ OFF Start Sump Press X X . X b or p Max .Diff Pressure X X . X b or p Warn RST delay Star delay DTR delay RTS delay Stanby Time X X X s (second) XXs XXs XXs Sby XXm (minute) St/Sp PH X X

Pressure

Delay

DCS port

Type Modbus / SCADA ID XX Baud 9600/19200 Parity None / Even Length 8/7 Stop Bit 2 / 1 Trip Temperature Warn Temp Fan Temp Low Dew Pt High Dew Pt X X X C or F X X X C or F X X X C or F X X C or F X X C or F

Temperature

5.1.2 Fault Report

Use , to select the Fault Record number (1 to 99).
LEVEL 1 View LEVEL 2 Fault report LEVEL 3 Fault code: XX, Message Time: HH:MM:SS Date: DD/MM/YY Dis.Pr: X X .X Dis.Tr: XXX Status: Load/ UnLoad /OFF

Fault Code: 01 & 09 Reserved 02-Main Motor Overload, 03-Cooler, 04-HSP(Analog), 05Trip Temperature, 06Reverse Rotation, 07-Pressure Probe Failure, 08-Temperature Probe Failure, 0AHSP(Digital), 0B-Power Failure( Short Power Interrupt), 0C-Sump Pressure Not Developing , 0D-Sump Pressure probe Failure.

5.1.3 Day Report

Use , to select the Record number (1 to 30).
LEVEL 1 View LEVEL 2 Day report LEVEL 3 Date: DD/MM/YY L: X X Hours St: UL: X X Hours F: R: X X Hours Sby: STC: X X X LDC:

X X Hours X X Hours X X Hours XXXXX

L- Load, St Stop, UL Unload, F- Fault, R- Run, Sby- Standby, STC Start Count, LDC Load Count

5.1.4 Service Time

LEVEL 1 View LEVEL 2 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

5.1.5 Cumulative Time

LEVEL 1 View LEVEL 2 Cumulative time Load Unload Run Stop Fault Standby Start Count Load Count Utilisation LEVEL 3 X X X X X X hrs: X X Min X X X X X X hrs: X X Min X X X X X X hrs: X X Min X X X X X X hrs: X X Min X X X X X X hrs: X X Min X X X X X X hrs: X X Min XXXXXX XXXXXXXXX XX%

5.1.6 VFD
If VFD is connected to the compressor and VFD port is connected, user can view the following parameters of VFD in Neuron II. 1. 2. 3. 4. 5. 6. 7. Voltage in V Current in A Frequency in Hz Power in KW Run Hours Kilowatt Hour (Multiply the value shown by 100 to get the real KWH) Status of the VFD

5.2 Operator
Password required.

Operator

Machine

Schedule

Maintenance

Language

Change Password

Mode

Pressure

Set Delay

DCS Port

Auto Drain Valve

Set Dew Point

5.2.1 Machine
# 1 2 3 4 5 6 Item Auto Restart Pr Unit Tr Unit Control mode Unload mode Analog output Unload Pressure Load Pressure Min Max Mode Option on / off bar / psi cen / fah loc/rem/dcs en/dis Tmp / Sp / Pt Default Unit off bar cen loc dis Tmp -

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Warn RST Star DTR RTS Standby St/Sp per hr Type ID Baud Parity Length Stop Bit Off time On time Low Dew point High Dew point

Pressure > load < max unload pressure+0.5 pressure (bar) (bar) 4.0 (bar) < unload pressure-0.5 (bar) Set Delay 90 300 6 10 10 60 5 30 1 99 3 10 DCS Port 01 1 1 -6 C 6C

7.0 bar

bar/psi

5.5 bar

bar/psi

Modbus /SCADA 9600/19200 None /Even 8/7 2/1

90 6 10 10 5 5

second second second second minute -

modbus 01 9600 None 8 2 4 5 -2 C 8C bps minute Second C/F C/F

99 Auto Drain Valve 150 15 Set Dew Point +2 C 12 C -

5.2.2 Schedule
Enable Pressure Schedule, and then use , to select the schedule number (1 to 32). Then Press Enter to set the following # 1 Item Day Min Max Option Sun to Sat / --- (means no schedule) on / off Default --Unit -

2 3 4 5

Action Time HH Time MM Unload Pressure

00 00 > Load Pressure + 0.5 (bar) Load Pressure 4.0 bar

23 59 < Max Unload Pressure (bar) < Unload Pressure 0.5 (bar)

off 00 00 6.5 bar

Hour Minute bar/psi

4.5 bar

bar/psi

5.2.3 Maintenance
# 1 2 3 4 5 Item AF changed OF changed OS changed Oil changed Re Grease Min Max Option no/yes no/yes no/yes no/yes no/yes Default no no no no no Unit -

5.2.4 Language
# 1 2 3 Item English Hindi Portuguese

Default is English.

5.2.5 Change Password

Procedure for changing the 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. Enter the New password 4. Enter the New password again 5. If the new password matches both the times then new password is updated. If mismatch the control goes back to step 3. Pressing Esc will bring the control to the main menu screen

5.3 Service
Password required. Service

Calibration

Relay

Change Password

Maintenance

Clock

Self Test

5.3.1 Calibration
Select the parameter need to calibrated using the , keys. Then Press Enter to calibrate. Dis Pressure/ Dis Temperature/ Sump Pressure Calibration Run the Compressor. When the value is stable at some point, measure the actual value using a standard & recently calibrated meter and enter the meter reading in to the set value field displayed in Neuron II. Set Value should not exceed +/- 1 bar, +/- 10 C. Pt 100 Calibration When the Dew point/ Ambient Temperature is stable at some point, measure the actual value using a standard & recently calibrated meter and enter the meter reading in to the set value field displayed in Neuron II. Set Value should not exceed +/- 3 C. Analog Output 1 & 2 Calibration for analog output should be done for two values one at zero and one at 8.0 bar / 80 degree C. These values are set by connecting a Variable Resistor (TRIM POT) in 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 pr:

Note: Calibration need to be done only when the compressor is in off condition and the digital outputs (relay terminals) are disconnected from the controller. Note: Calibration for Pressure will be only in bar and for temperature only in Centigrade.

5.3.2 Relay
Select the Programmable Relay 1 or 2 using the , keys. Then Press Enter to assign the any one of the following functionality 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 then Programmable Relay 2 is not user programmable. It is used for automatic dryer control.

5.3.3 Change Password

Procedure for changing the 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. Enter the New password 4. Enter the New password again 5. If the new password matches both the times then new password is updated. If mismatch the control goes back to step 3. Pressing Esc will bring the control to the main menu screen

5.3.4 Maintenance
# 1 2 3 4 5 Item Set AFCT Set OFCT Set OSCT Set OCT Set RGT Min 000000 000000 000000 000000 000000 Max 999999 999999 999999 999999 999999 Option Default 002000H 002000H 004000H 002000H 002000H Unit Hour Hour Hour Hour Hour

5.3.5 Clock
# 1 2 3 4 5 6 7 Item Hour Minute Second Date Month Year Day Min Max 00 23 00 59 00 59 01 31 01 12 00 99 Sun/Mon/Tue/Wed/Thu/Fri/Sat

5.3.6 Self Test

Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output, Memory & Communication Ports working. Follow the instructions displayed in the screen

Warning!!!
Self Test should be conducted only when the compressor wiring is totally disconnected from the controller. Do NOT perform self test when the controller is connected to the compressor. Doing so will cause severe damage to the compressor.

5.4 Factory menu

Password required.

Factory

Machine

Change Password

Dryer

Compressor Info

DPSE

DPOF

Max. Pressure Settings

Temperature Settings

5.4.1 Machine
# 1 2 3 Item Rating Pressure Fab no Max Option Compressor Info 11 to 315 LP/ 7.0 to 12.5 A-Z 00000 A-Z 999999 on/off Min Default 22 LP A00000 Unit KW bar -

4 5 6 7

DPSE DPOF Max UL Pressure High Sump Pressure

off off 7.5 bar 10.5 bar

bar /psi bar /psi

8 9 10

Sump Pressure Start Sump Pressure Max. Differential Pressure Trip temperature Warn temperature Fan temperature

on/off Max. Pressure Settings > Unload < 13.5 bar Pressure > Max < Max Unload Unload pressure +1 pressure +3 enable/disable 0.0 bar 0.0 bar 16.0 bar 2.0 bar -

disable 2.2 bar 1.5 bar

bar /psi bar /psi

11 12 13

Temperature Settings 110 C 120 C 90 C 60 110 C 80 C -

110 C 105 C 70 C

C/F C/F C/F

5.4.2 Change Password

Procedure for changing the 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. Enter the New password 4. Enter the New password again 5. If the new password matches both the times then new password is updated. If mismatch the control goes back to step 3. Pressing Esc will bring the control to the main menu screen

5.4.3 Dryer
# 1 2 Item Dryer Mode Dryer Delay Min 2 Max 10 Option on/off Default off 3 Unit Minute

5.5 Customer care

Dis. Pr Dis. Tr Status

: 6.0 bar : 32 C Toll Free No 1800-425-3544 e-mail ccs@elgi.com

6.0 Controls
6.1 Start Sequence
ON Command Exit loop

FAULT?

Yes

No

Standby

AUTO mode ON?

Yes

Dis. Pr. <Load Pr

No

No

Yes

Standby Control

Yes

Standby ?

No

AUTO ON from Power Failure?

Yes

No

No Sump Pr. < Set value? Yes Delay 60 Sec Start Sequence Yes Sump Pr. Enabled?

Warn Restart Delay

No Sump Pr. Enabled? No Start Sequence Yes Yes Sump Pr. < Set value?

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 delay) Exit loop

6.2 Stop Sequence

Stop

Is STAR ON

Yes

No

LOAD OFF

(RTS delay) Run to stop x sec

DELTA & MAIN OFF

IDLE delay for 5 secs Fixed delay

READY

6.3 Fan Control

State = Run? No

Dis. Temp > Set FAN Temp

No

Yes FAN ON

Exit Loop

FAN = ON?

No

Yes

Exit Loop

Dis. Temp < (Set FAN Temp 5 C)

No

Yes FAN OFF

6.4 ADV control

As per the User set On & Off time the Drain Valve is automatically controlled. On time

Off time

6.5 Dryer Control

Dryer ON command generates internally when Compressor motor starts running Calculate elapsed time from last stop

Is Elapsed time>set dryer delay ?

No

Yes Dryer ON

Dryer OFF when Compressor is stopped

7.0 Data Interface

Neuron II has two types of Data Interface

Analog output DCS Port

7.1 Analog output

Two Channels are available as analog output. The First Channel will output the current Discharge Pressure value 0.0 to16.0 bar, converted into 1 to 4.75V.

The Second channel is programmable. User can select any one of the following in menu Operator/ Machine/ Mode/ Analog output a. Dis. Temperature b. Sump Pressure 0 to 150 C, converted into 1 to 4.75V 0 to 16.0 bar, converted into 1 to 4.75V

c. Pt100 Temperature -50 to 90 C, converted into 1.25 to 4.75V Note: Analog output will be 0V in case of probe failure.

7.2 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. Also the ID, Baud Rate, Parity, data Length, Stop Bit are user settable. The Modbus data table is provided in the Appendix.

8.0 Construction
Corrosion & Dust protected Back Cover IP65 polyethylene front keypad Inputs and Outputs through terminal block, board to wires, disconnect able, screw terminals Front Plate Dimensions 260 x 145mm Enclosure Dimensions 235 X 120 X 70 mm Operating Temperature - 0C to +75C Relative Humidity <85% RH non-condensing @ 40C

8.1 Dimension Drawing

Panel Front Plate 100

260

133

145

Panel Cut out Dimension 70

235

X01 X04 X05 ISP X03

X06

120

All Dimensions are in mm

120

X07 X02

9.0 Revision Details

Version
1.0 1.1

Date
2 April 2009 8 July 2009

Changes
Initial Draft Pilot Batch S/W Version 1.1

10.0 Appendix
APPENDIX A: MODBUS TABLE [Function Code: 0x03(Read) & 0x10(Write)] # Data Description Load Hours Unload Hours Run Hours Stop Hours Fault Hours Standby Hours No of Start Load Count Utilization % Address Type Bytes Example / Format Access

1 2 3 4 5 6 7 8 9

Cumulative Time & Count Registers 1010 BCD 4 HHHHHH:MM 1012 BCD 4 HHHHHH:MM 1014 1016 1018 101A BCD BCD BCD BCD 4 4 4 4 HHHHHH:MM HHHHHH:MM HHHHHH:MM HHHHHH:MM

R R R R R R R R R R

10 Rem AFCT Hours Minutes 11 Rem OFCT Hours Minutes 12 Rem OSCT Hours Minutes 13 Rem OCT Hours Minutes 14 Rem RGT Hours Minutes

101C BCD 4 NNNNNNNN 101E BCD 6 NNNNNNNNNNNN 1022 BCD 2 XXXX Service Remaining Time Registers 1028 Int 2 H8063 = -99 (X10000) 1029 ULong 4 H000927BF = 599999 102B Int 2 H8063 = -99 (X10000) 102C ULong 4 H000927BF = 599999 102E Int 2 H8063 = -99 (X10000) 102F ULong 4 H000927BF = 599999 1031 Int 2 H8063 = -99 (X10000) 1032 ULong 4 H000927BF = 599999 1034 Int 2 H8063 = -99 (X10000) 1035 ULong 4 H000927BF = 599999

15 Control Mode 16 Unload Mode 17 Auto Restart 18 Pr Unit 19 Tr unit 20 Pr. Schdl(on/off) 27 Dis. Pressure 28 Dis. Temperature 29 Dew Point / Ambient Temperature 30 Sump Pressure 31 Diff Pressure 32 Set Unload Pressure 33 Set Load Pressure 34 Set Diff Pressure 35 Trip Temp 36 Warn Temp 37 Low Dew Point 38 High Dew Point 39 Fan Temp

1040

Mode Registers BCD 2

1041 1042 1043 1044 1045

BCD BCD BCD BCD BCD

2 2 2 2 2

0001-DCS 0002-Local 0003-Remote 0001-Disabled 0002-Enabled 0001-OFF 0002-ON 0001-BAR 0002-PSI 0001-Centi 0002-Farhen 0001-OFF 0002-ON

R/W

R/W R/W R/W R/W R

Analog Registers 104A BCD 2 1200 (/100) = 12.0 bar 104B BCD 2 1100 (/10) = 110 C 104C BCD 2 MSB 01 = + MSB 02 = LSB = 30 104D BCD 2 1200 (/100) = 12.0 bar 104E BCD 2 0100 (/100) =1.0 bar 104F BCD 2 0120 (/10) = 12.0 bar 1050 BCD 2 0080 (/10) = 8.0 bar 1051 BCD 2 0010 (/10) = 1.0 bar 1052 BCD 2 0110 = 110 C 1053 BCD 2 0105 = 105 C 1054 BCD 2 MSB 01 = + MSB 02 = LSB = 30 1055 BCD 2 MSB 01 = + MSB 02 = LSB = 30 1056 BCD 2 0070 = 70 C

R R R

R R R/W R/W R/W R R/W R/W

R/W

R/W

21 Auto Restart Delay (Sec) 22 Star Delay (Sec) 23 DTR Delay (Sec) 24 RTS Delay (Sec) 25 Standby Time (Min) 26 Max. No of Start per hour 40 41 42 43 44 45 46 Hour Minutes Seconds Date Month Year Day

1060 1061 1062 1063 1064 1065

Delay Registers BCD 2 0100 BCD 2 BCD 2 BCD 2 BCD 2 BCD 2 RTC Registers BCD 2 BCD 2 BCD 2 BCD 2 BCD 2 BCD 2 BCD 2 0005 0010 0010 0005 0005

R/W R/W R/W R/W R/W R/W

106A 106B 106C 106D 106E 106F 1070

0023 0059 0059 0031 0012 0009 0001 Sunday -1

R R R R R R R

47 General Status 48 Warning Status 49 Fault Status

1071 1072 1073

Status Registers UInt 2 Refer table UInt UInt 2 2 Refer table Refer table

R R R

Start / Stop Function Code: 05 Address : 1074 Value : 0xFF00 0x0000

Start Stop

Status Register Bit Definition: Bit Position 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 General Ready Star Run Run Load Run Unload Stop Busy Idle Emergency Stop Start Inhibit Start ack wait Standby Reserved Reserved Reserved Reserved Reserved Warning DPSE DPOF Dryer Probe Failure Low Dew Point High Dew Point High Differential pressure Warn Temperature Change Air Filter Change Oil Filter Change Oil Separator Change Oil Change Grease Reserved Reserved Reserved Reserved Fault HSP Cooler Main Motor Overload Reverse Rotation Pressure Probe Failure Temperature Probe Failure Trip Temperature Sump Pressure Not Developing Sump Pressure probe Failure Power failure Reserved Reserved Reserved Reserved Reserved Reserved

APPENDIX B: MIMIC LED TABLE # 1 LED Auto Description To indicate the machine is in automatic on/off mode. This Led glows in Amber Colour on these conditions 1. When Pressure Schedule is enabled (or) 2. When Auto Restart is enabled Glows in Amber colour when 1. Air Filter Service is due based on service hours 2. Air Filter Digital Input (DPAF) is Open Glows in Red when the main motor overload Digital Input is Open. Glows in Red when the Reverse Rotation Digital Input is Closed and the machine is in Run state Glows in Red when the cooler Digital Input is Open Glows in Red when the 1. HSP Digital Input is Open 2. Analog Pressure Input is Open (Probe Failure) 3. Dis. Pressure is higher than set HSP Glows in Red when the 1. Analog Temperature Input is Open (Probe Failure) 2. Dis. Temperature is higher than set Trip temp. Glows in Amber when the 1. DPOF Digital Input is Open & DPOF is enabled 2. Oil Filter Service is due Glows in Amber when the 1. DPSE Digital Input is Open & DPSE is enabled 2. Oil Separator Filter Service is due 1. Glows in Red when machine is stopped / idle 2. Glows in Green when machine is running

Air Filter

3 4 5 6

Main Motor Overload Reverse Rotation Cooler Pressure

Temperature

Differential Pressure Oil Filter (DPOF) 9 Differential Pressure Separator Element (DPSE) 10 Start & Stop

APPENDIX C: Short Cut Key Functions Note1: All shortcut key functions only when the display is in Main Screen. Note2: On every press of the key NEXT message is displayed. LEFT Warning messages Warning DPSE DPOF Dryer Probe Failure Low Dew Point High Dew Point High Differential pressure Warn Temperature Change Air Filter Change Oil Filter Change Oil Separator Change Oil Change Grease Start Stop Exceeded Description Differential Pressure Separator Element Due For Service Differential Pressure Oil Filter Due For Service Pt100 Sensor Probe Failure Live Dew Point less than the Set Low Dew Point Live Dew Point greater than the Set High Dew Point Difference Between the Sump & Discharge Pressure is greater than the set max Differential Pressure value. Discharge Temperature exceeds the set Warn value Air Filter Due For Service Oil Filter Due For Service Oil Separator Due For Service Oil Change Due For Service Re Grease Due For Service No. of Start stop per hour exceeded

RIGHT - Live Analog Values 1. Live Differential Pressure 2. Live Sump Pressure 3. Live Pt100 Temperature UP Set Analog Values 1. 2. 3. 4. Set Load Pressure Set Unload Pressure Set Start Sump Pressure Max Differential Pressure

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