Central Controller Connection Guide
Short Description
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Description
Atlas Copco Airpower NV
Central Controllers Guide
Central Controllers Guide
Name
Central Controllers Guide
Detail
Communication Links MkiV-Mk3-Mk1-ES100-ES300-ComBox-S – Energon – ESMillennum
Edition
Serc. Class
Modified from
1102 K/1 PC Print date
Owner
AII
6/07/2006 9:10 AM
07 Family
Written by CTE-GW
Compare
Design checked.
Production checked.
Approved
Replaces
06 Date
24/04/2006
Page 1
Designation
X104 64 S043
Atlas Copco Airpower NV
Central Controllers Guide
Document Information
Edition 00 01 02 03 04 05 06 07
Date 26/07/2002 31/07/2002 08/08/2002 09/10/2002 12/12/2002 27/09/2004 06/06/2005 24/04/2006
Description First edition Small modifications Official product descriptions (ComBox-S) VSD under MCC control (in)direct stop levels adjusted Compatibility table ES20-30 added, NodeId info added ES800 added Energon introduced iso (S)MCC and ES800 MCC for SF added / WIS AQ added / Elektronikon 1+ added
Page 2
Author CTE-GW CTE-GW CTE-GW CTE_GW CTE_GW CTE_GW CTE_GW CTE_GW
Atlas Copco Airpower NV
Central Controllers Guide Table of Contents 1. Compatibility table ...............................................................................................................................................................5 1.1 Compressor controllers ..........................................................................................................................................6 1.1.1 Elektronikon Mark 1 / 2....................................................................................................................................6 1.1.2 Elektronikon Mark 3.........................................................................................................................................6 1.1.2.1 Hardware.......................................................................................................................................................6 1.1.2.2 Applications ..................................................................................................................................................6 1.1.3 Elektronikon Mk iV ..........................................................................................................................................6 1.1.3.1 Hardware.......................................................................................................................................................6 1.1.3.2 Applications ..................................................................................................................................................7
2
1.2
Central Controllers.................................................................................................................................................8
1.3
Interfaces .................................................................................................................................................................8
Mk iV ComBox-S : communication lines .......................................................................................................................9 2.1 CAN-Bus..................................................................................................................................................................9 2.1.1 Pin Assignment .................................................................................................................................................9 2.2 RS232 .......................................................................................................................................................................9 2.2.1 Pin Assignment RS232 .....................................................................................................................................9 2.2.2 Protocol.............................................................................................................................................................9 2.3 CURRENT LOOP ................................................................................................................................................10 2.3.1 Pin Assignment ...............................................................................................................................................10 2.3.2 Protocol............................................................................................................................................................10
3
Energon1 - MCC............................................................................................................................................................11 3.1
Introduction...........................................................................................................................................................11
3.2 Cabling...................................................................................................................................................................11 3.2.1 CAN Network .................................................................................................................................................11 3.2.2 Cable from ComBox-S to Mark 1/ 2 / 3..........................................................................................................12
4
3.3
Regulation..............................................................................................................................................................12
3.4
Display ...................................................................................................................................................................13
3.5
Energon1 parameters ...........................................................................................................................................14
3.6
Energon1 configuration........................................................................................................................................14
3.7
Integrating Mark 1/2/3 controller .......................................................................................................................15
Energon1 – MCC for SF ...............................................................................................................................................15 4.1
Introduction...........................................................................................................................................................15
4.2 Cabling...................................................................................................................................................................15 4.2.1 CAN Network .................................................................................................................................................15 4.2.2 Digital link to Mk3-SF....................................................................................................................................15 4.3 Regulation..............................................................................................................................................................16 4.3.1 Pressure regulation algorithm .........................................................................................................................16 4.3.2 Priority ............................................................................................................................................................16 4.4 5
Display ...................................................................................................................................................................17
Energon2........................................................................................................................................................................18 5.1
Introduction...........................................................................................................................................................18
5.2 Cabling...................................................................................................................................................................18 5.2.1 CAN Network .................................................................................................................................................18 5.2.2 Cable from ComBox-S to Mark 1/ 2 / 3..........................................................................................................19 Page 3
Atlas Copco Airpower NV
Central Controllers Guide 5.2.3 5.2.4 5.2.5 5.3
Digital link connections ..................................................................................................................................19 Analogue readings ..........................................................................................................................................19 Optional ‘remote control’ DIOE .....................................................................................................................19 Setup ......................................................................................................................................................................20
5.4 Functionality .........................................................................................................................................................20 5.4.1 Pressure Regulation ........................................................................................................................................20 5.4.2 Control modes.................................................................................................................................................21 5.4.3 Different System Pressure Bands (SPS) .........................................................................................................21 5.4.4 Different Sequence Schemes ..........................................................................................................................21 5.4.5 Automatic Restart After Voltage Failure ........................................................................................................22 5.4.6 Week timer......................................................................................................................................................22 5.4.7 Visualization ...................................................................................................................................................22 5.4.8 Energon2 parameters ......................................................................................................................................22 5.4.9 Channel parameters.........................................................................................................................................22 5.4.10 Logging parameters ........................................................................................................................................23 5.4.11 Loading/saving the Energon2 configuration...................................................................................................23 6
ES100 .............................................................................................................................................................................24 6.1
Introduction...........................................................................................................................................................24
6.2
Digital input/output link.......................................................................................................................................25
6.3 Communication link .............................................................................................................................................25 6.3.1 Mark 1/2..........................................................................................................................................................25 6.3.2 Mark 3.............................................................................................................................................................25 6.3.3 Mk iV..............................................................................................................................................................25 7
ES300 .............................................................................................................................................................................27 7.1
Introduction...........................................................................................................................................................27
7.2 Communication link .............................................................................................................................................27 7.2.1 Load/NoLoad Compressor without Electronic Controller ..............................................................................27 7.2.2 Load/NoLoad Compressor with Mark 1 / 2 controller....................................................................................27 7.2.3 Load/NoLoad Compressor with Mark 3 controller.........................................................................................28 7.2.4 Load/NoLoad compressor with Mk iV controller...........................................................................................28 8
ES20 / ES30 ...................................................................................................................................................................29 8.1
Introduction...........................................................................................................................................................29
8.2 Communication link .............................................................................................................................................29 8.2.1 Load/NoLoad Compressor without Electronic Controller ..............................................................................29 8.2.2 Load/NoLoad Compressor with Mark 1 / 2 controller....................................................................................29 8.2.3 Load/NoLoad Compressor with Mark 3 controller.........................................................................................29 8.2.4 Load/NoLoad compressor with Mk iV controller...........................................................................................29
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Atlas Copco Airpower NV
Central Controllers Guide 1. Compatibility table ⇒ Central Control System ⇒
Energon1 MCC
MCC for SF
ES20-30
ES100
ES300
Energon2
Air-monitor
Air Leader (CMC)
ComBox-S + ComBox-S -
-
+ + -
+ + + D (*)
+ ComBox-S D (*)
+ ComBox-S -
+ -
Mk 3 : SF
-
+
-
D (*)
+ + ES001 + REB -
D (*)
-
-
Mk 3 : HRRS (Load/UnLoad)
-
-
-
D (*)
-
D (*)
-
-
⇓ Compressor
⇓
EPN-Compressor ES01 – interface to EPN ES001 – interface to EPN ES002 – interface to EPN ES003 – interface to EPN Mark 1/2 controllers Mk 3 : LRR
Mk 3 : HRRE (Load/UnLoad)
-
-
-
D
-
D
-
-
Mk 3 : HRRS (Load/UnLoad)+COM1
ComBox-S
-
+ (*)
C (*)
+ (*)
ComBox-S
ComBox-S
-
Mk 3 : HRRE (Load/UnLoad)+COM1
ComBox-S
-
+
C
+
ComBox-S
ComBox-S
-
Mk 3 : HRRS/E (VSD)
-
-
-
-
-
-
-
-
Mk 3 : GA90VSD Serial < AII492000
-
-
-
-
-
-
-
-
ComBox-S
-
-
-
-
-
ComBox-S
-
-
-
-
-
-
-
-
-
Mk 3 : HRRS/E (VSD) + COM1 Mk 3 : HRRE (ZH Turbo) Mk 3: HRRE Ded2 (L/UL Crép.)
-
-
-
D
-
D
-
-
Mk 3: HRRE (L/UL Crép.) + COM1
-
-
-
C
+
ComBox-S
ComBox-S
-
Mk 3: HRRE (VSD Crép.) + COM1
-
ComBox-S
-
-
-
-
-
ComBox-S
Mk iV Elektronikon 1 (L/UL)
-
-
-
-
-
-
-
-
Mk iV Elektronikon 1+ (GA L/UL)
+
-
-
-
-
+
+
-
Mk iV Elektronikon 1+ (FD)
-
-
-
-
-
-
+
-
Mk iV LMS (L/UL)
+
-
ComBoxC
D OR ComBox-C
ComBox-C
+
+
-
Mk iV LMS B controller (VSD)
+
-
-
-
-
-
+
-
Mk iV HMS (L/UL)
+
-
ComBoxC
D OR ComBox-C
ComBox-C
+
+
-
Mk iV HMS (VSD)
+
-
-
-
-
+
+
-
Mk iV HMS (SF)
-
+
-
-
-
-
+
-
Mk iV HMS (L/UL) for WCO
+
-
-
-
-
+
+
-
Mk iV HMS (ZH Turbo)
-
-
-
-
-
-
+
-
Mk iV HMS (ZB Turbo)
-
-
-
-
-
-
+
-
PLC (ZH Turbo)
-
-
-
-
-
-
-
-
Mk iV HMS (L/UL-Crépelle.)
+
-
-
D
-
+
+
-
Mk iV HMS (VSD-Crépelle)
+
-
-
-
-
+
+
-
Mk iV HMS (L/UL PetPack)
-
-
-
-
-
-
+
-
Mk iV HMS (VSD PetPack)
-
-
-
-
-
-
+
-
Mk iV HMS (ZD)
-
-
-
-
-
-
+
-
Mk iV HMS (ZD-VSD)
-
-
-
-
-
-
+
-
AQ / WIS – fixed speed
+
-
-
-
-
+
+
ComBoxLA
AQ / WIS – VSD
+
-
-
-
-
+
+
ComBoxLA
WCO Airlogic –MkIV - L/UL
+
-
-
-
-
+
+
ComBoxLA
WCO Airlogic –MkIV - VSD
+
-
-
-
-
+
+
ComBoxLA
WCO MCI-01 - L/UL (CMC)
-
-
-
-
-
-
-
+
WCO VCI-07 – L/UL (CMC)
-
-
-
-
-
-
-
+
WCO VCI-07 – VSD (CMC)
-
-
-
-
-
-
-
+
Mk iV Dryers CD/BD/FD Mk iV Dryers FD-VSD Mk iV Dryers MD/XD
-
-
-
-
-
-
+ + +
-
Legend :
-/+ not supported / supported D connection via digital I/O; (*) key switch for selection of the control mode has to be added C connection via serial communication line REB Mk3 - Relay Expansion Box required ComBox-S MkiVComBox-S interface converts serial protocol RS232 (Mk3) Ù MkiV CAN ComBox-C MkiV ComBox-S interface converts serial protocol Current Loop (Mk3) Ù MkiV CAN ComBox-LA MkiV ComBox-S interface converts protocol CAN Ù RS485 line – specific software for AirLeader protocol HMS Mk iV controllers with high memory size (A+ / B+ C en D controllers) LMS Mk iV controllers with low memory size (A / B controllers) Remarks: Sometimes it might be necessary to download a newer application into MkiV controller or to add/correct some settings
Page 5
Atlas Copco Airpower NV
Central Controllers Guide 1.1
Compressor controllers
1.1.1
Elektronikon Mark 1 / 2 Obsolete type of compressor controllers made by Velleman or Evic. Used on Industrial Air and Oil Free Air Load/NoLoad compressors.
1.1.2
Elektronikon Mark 3 Previous used generation of Elektronikon controllers, made by Prima Electronics. Used in combination with several applications software.
1.1.2.1
Hardware • Low Range Regulator (1900 0700 0x) Basic stand alone controller, 3 additional digital outputs are available with the Relay Expansion Box • High Range Regulator Standard (1900 0701 0x) Master controller with 4 x 16 display, supports expansion modules, COM1 for external serial communication • High Range Regulator Extended (1900 0701 2x) Master controller with 4 x 40 display, supports expansion modules, COM1 for external serial communication • High Range Regulator Extended suitable for transmitters (1900 0701 3x) Master controller with 4 x 40 display, supports expansion modules, COM1 for external serial communication, analogue inputs are suitable for transmitters
1.1.2.2
Applications • Load / No Load Standard regulation algorithm, supports external load unload control via digital contacts and via external commands • VSD PI regulation for Variable Speed Compressors, COM1/2 used for controlling the converter, COM1 expansion module provides external setpoint and speed control • SF/ MultiSF Special software for small scroll compressors and Multi-Scroll units; dedicated applications for stand alone units • ZH Turbo Use of specific Analogue In/Output expansion module to control Inlet Guide Valve and Blow off Valve, includes surge control. Supports external setpoint control and Minimum / Maximum Load commands via COM1 module. Internal PI /surge /motor algorithms are controlling the machine at all times. • High Pressure Load/No load (for Crépelle) Application for PET industry, typical 40 bar. Uses High Range Controller Extended with transmitter inputs, with COM1 external serial communication support since 2003. • High Pressure VSD (for Crépelle) Application for PET industry, typical 40 bar. Uses High Range Controller Extended with standard transducer inputs, COM1 external serial communication is supported with external speed control.
1.1.3 1.1.3.1
Elektronikon Mk iV Hardware Elektronikon I: Basic stand alone controller, supports only external start/stop via a digital contact (1900 0711 01) Elektronikon 1+(Plus): Basic stand alone controller, including CAN-interface (High Memory Size) (1900 0712 71) Elektronikon II A/B (LMS): Master controller with 4 x 16 display, supports all expansion modules, B controller has a RS485 serial port (typical for steering VSD converter). CANbus provides external control. (1900 0710 01 /1900 0710 11) Elektronikon II A+/B+ (HMS): same as previous controller module with more memory (1900 0710 02 /1900 0710 12) AirLogic Controller (HMS) based on B+, but other front (62 563 100 00) Page 6
Atlas Copco Airpower NV
Central Controllers Guide Elektronikon III C/D (HMS): Master controller with 4 x 40 display, supports all expansion modules, D controller has a RS485 serial port (typical for steering VSD converter). CANbus provides external control. (1900 0710 21 / 1900 0710 31) For Other Brands (WIS) (HMS) based on D, but other front. 1.1.3.2
Applications • Load / No Load: LMS and HMS (including 1+ controller) Standard regulation algorithm, supports external load unload control via digital contacts and via external commands through CANbus • Load / No Load for WCO - AirLogic Based on standard load/unload • AQ Load / No Load; also old versions for GrassAir (WIS) Based on standard load/unload, but some specific algorithms added • VSD: LMS (old versions: ABB and Siemens) / HMS PI regulation for Variable Speed Compressors, B/D controller RS485 line used for controlling the converter(s), CANbus provides external setpoint and speed control • VSD for WCO - AirLogic Based on standard VSD • AQ VSD Based on standard load/unload, but some specific algorithms added • SF / MultiSF Special software for small scroll compressors and Multi-Scroll units; dedicated stand alone applications, external control via CANbus is possible, but limited. • Crépelle: Load/No Load; compressors and boosters Application for PET industry, typical 40 bar. Uses standard transducer inputs, external start/stop and load/unload control via digital inputs and CANbus. • Crépelle: Load/No Load PetPack Specific ZR+Crépelle-Booster combination including vessel in between; Booster is CAN master controlling ZR in CCM4a • ZD Load/No Load Specific ZR+Crépelle-Booster combination without vessel in between; Booster is CAN master controlling ZR in CCM4b • Crépelle: VSD; compressors and boosters Application for PET industry, typical 40 bar. Uses standard transducer inputs and RS485 line for controlling the converter(s), external setpoint / speed control via CANbus. • Crépelle: VSD PetPack Specific ZR-VSD+Crépelle-VSD-Booster combination including vessel in between; Booster is CAN master controlling ZR-VSD in CCM4a • ZD VSD Specific ZR-VSD+Crépelle-VSD-Booster combination without vessel in between; Booster is CAN master controlling ZR-VSD in CCM4c • ZH Turbo Use of specific Analogue In/Output expansion module to control Inlet Guide Valve and Blow off Valve, includes surge control. Supports Minimum / Maximum Load commands and external setpoint control via CANbus. Internal PI /surge /motor algorithms are controlling the machine at all times. • ZB Turbo Use of specific Analogue In/Output expansion module to control Inlet Guide Valve and Blow off Valve, includes surge control. • Stand alone dryers (LMS) CD / FD fixed speed / FD VSD • Stand alone dryers (HMS) BD / CD / FD / FD VSD / MD / XD (3 variants)
Page 7
Atlas Copco Airpower NV
Central Controllers Guide 1.2
Central Controllers • • • •
• • •
• •
1.3
ES20-30 Advanced Central controller based on Mark 1 hardware, can control up to 6 or 12 Load / NoLoad compressors via serial communication lines (current loop). ES100 Sequence Controller, can control up to 7 Load / NoLoad compressors via digital linking or serial communication (current loop) ES300 Advanced Central controller for saving energy, can control up to 16 Load / NoLoad compressors via serial communication lines (current loop) Energon1 (also known as MCC) Built-in Multi Compressor Controller, supports up to 4 compressors via the CANbus, including one VSD. VSD will always be top load, it controls the other compressor to achieve equal running hours. One compressor (can be Load/NoNolad or VSD) is both Energon1 master and slave. MCC for SF Built-in Multi Compressor Controller, supports up to 4 SF compressors; if equipped with MkiV via the CANbus, if equipped with Mk3 via Digital I/O (DIOE expansion module). Energon2 New generation of sequence controller, supports up to 8 compressors, load/NoLoad and VSD compressor via CAN communication or Digitally linked (only load/NoLoad). CRC controllers, ESMillennium - developed by Oil Free Department o ES1000: only load / NoLoad compressors o ES2000: Load/NoLoad and VSD compressors o ES3000: Load/Noload and VSD and Turbo compressors AirMonitor (not taking over control, only for monitoring purposes) Can also push data to data warehouse (similar to ES-XX) Air Leader from CMC, supports up to 12 compressors Load/NoLoad and VSD; digitally connected or serial via RS485; The AirLeader can also control AirLogic controllers (based on MkiV) via a special ComBox-S interface. This document does not give more details about the AirLeader.
Interfaces • • •
•
ES001 Based on Mk3 hardware, converts digital in/outputs to a serial communication protocol ES002 / ES003 Based on Mk iV hardware, converts digital in/outputs to a serial communication protocol ComBox - S (1900 0711 41) Based on Mk iV ComBox-S hardware, different applications are available ° Mk3 integration into Mk iV (indicated as ComBox-S-RS232) Converting CAN to RS232 serial communication, typical application : connection between Energon and Mk1/2/3 compressor controller, for each compressor a ComBox-S is required ° Mk iV integration into Mk3 (indicated as ComBox-S-CL) Converting Current Loop serial communication to CAN, typical application : connection between ES2030/ ES100 / ES300 with a Mk iV compressor, for each compressor a ComBox-S is required ° Mk3 support for CRC / ESMillennium (ComBox-S-CRC) ° Modbus Master application converting Modbus data from ZH-PLC controller into CAN protocol ° MkiV to Modbus Interface (ComBox-S-MODBUS): one interface for a complete CAN network ComBox – P (1900 0711 42) ° MkiV to Profibus Interface (ComBox-P-PROFIBUS): one interface for a complete CAN network
Page 8
Atlas Copco Airpower NV
Central Controllers Guide 2 Mk iV ComBox-S : communication lines 2.1
CAN-Bus
Controller Area Network. Standard field bus, which is used in automotive as well as in industrial applications. The ComBox-S module handles the completely autonomous transmission and reception of CAN telegrams. That means, once the transmit buffer has written or the receive buffer is empty no CPU time is required. The CAN unit can receive and transmit standard frames with 11-bit identifier as well as extended frames with 29-bit identifier. The baud rate is standard. 2.1.1
Pin Assignment
Sub-D 9 pole male (10X1) Pin 1 6
1 2 3 4 5 6 7 8 9
Function Reserved CAN_LOW CAN_GND Reserved Reserved GND external supply CAN_HIGH Reserved CAN external supply*
* not used for MKIV Component. Supply for CAN-Driver already integrated
2.2 2.2.1
RS232 Pin Assignment RS232
Sub-D 9 pole female (10X15) Pin
6 1 2.2.2 -
1 2 3 4 5 6 7 8 9
Function Reserved TxD RxD Reserved GND Reserved Reserved Reserved Reserved
Protocol baud rate: 300, 600, 1200, 2400, 4800, 9600, 19200 or 38400; default 19200 start bit: 1 data bits: 7 parity: odd stop bit: 1 load impedance: 3 to 7 kOhm cable length: max. 20m
Page 9
Atlas Copco Airpower NV
Central Controllers Guide
2.3 2.3.1
CURRENT LOOP Pin Assignment
Sub-D 9 pole male(10X18) 1 6
2.3.2 -
Pin 1
Function RxD I+
2 3 4 5 6 7 8 9
TxD I+ Reserved +12V / 20mA +12V / 20mA RxD ITxD IGND GND
Protocol baud rate: 300, 600, 1200, 2400, 4800, 9600, 19200 or 38400; default 1200 start bit: 1 data bits: 7 parity: odd stop bit: 1 cable length: max. 1000m
Page 10
Atlas Copco Airpower NV
Central Controllers Guide 3 Energon1 - MCC 3.1
Introduction
The built-in Multi Compressor Controller can control up to 4 compressors including itself. Other compressor controllers then Mk iV require a ComBox-S connected to the CAN-network. Each controller on the network must have a NodeID from 1 to 4. No other addresses are allowed, and each address can be used only once. Maximum 1 VSD compressor is allowed in the Energon1 configuration. Also the VSD can be Energon1 master.
Mk iV MCC
MkiV NodeId 3
NodeId 1
CAN
NodeId 4
ComBox PC
NodeId 2
RS232
ES002
COM1
DIG CONTACTS
MK3
DIG GROUP
3.2
Cabling
3.2.1
CAN Network
Cable : Lappkabel Unitronix BUS-CAN 2x2x0.34 : AC Nr. 0017 2610 10, total max length 250m, with a repeater max length can be 500m. Maximum 30 Nodes are allowed on the Can network. Alternative cable : Belden 3106A (AC Nr. 1900 0707 92) Connectors : Normal connector : 1088 0033 01 Service connector : 1088 0033 02; to support external connection e.g. for service & diagnostic program The connectors have a built-in terminator resistor, and the end of the network, the switch has to be set to the ON position. The connections are made with the 2X1 9 pins SUB-D connector of the Mk iVcontrollers. 2
2
3
3
7
7 screen
2 3 7
2 3 7
Page 11
Atlas Copco Airpower NV
Central Controllers Guide
3.2.2
Cable from ComBox-S to Mark 1/ 2 / 3
Cable : 4 x 0.5 mm² + screen, maximum length = 25 m 25 pins SUB-D connector COM1 - 5X14 (Mk 3)
9 pins SUB-D ComBox 10X15 4
4
6
5
2
3
3
2 7
5 screen
7
6 8
8
20
This cable with a length of 5 m is available as 1622 0569 00
3.3
Regulation Unload
P max ∆P/3
∆P
VSD Set point ∆P/2
∆P/3
P min ∆P/3
∆P/6
VSD Indirect stop
Anticipating unload Middle area Anticipating load Load
∆P is at least 0.1 bar; for good regulation band must be wide enough (dependent of sensor range) The compressor outlet pressure (of the MCC-Master) is used as the net pressure. It is also possible to configure a specific net pressure reading (even a pressure transmitter can be used): for more details: see X104 64S 088 Instruction remote sensor for MCC. Start / Load action if there is a VSD integrated in the Energon1 system : start/load action only if speed of VSD >= 0.95 x MaximumSpeedVSD Load area : Pressure below ∆P/3 zone : if dp/dt =< 5 mbar/s => action Load area : Pressure in ∆P/3 zone : if dp/dt =< 1 mbar/s => action Anticipating load zone : if dp/dt < 0 mbar/s => action Pressure in middle area or higher : no actions Unload action if there is a VSD integrated in the Energon1 system : unload action only if speed of VSD =< 1.05 x MinimumSpeedVSD Pressure in middle area or lower : no actions Anticipating unload zone : pressure in ∆P/3 zone : if dp/dt > 50 mbar/s => action Anticipating unload zone : pressure in ∆P/6 zone : if dp/dt > 0 mbar/s => action Unload zone : if dp/dt >= -2 mbar/s => action Stop action if there is a VSD integrated in the Energon1 system : Page 12
Atlas Copco Airpower NV
Central Controllers Guide VSD will stop based on its own algorithms, but referring to adjusted (in)direct stop levels and setpoint / netpressure coming from Energon1 master no influence on stopping other compressors Pressure lower then middle area : no stop actions Pressure in middle area or higher : stop action if Dp/dt > -5 mbar/s Unload Timer elapsed Load Timer elapsed DSS counter (based on allowed starts/day) elapsed VSD compressor: only 1 can be integrated in Energon1 system, it will always be the top load, regulates to a set point coming from Energon1 master – middle of the Energon1 pressure band. Also the actual regulation pressure is coming from the Energon1 master, to avoid influences of pressure difference between pressure seen by Energon1master and VSD. Also the stop levels are adjusted if VSD is under Energon1 control : the indirect stop level will be Pmax the direct stop = new setpoint + local direct stop level; but if the direct stop level < indirect stop level then the direct stop level = indirect stop level.
3.4
Display Energon1 main screen 1
█ ▄ █ █ - █ 1 2 3 4 Main Rset
7.0 6.5 6.1↓
Number 1 2 3 4 CAN address When number flashes : compressor controller in local pressure sensing mode (4a) -
stopped condition when this dash flashes : not available (during minimum stop time)
█ running unload when flashes : not available (during programmed stop of Mk3) █ █ running load ▄ █ ▄ Bar indicating speed of VSD compressor ? ? no communication * * Shutdown ! ! not responding X X not supported type At the right of the screen the actual net pressure is shown within the actual pressure band : the upper / lower limit of the band will flash if actual net pressure is outside the pressure band. Page 13
Atlas Copco Airpower NV
Central Controllers Guide
Main F1 button : jumps to compressor main screen; in that screen F2 (MCC) jumps back to this screen Rset F2 button : to integrate an automatic isolated compressor, to reset the Energon1 ↓ scroll down to Energon1 main screen 2 Energon1 main screen 2
Net pressure ↑ Bar 6.5 CC regulating Start Stop Loc. Shows the actual net pressure and the status of the Energon1 : central regulating / central stopped / ready for start /start impossible (e.g. when no actual net pressure data is available =this has to be reset (F3 will be Rset). Function keys are commands to change the control status of the Energon1.
3.5
Energon1 parameters Pressure band 1 : low and high level : can be modified on the display (between 4 Ù 15 bar) Pressure band 2 : low and high level : can be modified on the display (between 4 Ù 15 bar) For each compressor the allowed starts/day: can be modified on the display (between 3 Ù 720 /day) Remote to local time: minimum time always respected between steering 2 compressor to local control can be modified on the display (between 5 Ù 600 seconds) Start/load time : minimum time always respected between starting and/or loading 2 compressors can be modified on the display (between 5 Ù 600 seconds) Start/load answer time : compressor will be put ‘not responding’ if not running load when this time is elapsed after sending the start/load command : can be modified on the display (between 10 Ù60 seconds) Unload time : minimum time always respected between unloading 2 compressors can be modified on the display (between 2Ù60 seconds) Unload answer time : compressor will be put ‘not responding’ if not running unload when this time is elapsed after sending the unload command : cannot be modified on the display (default value = 5 seconds) Stop answer time : compressor will be put ‘not responding’ if not stopped when this time is elapsed after sending the stop command : can be modified on the display (between 5Ù120 seconds) Delta time : maximum difference in running hours between the (un)load compressors (not valid for constant pressure systems – Forced time will correct sequence). Can be modified on the display (between 10Ù672 hours) Forced time : maximum difference in running hours between the (un)load compressors for constant pressure systems : after this period a forced sequence shift will be executed. Can be modified on the display (between 1Ù60 days) Timeout : When the Can communication receives no answer within this period, compressor will be put to ‘no communication’ : can not be modified on the display (default value = 5 seconds)
3.6
Energon1 configuration Status: MCC master active or not: can be modified on the display There can only one Energon1 master in the system Number of compressors: 2, 3 or 4, the number must correspond with the LAN ID address Can be modified on the display System stop status: active or not: if not active a system stop can not be generated Can be modified on the display System forced status: active or not: for constant pressure systems : if active a forced sequence will be performed After elapsing the Forced Time parameter: can be modified on the display * Configuration of the ‘net pressure’ input: it is possible to regulate the net pressure based on a measurement of a dedicated ‘net pressure’ sensor; by default always the ‘compressor outlet’ of the Energon1 master will be used; by Page 14
Atlas Copco Airpower NV
Central Controllers Guide service & commissioning software another input can be activated and linked to the ‘input used by MCC’, this cannot be modified by the display. For more details: see X104 64S 088 Instruction remote sensor for MCC. * It is possible to start / stop the Energon1 function by a digital contact from a distance: the document “How to setup MCC remote start” from AII service department (W. Cattoor) gives more details.
3.7
Integrating Mark 1/2/3 controller A ComBox-S interface is required; this box converts the CAN-protocol to RS232 serial protocol. The NodeId of the ComBox-S must be set to 1, 2, 3 or 4 to support Energon1 control.
4 Energon1 – MCC for SF 4.1
Introduction This product is the same as the previous Energon 1, but specific for controlling SF/MultiSF. No other types are supported. Also SF/MultiSF based on a Mark 3 controller can be directly connected via 1 digital input and 1 digital output for each Mk3-SF. As the MCC can have only 4 compressors, maximum 3 compressors can be connected to the DIOE module.
MKIV MCC MASTER (Multi SF)
I²C Bus
DIOE Module
DI
DO
Node ID 1
MKIII Multi SF
CAN
DO
DI
MKIII Multi SF
MKIV Multi SF Slave
4.2 4.2.1
Cabling CAN Network
See previous chapter Energon 1 4.2.2
Digital link to Mk3-SF
The connection is done via a DIOE expansion module. For each Mk3 there is on digital input wired to the Shutdown relay output of the Mk3 controller and one digital output towards the remote start/stop input of the Mk3 controller. Fixed relation for the digital I/O of the DIOE DI01 input: not used K01 output: not used DI02 input shutdown from Mk3 controller Logical Channel 2 K02 output: start/stop for Mk3 controller LC 2 DI03 input shutdown from Mk3 controller Logical Channel 3 K03 output: start/stop for Mk3 controller LC 3 DI04 input shutdown from Mk3 controller Logical Channel 4 K04 output: start/stop for Mk3 controller LC 4 Page 15
Atlas Copco Airpower NV
Central Controllers Guide 4.3 4.3.1
Regulation Pressure regulation algorithm The Net Pressure Conditions which demands the Start of next Compressor/Element • Pnet < (Pload + DP/3) AND Dp/Dt < 0 (Pressure is decreasing) • Pnet < Pload AND Pact > (Pload - DP/3) AND Dp/Dt 0 • Pnet > Punload – DP/3 AND dp/dt > 50 • Pnet > Punload AND dp/dt > = -2 Timings to be respected in central regulating control mode: * Time respected after starting a MkIV-SF-element before another MkIV-SF-element or a Mk3-SF compressor can be started: if net pressure is within the Pressure Band: T action in PB if net pressure is lower then Plow: T action out PB * Time respected after stopping a MkiV-SF-element before another MkiV-SF-element or a Mk3-SF compressor can be stopped: if net pressure is within the Pressure Band: T action in PB if net pressure is higher then Phigh: T action out PB * Time respected after starting a Mk3-SF-compressor before another MkIV-SF-element or a Mk3-SF compressor can be started: T action for Compressor AND Mk3-SF Starting up time = (# elements-1) * Time to next start * Time respected after stopping a Mk3-SF-compressor before another MkiV-SF-element or a Mk3-SF compressor can be stopped: T action for Compressor Timings to be respected after central stop command: Time respected after stopping a SF-compressor before next compressor can be stopped = T action for Compressor Timings to be respected after local control command: Time respected after sending a MkIV-SF-compressor to local control (CCM=4a) before sending another MkIVSF-compressor to local control = Time remote to local Note: action for a Mk3 compressor: in stead of sending to local control the compressor is started - if it was standing still - else no action, the same timing is respected after this action towards a Mk3 compressor and before dealing with the next compressor. Recommended pressure band setting for Mk3-SF: If the net pressure seen by MCC Master and the outlet of the Mk3 slave are equal: Plow = P_MCC_high – 0.1 bar Phigh = P_MCC_high + 0.2 bar More details and recommended settings: see instructions 9820 4547 05
4.3.2
Priority
It is foreseen to have 2 priority schemes. Priority scheme 1 and scheme 2. In every priority scheme, it is possible to assign certain priority level to every compressor. As 4 compressors can be connected in a MCC, there are 4 priority levels possible (1,2,3 and 4) The compressor with lowest priority number will have highest priority for starting and the compressor with highest priority number will have lowest priority for starting. If the same priority level is assigned to 2 or more compressors, then Running Hours of those compressors are taken into consideration for deciding the highest priority among those compressors for starting. The priority schemes can be changed manually (using parameter settings) as well as automatically (by week timer).
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Atlas Copco Airpower NV
Central Controllers Guide 4.4
Display
1
*
2 RUNN I NG MA I N S CR E EN Running Not Ready (if Blinking) ? No Communication X Not Recognised
3
S H U T D OWN 1 0 . 4
4
1 1 . 0 b a r 1 0 . 0
R E S E T
* !
Shutdown Stopped (if Steady) No Response
Status of Mk4-SF-Element: ‘NOT READY’ after stopping during the ‘minimum stop time’ Counter based on allowed starts/day must be elapsed between two starts ‘RUNNING’ When element is running ‘STOPPED’ When element is stopped ‘SHUTDOWN’ When element is in warning (motor overload / temperature too high) When Compressor is in shutdown ‘NO COMMUNICATION’ When no reply on ‘life-bit’ broadcast within Timeout Time. ‘NOT RESPONDING’ When a command is not executed within Timeout Time. (all elements are shown as ‘not responding’ and compressor is automatically sent to local control and F2=RESET appears ‘NOT RECOGNIZED’ When SF-Type is not correct When PDO layout is not compatible Status of Mk3-SF: ‘NOT READY’ after stopping during the ‘minimum stop time’ Counter based on allowed starts/day must be elapsed between two starts ‘RUNNING’ After giving a start starts via digital output ‘STOPPED’ After giving a stop starts via digital output ‘SHUTDOWN’ When digital input of DIOE is open
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Atlas Copco Airpower NV
Central Controllers Guide 5 Energon2 5.1
Introduction A stand alone Central Control system based on MC2 controller from MicroInnovation can control up to 8 compressors; Load/NoLoad and VSD machines; Elektro Pneumatic can directly be wired to the Energon2. DIOE modules
MkIV VSD
Energon2
DIG I/O wiring
MkIV L/NoL
MkIV VSD
CAN
ComBox-S
EPn Compressor
EPn Compressor
ComBox-S
PC RS232 Modbus
RS232 COM1
ComBox-S
Mk3 L/NoL
Mk1/2 L/NoL Profibus ComBox -P
5.2
Cabling
5.2.1
CAN Network
Cable: Lappkabel Unitronix BUS-CAN 2x2x0.34 : AC Nr. 0017 2610 10, total max length 250m, with a repeater max length can be 500m. Maximum 30 Nodes are allowed on the Can network. Alternative cable: Belden 3106A (AC Nr. 1900 0707 92) Connectors: Normal connector: 1088 0033 01 / Service connector: 1088 0033 02; to support external connection e.g. for service & diagnostic program. The connectors have a built-in terminator resistor, and the end of the network, the switch has to be set to the ON position. The connections are made with the 2X1 9 pins SUB-D connector of the Mk iV controllers. 2
2
3
3
7
7 screen
2 3 7
2 3 7
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Atlas Copco Airpower NV
Central Controllers Guide
The address of the Energon2 can be changed. The addresses of the Energon2 and the other components on the Can network must be unique and from 1 to 30. 5.2.2
Cable from ComBox-S to Mark 1/ 2 / 3
Cable: 4 x 0.5 mm² + screen, maximum length = 25 m 25 pins SUB-D connector COM1 - 5X14 (Mk 3)
9 pins SUB-D ComBox 10X15 4
4
6
5
2
3
3
2 7
5 7
screen
6 8
8
20
This cable with a length of 5 m is available as 1622 0569 00 5.2.3
Digital link connections
With the digital linking only Load/NoLoad compressors can be connected. For each compressor two digital inputs and two digital outputs are foreseen. One DIOE expansion box supports two digital linking channels. By downloading the DIOE type must be ‘Digital Link’. Digital inputs (use voltage free contacts from the compressor): o motor stopped (open) or running (closed) – DI01 or DI03 o unload (open) or load (closed) – DI02 or DI04 Digital outputs (both normal open and normal closed contacts are available): o local (de-energized) or remote (energized) – K01 or K03 o load (de-energized) or unload (energized) – K02 or K04 Maximum 6 Digital links are possible: Digital link 1 uses DI01, DI02 and K01, K02 of first DIOE module of type ‘digital link’, connected via I²C to Energon2 master module (with touch screen) Digital link 2 uses DI03, DI04 and K03, K04 of first DIOE module of type ‘digital link’ Digital link 3 uses DI01, DI02 and K01, K02 of second DIOE module of type ‘digital link’, connected via I²C Digital link 4 uses DI03, DI04 and K03, K04 of second DIOE module of type ‘digital link’ Digital link 5 uses DI01, DI02 and K01, K02 of third DIOE module of type ‘digital link’, connected via I²C Digital link 6 uses DI03, DI04 and K03, K04 of third DIOE module of type ‘digital link’ 5.2.4
Analogue readings
The net pressure is measured by a pressure transmitter -two wires connection. The supply of the Energon2 is used to generate the current. Only two wires and a shielding have to be wired from the Energon2 box towards the transmitter. For more details see service diagram 9820 3754 03. A second pressure transmitter can be connected as a back-up net pressure measurement. 5.2.5
Optional ‘remote control’ DIOE
This DIOE is always the first connected DIOE via I²C to the Energon2 master module. It provides 4 digital inputs for remote control, this functionality is only available if the DIOE type ‘remote control’ is available and the Energon2 control mode is ‘digital remote’ Digital inputs (wiring between pin 8 and pins 3/4/5/6 of 6X9): o DI01: local control (open) or central control Page 19
Atlas Copco Airpower NV
Central Controllers Guide o
o
DI02 and DI03 Both open = central stopped DI02 closed and DI03 open = SPS1 DI02 open and DI03 closed = SPS2 DI02 closed and DI03 closed = SPS3 DI04: not used
There are 4 digital outputs for indication-purposes; this functionality is only available if the DIOE type ‘remote control’ is available. For each digital output both normal open and normal closed contacts are available o K01 = Normal (energized) or System Alarm (de-energized) o K02 = Normal (energized) or Net pressure Alarm (de-energized) o K03 = Normal (energized) or Net pressure Warning (de-energized) o K04 = Local Control (de-energized) or Central Control (energized)
5.3
Setup Hardware (see instruction manual 2920 1597 00 and service diagram 9820 3754 03): During the commissioning the pressure transmitters are wired towards the Energon2 cabinet The DIOE expansion boxes are mounted onto a DIN-rail in the cabinet; power supply and digital I/O has to be wired to the DIOE. A CAN cable is wired from the Energon2 main controller to all compressors linked via CL. For DL wiring is made from the EPn compressors directly to the DIOE modules in the Energon2 cabinet. Software: Using the Energon2_CP commissioning software the Energon2 can be downloaded. • via cross Ethernet cable directly between PC and Energon2 • onto the flash card using a card reader/writer, after download, insert the flash card into Energon2 With the commissioning program all settings and parameters can be seen and manipulated. It is also possible to transfer and convert logging files from the Energon2 for further analysis.
5.4
Functionality
5.4.1
Pressure Regulation P alarm Too High area
P overshoot
∆P (changeable)
P max
∆P/4
∆P
High area Middle area
∆P/2
P min
P drop VSD Set point P rise
∆P/4
Low area
∆P (changeable)
P alarm
Too Low area
P undershoot
∆P is at least 0.1 bar; for good regulation band must be wide enough (dependent of sensor range); When Load/NoLoad compressors are part of the network typical a pressure band of minimum 0.4 bar is required. When more VSD compressors are present, one will regulate as the top load regulating to the middle of the pressure band using its local PI settings. The other VSD’s are steered in speed steps based on the slope of pressure change. Load/NoLoad compressors are (un)loaded when slopes are higher and/or when pressure is outside middle area.
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Atlas Copco Airpower NV
Central Controllers Guide When the net pressure goes outside the alarm levels and if alarm protection is active, the Energon2 will revert all compressors to local control. The regulation algorithm takes into account the following data to decide taking a specific action • Actual net pressure • Slope of de-creasing or in-creasing of the net pressure • Availability and type of connected compressors • Definition of the sequence groups • Running hours of each compressor (for equal wear) – within sequence groups • Minimum, maximum speed and the optimal used area for VSD The result of the pressure regulation algorithm is one of the following actions: FOR VSD • Install C-VSD (VSD will regulate based on its own PI-control algorithm) • Uninstall C- VSD (PI-control of VSD disabled; speed fixed) • Stop (only applicable for VSD without throttle) • Unload (only applicable for VSD with throttle) • Less speed • More speed FOR LOAD/UNLOAD • Start & Load • Load • Unload Based on the amount of added or removed capacity, a compensation-action can be performed. Loading a big compressor will be compensated by steering less speed command to a VSD and unloading a big compressor will be compensated by steering more speed to a VSD. 5.4.2
Control modes
The Energon2 has the following control modes: • Local control: all connected compressors are running/stopped locally, Energon2 only collects all data and is waiting for start/stop command from the operator. • Central – regulating: the Energon2 controls all integrated compressors (isolated compressor can be running or stopped locally) to keep the net pressure within the regulation band • Central – stopped: the Energon2 stops all integrated compressors, the net pressure will drop to 0 bar; this mode can be disabled. 5.4.3
Different System Pressure Bands (SPS)
There are 3 possible system pressure bands. Both manually and based on the week timer the Energon2 can regulate the net pressure within a different pressure band. Each pressure band has its own protection levels. When reaching the warning level an output can generate a warning signal. When the alarm level is reached the Energon2 will revert all compressors to local control and an alarm signal will be generated. The ‘automatic switching to local’ - function can be disabled. 5.4.4
Different Sequence Schemes
There are 8 possible sequence schemes. Both manually and based on the week timer the Energon2 will select the compressors based on a certain sequence. Compressors part of the same sequence group will be selected automatically to guarantee equal wear within this sequence group. Equal wear is guaranteed by selecting the compressor with the least running hours at an upload action and by selecting the compressor with the most running hours at a download action. The Energon2 has its own running hours-counter for each compressor. Whenever a VSD is keeping the pressure stable without the need of adding/removing capacity from load/NoLoad machines, the ‘forced sequencing’ algorithm will force adding the Load/NoLoad compressor with the least running hours, automatically will the pressure regulation algorithm unload/stop another Load/NoLoad machine (with the most running hours) Remark: equal wear is only guaranteed for Load/NoLoad compressors part of the same sequence group.
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Atlas Copco Airpower NV
Central Controllers Guide 5.4.5
Automatic Restart After Voltage Failure
After a power failure the Energon2 will automatically take over control again of all compressors and regulate the net pressure within the pressure band. The following settings are available Status: the function can be active or not Power recovery period: the function is only active if the power returns within this period (infinite exists also) Restart delay: after returning the power the first compressor will only be started after elapsing this period. 5.4.6
Week timer
The Energon2 has a real time clock and based on a week timer table up to 8 actions for each day can be programmed. The following commands are available: • System stop (will only be executed if this functionality is enabled • Activation of System Pressure Set 1, 2 or 3 (if necessary system start included) • Activation of Sequence Scheme 1, 2, 3, 4, 5, 6, 7 or 8. 5.4.7
Visualization
The Energon2 has a touch-panel display. The graphical display uses as much as possible icons and pictograms to give information. The instruction book gives more explanation regarding the user interface. Users and accessibility: each operator can be defined with a certain access level; based on this he is allowed to perform some actions or not. Graphical view: the net pressure can be seen in a trend view. 5.4.8
Energon2 parameters
The following parameters and settings are available to define each compressor channel: Global settings • date and time • unit selection for pressure, temperature and flow • language selection Regulation / system parameters • System stop: enable/disable • Control mode: local / remote / LAN (System start/stop and SPScontrol) • Motor Stop delay: time between two consecutive compressor stop commands • Motor Start delay: minimum time between two consecutive compressor start commands • Equal wear time (when difference between running hours becomes larger => select other compressor) • Integrate delay: time between two consecutive integrate actions • Isolate delay: time between two consecutive isolate actions • Used regulation parameter set: selection from 1 to 5; use a set with smaller number for installations with faster behaviour (small vessel) 5.4.9
Channel parameters
The following parameters and settings are available to define each compressor channel: Type Linked via Can communication (CL) Linked via DIOE and digital I/O (DL) Address For CL: the LANId of the compressor controller For DL: 1 – 6 defining which DIOE digital in/outputs are used Capacity Regulation takes into account difference between capacities; it does not perform capacity matching between air consumption and delivered flow Start response delay When a start command is sent, within this period the compressor must be running (to take care of permissive start conditions) Min/Max levels for optimal speed zone Specific for VSD, not applicable for Load/Unload (0 – 100 %) Page 22
Atlas Copco Airpower NV
Central Controllers Guide Pressure regulation algorithm will try to use the VSD within these limits. Idling time Additional condition for stopping a compressor: compressor will not be stopped if not running unload for this period (not applicable for DL => value = 0) Starting up time Specific for DL; when a start command is sent, within this period the compressor must be run loaded (to take care of Y-time and Load delay) Minimum Stop time Specific for DL (if linked via CL, the setting is automatically collected by the Energon2; after stopping of a compressor during this period the compressor is “not available” Running Hours For each compressor the Energon2 counts the running hours to guarantee equal wear. 5.4.10
Logging parameters
Energon2 has a built-in logging functionality. The PLC program writes the logging data onto the flash memory card. It’s important to make a back-up of the Flash Card before activating the logging, while the flash card can be become corrupted if power fails when writing onto the flash card. The following settings determine the logging: • Type o Event logging: every time the Energon2 takes an action a record is saved o Interval logging: records are saved base on a fixed period o Both logging can be done simultaneous • Interval : used by interval logging • Maximum Amount of Files o Maximum number of files that will be written on the flash card • Overwriting Files allowed: o If this is set: after writing the last logging file (Maximum Amount of Files) the first file will be overwritten o If this is not set: after writing the last logging file (Maximum Amount of Files) the logging stops 5.4.11
Loading/saving the Energon2 configuration
After the first download to the Energon2, it uses the default factory configuration and settings as defined by the operator using the Energon2_CP program. The Energon2 makes a copy of this in retain memory and will always use these configuration and settings. The settings (part of the retain memory) can be changed by the operator via the touch screen. The operator can make a copy of the configuration and settings onto the flash card. 5 slots are available. Also the factory file can be overwritten (only by user with access level 0, this is intended only for the Atlas Copco service engineer). The stored configuration and settings can be loaded into retain memory (only if Energon2 is in local control mode).
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Atlas Copco Airpower NV
Central Controllers Guide 6 ES100 6.1
Introduction
The ES100 is a Sequence Selector based on Elektronikon Mark 3. It can control up to 7 compressors. The Pressure Band Controller steers the compressors trying to keep the pressure within the regulation band and it controls the sequence of the connected compressors. It can control only load / no load compressors. The ES100 exists in different versions, dependent of the requested digital and/or communication links. HRR Standard + COM3 (standard ES100) : provides 3 digital and 4 comm. links HRR Standard + DIOE : provides 7 digital links HRR Standard + DIOE + COM3 : provides 7 digital and 4 comm. links HRR Standard + COM3 + COM3 : provides 3 digital and 8 comm. links The linking with the compressors can be made either by serial communication (both sending commands and receiving status data) through a current loop connection between ES100 and the compressor or by connecting digital inputs and outputs between the ES100 and the compressor. The ES100 will be mounted in a cubicle; connections for in- and outputs towards the compressors have to be made when the ES100 system is installed (see instruction manual). MK3 ES100
DIG CONTACTS
DIOE
DIG CONTACTS
COM1 COM3 1
2
3
4
5
6
CLCL
CL
CL
CL
CL
CL
ComBox
ComBox CAN
CAN
COM1
MK3
COM1
MK4
7
MK1
MK3 MK3
COM1
MK4 CAN
PC
Page 24
MK3 MK3
DIG GROUP
Atlas Copco Airpower NV
Central Controllers Guide 6.2
Digital input/output link.
The digital compressor link contains inputs and outputs. For each compressor the ES100 has two outputs (normal open and normal close contacts available) : local / remote control : for switching the compressor to remote pressure sensing mode load / unload control : for steering the compressor to (un)load The ES100 has also 2 digital inputs for each compressor for feedback purposes: stopped / running : indicating the motor status of the compressor unloaded / loaded : indicating unload / load status of the compressor Mk iV controller equipped compressors can be connected to the ES100 via digital linking, although the communication link is more easily for wiring. Only compressor of the Load/No Load type are supported. The position of the digital inputs for remote load/unload control is D4 and the load/unload digital input is D3, see service diagrams. The position of the digital outputs for stopped/running is K01 and for Unload/Load K04, a voltage free contact must be used, see service diagram for details.
6.3 6.3.1
Communication link Mark 1/2
The controller directly supports current loop, which can be connected to the ES100 cubicle, for more details : see Electronic Systems Guide : 9824 0719 00 6.3.2
Mark 3
The COM1 serial expansion module connected to the Mark 3 main controller provides a current loop connection, which can be connected to the ES100 cubicle, for more details : see Electronic Systems Guide : 9824 0719 00 6.3.3
Mk iV
To connect a Mk iV controller equipped compressors to the ES100 via communication linking, the current loop line must be converted to CAN; this can be done using the ComBox-S. For every compressor with a Mk iV controller you need a ComBox-S. You have to set the CAN NodeId of the MkiV controller to 1,2,3 or 4. The CAN NodeId of the ComBox-S can be set from 1 to 30, but has to be different from the address of the compressor controller and NodeId 31 may not be used.
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Atlas Copco Airpower NV
Central Controllers Guide Required Cabling:
Serial Cable from ES100 to ComBox (Current loop) ES100 CUBICLE
1 6
2
7
ComBox Current Loop
10X18
ComBox LAN
CAN Cable between 2 points
Compressor Mk IV LAN
2
2
3
3
7
7
10X1 9 pins SUB-D
Cable : Lappkabel Unitronix BUS-CAN 2x2x0.34 : AC Nr. 0017 2610 10, max length 250m
2X1 9 pins SUB-D
Connectors to be used : Normal connector: 1088 0033 01 Service connector: 1088 0033 02, to support external connection e.g. for service & diagnostic program These connectors have a built-in terminator resistor; the switch has to be on the ON position
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Atlas Copco Airpower NV
Central Controllers Guide 7 ES300 7.1
Introduction
The ES300 is an intelligent net pressure controller based on Mark 3 hardware. It can control up to 16 Load/NoLoad compressors. The pressure band controller steers the compressors to keep the net pressure within the regulation band, it controls the sequence of the connected compressors, it selects the optimal compressor mix to match the delivered air to the air consumption. It supports only current loop serial communication with the compressors.
MK3 ES300 COM1 COM3 1
2
3
CLCL
CL
CL
ES001 DIG CONTACTS
…
13
14
15
CL
CL
CL
ComBox
ComBox
CAN
CAN
16 CL
ComBox
ES003
CAN
ES002
DIG CONTACTS
DIG GROUP
COM1
MK4
MK1
MK3 MK3
COM1
MK4
MK3 MK3
DIG GROUP
CAN
PC
7.2 7.2.1
Communication link Load/NoLoad Compressor without Electronic Controller
The ES001 interface is required, it converts digital signals into the communication protocol required by the ES300. The communication link is established as with a compressor equipped with a Mark 3 controller for more details : see Electronic Systems Guide : 9824 0719 00. The ES001 is based on Mk3 hardware, with Mk iV hardware an interface box will be developed converting digital signals into the CAN protocol (called X), using the ComBox-S this compressor can be connected to the ES300 (see also chapter compressor equipped with Mk iV controller). 7.2.2
Load/NoLoad Compressor with Mark 1 / 2 controller
The controller directly supports current loop, which can be connected to the ES100 cubicle, for more details : see Electronic Systems Guide : 9824 0719 00
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Atlas Copco Airpower NV
Central Controllers Guide 7.2.3
Load/NoLoad Compressor with Mark 3 controller
The COM1 serial expansion module connected to the Mark 3 main controller provides a current loop connection, which can be connected to the ES100 cubicle, for more details : see Electronic Systems Guide : 9824 0719 00 7.2.4
Load/NoLoad compressor with Mk iV controller
To connect a Mk iV controller equipped compressors to the ES300 via communication linking, the current loop line must be converted to CAN; this can be done using the ComBox-S. For every compressor with a Mk iV controller you need a ComBox-S. You have to set the CAN NodeId of the MkiV controller to 1,2,3 or 4., The CAN NodeID of the ComBox-S can be set from 1 to 30, but has to be different from the address of the compressor controller Required Cabling :
Serial Cable from ES300 to ComBox (Current loop) ES300 CUBICLE
1
6
2
7
ComBox Current Loop
10X18
ComBox LAN
CAN Cable between 2 points
Compressor Mk IV LAN
2
2
3
3
7
7
10X1 9 pins SUB-D
Cable : Lappkabel Unitronix BUS-CAN 2x2x0.34 : AC Nr. 0017 2610 10, max length 250m
2X1 9 pins SUB-D
Connectors to be used : Normal connector : 1088 0033 01 Service connector : 1088 0033 02, to support external connection e.g. for service & diagnostic program These connectors have a built-in terminator resistor, the switch has to be on the ON position
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Atlas Copco Airpower NV
Central Controllers Guide 8 ES20 / ES30 8.1
Introduction
The ES20/30 is the first generation intelligent net pressure controller. It can control up to 6 / 12 Load/NoLoad compressors. The pressure band controller steers the compressors to keep the net pressure within the regulation band.
8.2 8.2.1
Communication link Load/NoLoad Compressor without Electronic Controller
The ES01 interface is required, this is an obsolete interface box. Also the newer generation ES001 (based on Mark3 hardware) and ES003 (based on MkIV hardware) can be used as interface box. Important Note : Using these interface in some extreme situation problems might occur. To be used only is exceptional cases, field tests are required ! The communication link is established as with a compressor equipped with a Mark 3 controller for more details : see Electronic Systems Guide : 9824 0719 00. 8.2.2
Load/NoLoad Compressor with Mark 1 / 2 controller
The controller directly supports current loop, which can be connected to the ES100 cubicle, for more details : see Electronic Systems Guide : 9824 0719 00 8.2.3
Load/NoLoad Compressor with Mark 3 controller
The COM1 serial expansion module connected to the Mark 3 main controller provides a current loop connection, which can be connected to the ES100 cubicle, for more details : see Electronic Systems Guide : 9824 0719 00 8.2.4
Load/NoLoad compressor with Mk iV controller
To connect a Mk iV controller equipped compressors to the ES300 via communication linking, the current loop line must be converted to CAN; this can be done using the ComBox-S. For every compressor with a Mk iV controller you need a ComBox-S. You have to set the CAN NodeId of the MkiV controller to 1,2,3 or 4., The CAN NodeID of the ComBox-S can be set from 1 to 30, but has to be different from the address of the compressor controller. Required Cabling :
Serial Cable from ES20/ES30 to ComBox (Current loop) ES20/ES30 CUBICLE
1
6
2
7
ComBox Current Loop
10X18
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Atlas Copco Airpower NV
Central Controllers Guide
ComBox LAN
CAN Cable between 2 points
Compressor Mk IV LAN
2
2
3
3
7
7
10X1 9 pins SUB-D
Cable : Lappkabel Unitronix BUS-CAN 2x2x0.34 : AC Nr. 0017 2610 10, max length 250m
2X1 9 pins SUB-D
Connectors to be used : Normal connector : 1088 0033 01 Service connector : 1088 0033 02, to support external connection e.g. for service & diagnostic program These connectors have a built-in terminator resistor, the switch has to be on the ON position
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