SmartAir Master Training Manual [PDF]

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Training Manual

DL102AA - May 09

SmartAir Master Compressor Management System

CompAir

Contents

Training Manual

SmartAir Master Compressor Management System

DL102AA - May 09

3

Contents

CompAir

Contents

4

1 1.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 2.1 2.2

Installation & Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Commissioning Wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14

The Main Screen . . . . . . . . Line Pressure Display. . . . . The Set Pressure Range . . . Network Air Demand . . . . . Reset Button . . . . . . . . . SD Card button . . . . . . . . Date and Time . . . . . . . . Program Button . . . . . . . . Information menu button . . . Last Warning Or Alert . . . . . Current Profile In Use . . . . . Compressor Status Indicators Compressor Information . . . Events . . . . . . . . . . . . Service on/off . . . . . . . . .

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. 12 . 13 . 13 . 13 . 13 . 13 . 14 . 14 . 14 . 14 . 14 . 14 . 15 . 16 . 16

4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

Information Menu . . . . . . Overview Timer Control . Current Profile. . . . . . . Events. . . . . . . . . . . < Back button . . . . . . . Software (version) . . . . Statistics . . . . . . . . . Operating Hours . . . . . Measured Values (1 of 2) . Measured Values (2 of 2) .

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. 18 . 19 . 19 . 19 . 19 . 19 . 20 . 20 . 20 . 21

5 5.1 5.2 5.3 5.4 5.5

Programming Menu . SmartAir Master. . Compressors . . . Extension Modules Codes . . . . . . . Languages . . . .

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6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10

SmartAir Master Menu . . . . . . . . . . . . . . . . . Profiles - to Create New . . . . . . . . . . . . . . . Profiles - to Modify Existing . . . . . . . . . . . . . . Timer Control - To Create New Channel . . . . . . . Timer Control - To Edit Channel . . . . . . . . . . . Timer Control - Overview Timer Control (Example 1) Timer Control - Overview Timer Control (Example 2) Regulation. . . . . . . . . . . . . . . . . . . . . . . Data Logging (Reset) . . . . . . . . . . . . . . . . . Inputs / Outputs . . . . . . . . . . . . . . . . . . . . RS485 Interfaces . . . . . . . . . . . . . . . . . . .

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. 26 . 27 . 27 . 28 . 28 . 29 . 29 . 29 . 30 . 30 . 31

7 7.1 7.2

Extension Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Module Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Digital Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 32

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DL102AA - May 09

Contents

CompAir

8 8.1 8.2

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Compressors Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Edit Compressor Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 33

9 9.1 9.2 9.3 9.4

External Connections. Analog Inputs . . . . Digital Inputs . . . . Digital Outputs . . . RS Interface Ports .

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34 35 36 37 38

5

1 Introduction

1

CompAir

Introduction

1.1 Features • Intelligent controller for up to 12 networked Compressors • Efficiently maintain pressure band within a network • Easy to use TS-GUI (Touch Screen Graphical User Interface) • Up to 12 programmable Air Station profiles • Up to 12 individual Timer Schedules • Instant overview of Air Station status • Instant overview of individual compressor status • Programmable Inputs and Outputs • Battery Buffered Real Time Clock • Code Protected Menus • RS485 Interface for PROFIBUS Module • Up to 4 Extension Modules

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DL102AA - May 09

Installation & Commissioning 2

CompAir

2

Installation & Commissioning

2.1 Installation The SmartAir Master must be daisy-chained in series.

The network connections must not be wired in a closed loop

The SmartAir Master can be connected anywhere along the chain, not necessarily at the start or end of the chain.

nor must they branch out individually to each machine.

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7

2 Installation & Commissioning

2.2 Commissioning Wizard Select Language is the first option that appears when SmartAir Master is switched on for the first time. Note: English U.S. also shows imperial values)

CompAir

Alternative sensors require values to be entered at 4mA and 20mA.

0 14

You will be asked if another Analog sensor is used on Analog Input Channel 2 Press 'YES' to contiue.

If used you will also be prompted to set the scaling of this sensor between 4mA and 20mA.

You will then be asked if the line pressure sensor is the original one, or if an alternative is being used.

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DL102AA - May 09

CompAir

Next, you will need to enter the volume of your network.

Installation & Commissioning 2

This can range between 1.3 bar (actual pressure) to 0.3 bar below the Maximum Pressure Warning value from the last screen. In this instance the pressure warning on the previous screen was set to 16 Bar. Therefore the maximum allowable Cut-out point would be 15.7 Bar The ‘Cut-in point’ is the lower limit.

Then a maximum pressure warning figure.

This can range between a minimum of 0.3 bar (actual pressure) to a maximum of 0.3 bar below the Cut-out point from the last screen. The Cut-out point on the last screen, in this example, was set to 10 Bar so the maximum allowable Cut-in point is 9.7 Bar. Then you will be asked to set a minimum pressure warning value. You’ll then be asked to define the upper and lower limits of the normal working pressure range

The highest this figure can be is 0.3 bar below the Cut-in point entered on the last screen. We used the value 9.5 bar, so it's shown here as 9.2 Bar.

The ‘Cut-out point’ is the upper limit.

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9

2 Installation & Commissioning

To start searching for compressors in the Air Station press:-

CompAir

The commissioning wizard then proceeds to find compressors on the network.

‘WIZARD: COMPRESSOR COMMISSIONING’

1 2 3 4 5 6 7 8 9 10 11 12

You will be prompted with a quick reminder screen to check:-

Delcos 3100-L Delcos 1000-L Delcos-Pro-L Delcos-Pro-DH -----------------

1231V203 1212V302 Dpro-L-1.13 Dpro-DH-1.13

You will be asked to enter the Free Air Delivery of each of the compressors in the Air Station.

• Correct Polarity of connections. • Power Supply has been switched on. • Compressors have the correct addresses. • Baud Rate is set to 9600 Press ‘NEXT’ when ready.

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DL102AA - May 09

CompAir

Installation & Commissioning 2

You will be asked to set the priorities of each compressor in the Air Station. The Priority options are:• High: High Priority • Norm: Normal - one level below "High" • Low: One level below "Norm" • Off: Compressor won’t be used

You have now finished entering the commissioning details. Depending on the number of compressors this process normally takes less than 5 minutes. Press ‘QUIT’ to leave the Commissioning Wizard and to start using SmartAir Master.

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11

3 The Main Screen

3

CompAir

The Main Screen

This is the default screen that is shown when Smart Air Master is running.




 















The Main Screen 1. 2. 3. 4. 5. 6.

Current Line Pressure Pressure Range Current Network Demand Reset (removes warnings and alerts) SD Card (Used for Data Logging) Current Date and Time (format changes in American mode) 7. Link to Programming screens

12

8. Link To Information Screens (data is read only) 9. Last Warning Or Alert (needs to be manually cleared using the Reset Button) 10. Current Profile In Use 11. Compressor Status Indicators (instantly view whether a machine is onload, on standby or needs attention)

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The Main Screen 3

CompAir

3.1 Line Pressure Display

3.5 SD Card button

This displays the customer’s current network line pressure.

Used for removing the onboard SD card for data logging purposes.

3.2 The Set Pressure Range This displays the ‘cut-in’ and ‘cut-out’ pressures as entered during setup. SmartAir will aim to maintain a target pressure that is in the middle of these two values.

3.3 Network Air Demand This displays the network’s current air demand and is used to determine which compressors should be running for best efficiency. It is calculated either by monitoring the pressure every second or via a separate flow monitor installed in the customer’s pipeline.

3.4 Reset Button Clears any warning messages displayed under the current profile display.

SM 1571

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13

3 The Main Screen

CompAir

3.6 Date and Time

3.10 Current Profile In Use

The current date and time are shown in the bottom centre of the screen.

Refer to Section 6.1 for more details on this feature

3.7 Program Button • Allows profiles and timers to be set • Add / delete compressor sensors, filters, dryers.

3.11 Compressor Status Indicators These provide an instant status report of all compressors (C1 up to C12) being controlled by SmartAir Master. Both compressors shown in the illustration below are on load.

3.8 Information menu button View information such as profiles, events, statistics etc.

3.9 Last Warning Or Alert Alert messages from external sensors (not compressor warnings). Multiple warnings are shown sequentially. These warnings can only be cleared using the Reset button.

This indicates that Compressor 1 (C1) is currently switched off. To activate this compressor you need to switch it on at the compressor's control panel.

This flashing icon indicates that Compressor 1 (C1) is currently in a blow down phase (pressure too high for the air end to start turning).

This icon indicates that Compressor 1 (C1) is currently in standby mode waiting for a signal from SmartAir Master.

This icon indicates that Compressor 1’s motor is running but the compressor is off load and is waiting for a signal from SmartAir Master to go onload.

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DL102AA - May 09

The Main Screen 3

CompAir

This indicates that Compressor 2 (C2) is currently onload.

3.12 Compressor Information More information about each specific compressor can be obtained by pressing the status icon of the required machine.

This indicates that Compressor 1 is a variable speed machine and is adjusting its speed to match the demand. The speed is shown as a bar graph within the icon as well as a percentage figure.

This indicates that Compressor 1 has a warning message for the user and should be checked immediately. This warning will not cause a shutdown.

This indicates that Compressor 1 has triggered an Alert message and has shut down. The compressor needs immediate attention.

This indicates that there has been a communication problem with Compressor 2 (not necessarily a problem with the compressor itself) and the cables and connections to this compressor need to be checked.

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15

3 The Main Screen

Note: In addition to the “< BACK” button, there are two further buttons on the information screen; “EVENTS” and “SERVICE ON/OFF”:-

3.13 Events “EVENTS” displays (up to) the last 50 events for that compressor.

16

CompAir

3.14 Service on/off “SERVICE ON/OFF” replaces the status icon with a spanner symbol, to indicate that the compressor is currently off line and being serviced. This also disconnects SmartAir Master so it can be switched off without causing an Alert message.

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The Main Screen 3

CompAir

This page has been intentionally left blank

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17

4 Information Menu

4

CompAir

Information Menu

8

1

2 7 3 6

5

4

SM 1535

Information Menu 1. Overview Timer Control (allows you to see when each profile will become active)

2. Current Profile (allows you to see details of the currently active profile)

3. Events (allows you to see all events, Warning and Alert shutdowns across the whole Air Station)

4. < Back (takes you back to the Main screen)

6. Statistics (allows you to see statistics of the Air Station since the data logging was last reset)

7. Operating Hours (displays Absolute and Relative hours of each compressor in the Air Station)

8. Measured Values (shows both pressure and air demand over a time period - up to 12 hours)

5. Software (version) (allows you to see the version number of the currently installed software)

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Information Menu 4

CompAir

4.1 Overview Timer Control

4.3 Events

This allows you to view which compressor profiles will be used at any particular time.

This shows up-to the last 50 events that have occurred with the Air Station (all the compressors combined).

The example below shows that profile 1 will be used from Monday to Saturday, and then no profiles will be used after midnight Saturday.

This list of events isn’t typical and was generated deliberately to show what the list would look like.

Although this shows 1 profile, up to 12 different profiles can be created. Profiles will be looked at in more detail in the programming menu section.

4.4 < Back button Takes you back to the Main screen

4.2 Current Profile This displays read only information of the current profile in use. It details the profile number, how the profile is activated (either by timer or perhaps external switching) as well as different Cut-in and Cut-out pressure points etc…

4.5 Software (version) This screen shows the current installed version of the SmartAir Master’s software. Later updates will show software versions of each compressor

The concept of profiles and how they can be activated will be discussed in the next section.

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19

4 Information Menu

CompAir

4.6 Statistics

4.8 Measured Values (1 of 2)

This screen shows the statistics of the air station since the date shown.

This links to 2 graphs. One plots the line pressure, cut-in and cut-out pressures and the other plots the flow demand. You can switch between the two graphs by pressing the left or right buttons on the screen.

The minimum and maximum values are time stamped so you know when they occurred. This is useful to determine when the peak demand occurs in a factory to allow you to adapt profiles for these times.

4.7 Operating Hours This option shows both actual and relative operating hours of each compressor (C1 up to C12). You can scroll through the compressors using the left and right arrow buttons. ‘Absolute hours’ show the actual running hour data interrogated from each machine. ‘Relative hours’ Is the amount of hours run since the relative hours was last reset. Useful if, for example, you want to check running hours at the end of each month.

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Information Menu 4

CompAir

4.9 Measured Values (2 of 2) The x axis of the graph (hours) can be scaled to 1h, 3h, 6h and 12h by pressing the button that is currently showing 1h.

Cut-out pressure line (can change if a different profile is activated). Here it’s 9 bar. Set Pressure line Cut-in pressure line (can change if a different profile is activated). Here it’s 8 bar. The y axis (pressure or air flow, depending on the graph) can be re-scaled by entering in your chosen upper and lower values. Currently they are showing 0m3 to 200m3 and 7 bar to 10 bar on the respective graphs.

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21

5 Programming Menu

5

CompAir

Programming Menu

1

2

3

SM 1536

6

5

4

Programming Menu 1. SmartAir Master (Allows you to configure the SmartAir system, including timers, profiles and interfaces.)

2. Compressors (Allows you to add, delete or alter parameters of compressors in the Air Station)

4. Codes (Allows entry into the parameters)

5. Languages (Allows you to select a language for the user interface)

6. < Back (takes you back to the Main screen)

3. Extension Modules (Allows you to select a language for the user interface)

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Programming Menu 5

CompAir

5.1 SmartAir Master

5.3 Extension Modules

This button brings up a sub menu listing further options that allows you to create and edit profiles, set timer schedules for when these profiles get used, control data logging, set up digital and analog inputs / outputs etc…

This button brings up a menu that allows you to add up to four extension modules. This will be looked at in more detail in Section 7.

This sub-menu will be looked at in more detail in section 6.

5.4 Codes 5.2 Compressors Setting up the information for the compressors will probably have been done using the setup wizard. This button brings up a screen that allows you to edit these details as well as add or delete compressors from your current Air Station. This will be looked at in section 8.

When a red padlock is displayed in the Codes button, all parameters are locked and cannot be adjusted. To change parameters you first need to unlock the system. The code for this is 7070. Once the required parameters have been changed you need to key in 7070 again to re-lock the parameters. The padlock automatically reverts to a locked state 10 minutes after it has been unlocked. To reboot the system back to its factory settings (and return you to the setup wizard) the code is 7777.

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23

5 Programming Menu

CompAir

5.5 Languages This menu allows you to switch between different languages. The US English version also displays values in CFM and PSI as well as transposed day and month values when dates are referred to.

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Programming Menu 5

CompAir

This page has been intentionally left blank

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25

6 SmartAir Master Menu

6

CompAir

SmartAir Master Menu

1

6

2

5

3

4

SM 1537

SmartAir Master Menu 1. 2. 3.

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Timer Control Button Profiles Button Regulation Button

4. RS485 Interfaces Button 5. In-/Outputs Button 6. Data Logging Button

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SmartAir Master Menu 6

CompAir

6.1 Profiles - to Create New

6.2 Profiles - to Modify Existing

A profile is a set of parameters and settings that can be activated as soon as that profile has been called.

To edit a profile, click on the profile number button (e.g. Profile 1).

Only one profile can run at any one time and the current running profile is displayed on the Main screen.

This will call up all the parameters that can be defined in that profile, i.e.

The profile screen allows you to create up to 12 individual profiles that can be activated either via the timer function or via an external trigger such as a sensor or external time clock. To add a new profile press “NEW PROFILE”. There must always be at least 1 profile.

• Max. pressure warning • Cut-out point • Cut-in point • Min pressure warning • Net volume • Priorities of compressors Remember to make sure the Code padlock colour is green; if not, enter the code 7070.

Note: There must always be a profile 1. A ‘DELETE PROFILE’ button appears in this space on profiles 2 to 12.

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27

6 SmartAir Master Menu

6.3 Timer Control - To Create New Channel The “Timer control” allows you to schedule the times that different Profiles are activated or deactivated. You can create up to 12 time schedules (Channels) and each channel can control the start and stop times for one profile. The following illustration shows just one time channel (Channel 1), but you can create more by pressing the ‘NEW CHANNEL’ button.

CompAir

6.4 Timer Control - To Edit Channel Pressing the Channel 1 button allows you to edit its settings. You can select:• The profile you want to be activated on this channel. • The days you want this profile to run and the start and end times. You can also delete a channel from this screen by pressing ‘DELETE CHANNEL’

You can also adjust the current time by pressing the ‘ABJ. TIME’ button (should read 'ADJ. TIME').

Press the appropriate 'DAY' buttons to toggle on and off the day/s on which that particular profile will run. Press the 'TIME' buttons to enable the times to be changed. In the illustration below, you can see that Profile 1 has now been set to run every day.

Once you’ve finished editing this channel, just press the 'BACK' button to return to the timer control menu.

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CompAir

6.5 Timer Control - Overview Timer Control (Example 1) Press the Overview Timer control button and the times when Profile 1 becomes active is shown in orange.

SmartAir Master Menu 6

Note: Higher channel numbers take precedence over lower ones! So, if ‘channel 1’ sets profile 3 to run all day and ‘channel 2’ sets profile 2 to run between 11am and 3pm, then channel 2 will take priority and profile 2 will run between those times.

6.7 Regulation The Regulation screen allows you to Switch SmartAir Master on or off, program delays and make other parameter adjustments to the way SmartAir Master works.

6.6 Timer Control - Overview Timer Control (Example 2) The following illustration shows that 12 timer control channels are set, each with a different Profile. Each profile is indicated by a slightly different colour.

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29

6 SmartAir Master Menu

CompAir

6.8 Data Logging (Reset)

6.9 Inputs / Outputs

This allows you to reset selected Events and Statistics such as:-

The Inputs / Outputs screen allows you to set the:-

• Reset all Air Station Events • Reset Relative Hours (set to 0:00h)

• 3x Digital Inputs • 2x Digital Outputs • 2x Analog Inputs

• Reset all Air Station Statistics • Reset Events for compressor 1 • Reset Events for compressors 2 ➛ 12

Digital Input options for DI 1, DI 2 and DI 3 All 3 can be delayed by between 0-99 seconds

30

Free

Warning dew point

Active profile 4

Fault dryer 1

Warning filter

Active profile 5

Warning dryer 1

Warning Bekomat

Active profile 6

Fault dryer 2

Fault Bekomat

Active profile 7

Warning dryer 2

External fault

Active profile 8

Fault dryer 3

External warning

Active profile 9

Warning dryer 3

Active profile 1

Active profile 10

Fault dryer 4

Active profile 2

Active profile 11

Warning dryer 4

Active profile 3

Active profile 12

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SmartAir Master Menu 6

CompAir

Digital Output options for DO 1 and DO 2

6.10 RS485 Interfaces This screen allows you to set the number of:-

Free

Fault / warn. compr.

Dryer warning

Collective warning

Comp. motor running

Dew point warning

Collective fault

Dryer 1 on

Warning filter

Max. pressure warning

Dryer 2 on

Fault Bekomat

Min. pressure warning

Dryer 3 on

Warning Bekomat

Warning diff pressure

Dryer 4 on

External fault

Fault compressor

Dryer fault

External warning

a) The slave. (Options:- 10h, 20h, 30h, 40h, 50h, 60h, 70h, 80h, 90h, A0h, B0h, C0h, D0h, E0h, F0h) b) The Baud rate: (Options:- 2400, 4800, 9600, 19200, 38400)

Analog Input options for AI 1 (Line pressure) Press. Sensor SmartAir Other pressure sensor

Analog Inputs options for AI2 (Free) No use Press. Sensor SmartAir Other pressure sensor Volume flow sensor Dew point sensor Temperature sensor

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31

7 Extension Modules

7

CompAir

Extension Modules

7.1 Module Select

7.2 Digital Inputs and Outputs

This menu allows you to select and customise up to four extension modules which can be connected to SmartAir Master.

Each of the 4 modules has up to: • 8 Digital Inputs and • 4 Digital Outputs.

Digital Outputs

Digital Inputs

The Digital inputs can be suppressed with a delay if required.

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Compressors 8

CompAir

8

Compressors

8.1 Compressors Screen

8.2 Edit Compressor Settings

This screen allows you to add or change the details of any compressor within the air station.

This screens allow you to: -

• To add a compressor press “NEW COMPR.” (maximum 12) • To edit details of a compressor, press the appropriate compressor number button. • To add a Dryer or Filter to the air station, press “DRYER / FILTER”

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• Alter address of each compressor • Change type of compressor • Alter FAD value of compressor • Delete a compressor The address number and type is normally generated during the setup wizard.

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9 External Connections

9

CompAir

External Connections

Analog Inputs, Digital Inputs and Digital Outputs are all located on terminal block X5.

X5

1 2 3 4 PE PE 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PE PE PE

X5 SM 1539

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External Connections 9

CompAir

9.1 Analog Inputs Two Analog inputs are available (AI-1 and AI-2). A pressure sensor must be fitted to AI-1. Values across these inputs must range between 4 and 20mA. Scaling of these inputs can be set in the Commissioning wizard. Terminals for AI-1 are: 5 (Return) 6 (24v DC Supply) Terminals for AI-2 are: 7 (Return) 8 (24v DC Supply) 9 (GND if required) Cable shielding must be connected to PE for all Analog inputs.

AI-1 must be the line pressure sensor

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AI-2 Optional sensor can be installed here

35

9 External Connections

CompAir

9.2 Digital Inputs Three Digital inputs can be added to connect to external pressure switches or timers etc… Digital inputs 1,2 & 3 are supplied by 24v DC via terminals 10,11 & 12 (11 & 12 take supply from 10), and return on terminals 13, 14 & 15 as indicated. Note: Coupling Relays should be used on longer cable runs.

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DL102AA - May 09

CompAir

External Connections 9

9.3 Digital Outputs Two Digital outputs can provide switching to external devices. Digital Outputs 1 is on pins:16 External Switch Feed (max 240v DC / 1 amp) 17 Normally Open 18 Normally Closed Digital Outputs 2 is on pins:19 External Switch Feed (max 24v DC / 1 amp) 20 Normally Open 21 Normally Closed

DL102AA - May 09

37

9 External Connections

CompAir

9.4 RS Interface Ports X1

Compressors (RS485-1)

X2

Extension Modules (RS485-2)

X3

Customer (RS485-3)

X4

For Profibus (RS485-3)

1

2

X1

3

1

2

X2

3

1

2

X3

3

1

2

3

4

5

6

7

X4 SM 1538

38

DL102AA - May 09