Professional Documents
Culture Documents
1. General information
2946 1453 00
Applicable to
Compressors
Preliminary Operations:
Safety Instructions
General
Persons Required
Special Tools
Consumables
2. Document overview
This document describes the following:
1.
2.
3.
ES device....................................................................................................................................................................3
3.1.
Overview ................................................................................................................................................................3
3.2.
Specifications .........................................................................................................................................................3
3.4.
Electrical connectivity.............................................................................................................................................5
Maintenance.........................................................................................................................................................10
Battery..............................................................................................................................................................................10
Compact Flash.................................................................................................................................................................10
4.
Pressure measurement.............................................................................................................................................11
5.
6.
7.
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Ethernet ...........................................................................................................................................................................12
Analogue modem .............................................................................................................................................................12
GSM/GPRS modem.........................................................................................................................................................13
8.
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3. ES device
3.1.
Overview
The core of the installation is the ES device which retrieves and processes information coming from the compressors, dryers
and other measurement equipment.
Compressors and dryers must be connected to the ES device by means of a CAN or ethernet network. Per airnet, one or
multiple 4-20 mA pressure transmitters can be connected. A flow meter, dewpoint meter, etc are optional.
In case of data upload to the datawarehouse, an internet connection should be made (direct or over modem).
3.2.
Specifications
Industrial PC with celeron M 600 MHz processor, 256MB L2 cache, 256 MB RAM
Optional modem
Optional Combox
Upper part:
optional data upload modem (analogue modem T800, quadband GSM/GPRS modem T801),
Middle part:
industrial PC A500,
Lower part:
50/60 Hz feeding,
earth (PE,GND).
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NOTE:
The PC does not have an on/off button. To reboot the ES, use fuses F111 or F110.
Display buttons
On the back of the touch screen, there is an on/off button and menu navigation possibility. In normal circumstances, these
buttons are not to be used. If desired, the contrast/colour etc. of the screen can be adjusted though the menu.
Thermal
The unit is designed to operate without the aid of external cooling fans.
Operational temperature: the unit can operate in the range 0 to +50C, with maximum relative humidity of 85% at 40C.
Storage temperature: the storage temperature shall be 20C to +60C, with maximum relative humidity of 85% at 40C.
Compliance
The product is CE, cULus marked.
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3.3.
Mechanical mounting
Stick labels on the control panels of the machines connected to the ES as well as on an obvious place inside these machines,
warning the operator that the machine is remotely started and stopped by a separate controller. These labels warn the operator that,
also after voltage failure, the ES can remotely start and stop the machine.
3.4.
Electrical connectivity
Service diagram
Check service diagram (AC PN: 9823 4327 00)
Power connection
Connect a 110-240 VAC, 50/60 Hz power supply to terminals L1 and L2 of the ES controller. Make sure the earthing is
connected to terminal PE.
The control cabinet has to be connected to a branch fuse circuit. The branch fuse must fit the feeding cable wire type.
Electrical connections should be made by qualified personnel and according to the local standards.
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I/O
The IO block K010 is connected to the industrial PC A500 by a CAN open network (connector X3 on the industrial PC).
The ES device has an I/O block K010 with eight 4-20 mA analogue inputs, four digital inputs and four digital outputs. The
digital outputs can be wired to four relays: K101, K102, K103 and K104 (upon ordering this feature).
Electrical connections should be made by qualified personnel and according to the local standards.
Digital inputs
4 DIGITAL INPUTS
Input type
Isolated
Input filter
5 ms = 200Hz
Input protection
8 kV to ESD
Input impedance
Powered
Protection
Switching time
Max 100 ms
Input current
6.6 mA at 24V
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It is recommended to use 3-wire sensors for the digital inputs when they switch electronically. 2-wire will work in some
cases, but may behave unexpectedly. When using mechanical switches, 2 wires suffice.
Connections:
Digital outputs
4 DIGITAL OUTPUTS
Contact type
Switching voltage
24V DC
Switching current
0.5A
Isolation
2 kV process to system
Debouncing
no
When the relay option is built-in, the digital outputs are connected to the 4 relays on the right of the IO module. The relays
can switch 240V, 10A each and have both normal open and normal closed connections.
Assure correct operation of your installation when ES would be in power failure: i.e. the normal open/close should ensure good
operation of your installation.
3 connection points per output: one of which refers to normally open, and one to normally
close. Dual use possible.
Actuating voltage
24V DC
The relays are used for signalling or controlling external devices based on certain states of the software. They are designed for use
in UL Class 2 circuits.
The digital outputs should only be used to control or monitor functional systems. They may NOT be used to control,
switch or interrupt safety related circuits.
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Analogue inputs
8 ANALOGUE INPUTS,
4-20 mA
Input type
Load
Max. load current per channel is 120mA with a max. total of all 8 channels of 600 mA
Ranges
Current: 4-20 mA
Resolution
10 bit
Accuracy
<1.5%
Throughput rate
100 Hz
Isolated
Input filter
200 Hz
Input protection
8 kV to ESD
Input impedance
23.5 ohm
Powered
24V
Protection
When connecting a three-wire passive sensor to the screw terminal series XAI1, the maximum allowed current for sensor
operation is 120 mA per sensor and maximum 600 mA for the total of all connected sensors.
Grounding sensors
When connecting sensors to the ES, make sure that the shielding is connected to the grounding bar in the ES-device. When
sensors are grounded at the ES side, it is NOT advised to connect them to ground at the connector.
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Extension IO blocks
Optional extra IO blocks can be added outside the ES cabinet by wiring a CANopen network starting from the CAN
connector on the IO block K010.
Available IO blocks:
Using these optional IO blocks, the ES can connect to up to maximum 100 digital outputs, 100 digital inputs and 16
analogue inputs.
The address of each I/O block is configured through 8 DIP switches on its left side. The first address 00000000 is used by
the standard block in the cabinet.
During commissioning you have to set the CANopen address in the WizAir program. A drawing will show how to set the
dipswitches on the IO block.
Example:
The addresses between 0 and 31 are reserved for blocks with 8AI, 4DI and 4DO,
The addresses between 32 and 63 are reserved for blocks with 16 DI and 16DO.
The connectors and cabling to be used are the same as for the compressor CAN networking (Instruction nr: 9820 3582 00).
The CAN network is a separate network from the compressor Combox CAN network. Do not connect any IO blocks on the machine
CAN network.
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3.5.
Maintenance
Battery
The industrial PC contains a battery with lifetime of 5 years.
Replace every 5 years with a CR2025 battery, 3V Li-Mn.
The backup battery is located underneath the front plate of the industrial PC. To replace the battery perform the following:
1.
2.
3.
4.
Remove the front plate carefully to avoid any damage to plate or connectors.
5.
Remove the old battery and replace it with the new battery.
Ensure that ESD requirements are met. The battery can be removed using the thumb and forefinger: simply push the battery back with
the thumbnail until it is released from the holder and lift it with the thumbnail out of the holder.
6.
Reinstall the front plate ensuring that it is properly seated (LEDs properly fed through their holes in the front plate).
Compact Flash
If the CF card breaks down, replace with original spare part.
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4. Pressure measurement
1.
2.
via valves, allowing the pressure transmitter to be removed after isolating and depressurising it
Isolate and depressurise that part of the airnet to which the pressure transmitters will be connected.
The pressure transmitters have a working temperature limit from 30 to 125 C. Use an extension pipe for high temperatures to cool
of the air.
3.
Connect the transmitters to the analogue inputs of the ES using double twisted pairs shielded 0.75mm cable. The
maximum cable length is 1000 m.
If the pressure transmitters have a fixed cable with shielding attached, the shielding must not be connected to the shielding of the
ES to prevent loop-currents in the system.
5. Machine communication
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Instructions on functionality of and how to connect to a Modbus network can be found in the instruction User Guide Mk4
Modbus (Instruction nr: 9820 3582 02).
Instructions on functionality of and how to connect to a Profibus network can be found in the instruction User Guide
Mk4 Profibus (Instruction nr: 9820 3582 03)
Instructions on functionality of and how to connect to an Ethernet network can be found in the instruction ??????
***************
Ethernet
In case of a direct Ethernet connection, guide the Ethernet wire trough cable tray and cable gland and connect to X9
connector on the industrial PC A500.
Analogue modem
To connect to an analogue modem, insert RJ11 phone line connector in the modem (T800) and guide wire trough cable tray
and cable gland, outside the box.
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GSM/GPRS modem
To connect to a GSM/GPRS modem (T801), the SIM card has to be inserted in the corresponding slot:
1.
2.
Open the modem housing: release the housing cover on the right and left and pull the PCB out of the housing.
3.
If you have been supplied with a SIM card in credit card format, detach the small part and remove any excess plastic
from the edges.
4.
Slide the SIM card into the holder with the contact surface towards the PCB. The angled corner must point towards the
back of the PCB.
The device only supports 3 V SIM cards. For older SIM cards, please contact your GSM service provider.
5.
6.
Place the antenna outside the ES box. Make sure you can receive a good GSM signal on the location where this unit
will be placed.
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8. Initial ES configuration
Following can be adapted on the ES:
Touch calibration
2.
3.
If you want to unpower the ES, wait a couple of seconds longer before you do so (delayed write of registry might occur).
Date-Time-Timezone settings
1.
2.
3.
Press Apply.
4.
If you want to unpower the ES, wait a couple of seconds longer before you do so (delayed write of registry might occur).
NOTE:
You must set the date-time-timezone correctly even if you have upload. The time synchronisation with the upload server is only
applied to the upload data points.
2.
3.
4.
5.
6.
If you want to unpower the ES, wait a couple of seconds longer before you do so (delayed write of registry might occur).
2.
3.
4.
If you want to unpower the ES, wait a couple of seconds longer before you do so (delayed write of registry might occur).
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