55784340 compressor basics

COMPRESSORBASICS - ELECTRICCompressor Basics - Electric

CompressorBasicElectricsCompressor Basics - Electric

Content : Some definitions and basic laws- DC, AC Single phase, AC Three phase Three phase systems - Star and Delta connections Motor Data Motor Insulation Class and service factor Motor protections - Electrical protections- Overload protections How to read a service diagram Device connections and measurementsCompressor Basics - Electric

Compressor Basics - Electric

ELECTRICITY - What ? Something - INVISIBLE- POWERFULL- DANGEROUS !!

Something - SIMPLE forQUALIFIED PEOPLE

TAKE CARE !!!Compressor Basics - Electric

Power sources Direct Current (DC)VoltageUdcTime

Voltage is polarised with + and - Examples : BatteriesRectified power supplies ; 12.24 V Applications : Electronic instrument suppliesControl equipmentSupply for pressure transmitter, etc... Safety : Voltages up to 24 VDC are safe, higher voltages can be dangerous for people.Ex: 12 VoltCompressor Basics - Electric

Alternating Current (AC) - Single PhaseCharacteristic : Voltage and current regularly changes strength and direction in a sinusoidal variationApplication : General useCompressor Basics - Electric

Alternating Current (AC) - Single PhaseCharacteristic parameters : Period T = Time for 1 cycle Frequency (Hz) = 1/T 50 HZ = 50 periods per second 60 Hz = 60 periods per second RMS value : = max amplitude divided by sqrt 2 (For sinus)Safety : - A.C. Voltage 24 V is dangerousTerminology :< 50 V : extra low voltage < 1000 V : Low voltage 1000 V < U < 10000 V : Medium voltage > 10000 V : High voltageCompressor Basics - Electric

Alternating Current (AC) - Three PhaseCharacteristics : Three phase alternating current is produced in a generator with three separate windings. All values on the sinusoidal voltage are displaced 120 in relation to each otherCompressor Basics - Electric

Alternating current systemL1L2L3NUL=Line voltage = UL1-UL2Uf =Phase voltage = UL 3 ULULULUfCompressor Basics - ElectricIL

Relation between Reactance (X) - Resistance (R) - Impedance (Z) - Phase displacement (j)ZXjRPower factor - cos jUacXRReactanceResistanceCompressor Basics - Electric

Basic lawsDirect Current Law of OhmI = U / R with I = Current in Ampere U = Voltage in Volt R = Resistance in Ohm Absorbed powerP = U x I with U = Voltage in Volt I = Current in Ampere P = Power in Watt


Alternating Current Law of Ohm I = U / Z withI = Current in AmpereU = Voltage in VoltZ = Impedance in Ohm = Sqrt (R + X) where X is the reactance Power in a single phase systemP = U x I x cos j Power in a three phase systemP = UL x IL x cosj x Sqrt (3) with P = Power in Watt ( other units as stated above)Compressor Basics - Electric

Units and measurementsTension : Difference in potential between two pointsUnit = VOLT Example : Measurement in V ac Between V and ComCompressor Basics - Electric

Motor connection in StarTerminal box400 V400 V400 VCompressor Basics - ElectricUnU v1-v2= Un/root 3

Motor connection in DeltaTerminal box400 V400 V400 VUw1-w2 = Un Compressor Basics - ElectricUn

TORQUEA turning force applied to a shaft , tending to cause rotation . Torque is equal to the force applied , times the radius through which it acts.Continuous [rated]torqueThe maximum torque a motor can deliver continuouslyStarting [breakaway] torqueThe torque required to start a machine / compressor from stand-still. It is always greater than the torque required to maintain motion.


Full load torqueThe torque necessary to produce the rated HPat full load speedLocked rotor torqueThe minimum torque that a motor will developat rest for all angular positions of the rotor [with rated voltage applied at rated frequency]Pull-out torqueThe maximum running torque of a synchronous motor .


Pull-up torqueThe torque required to accelerate the load fromstandstill to full speed , expressed in % of running torque.Stall torqueThe torque that the rotor of an energized motor produces when restrained from motion.


MOMENT OF INERTIA!!!Definition???A measure of a bodys resistance to changes in velocity , whether the body is at rest or moving at a constant velocity.The velocity can be linear or rotational. The moment of inertia [ WK square] is the product of weight [W] of an object and the square of the radius of gyration [ K Square ].The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation. WK square is expressed in units like lb-ft square , kg-met square etc.

Total Moment of Inertia = motor +coupling +compressorGD square = 4 X WK square


Torque curve for a short circuited, induction motorTstartTminTmaxTnomRPMTorqueCompressor Basics - Electric

Torque curve of a screw compressor - started in Star/DeltaTorque curve (D)Loaded compressorUnloaded compressorSpeedTorque curve (Y)Speed : +/- 90-95 %Compressor Basics - Electric

MOTOR DATA PLATECompressor Basics - Electric

PROTECTION CLASS (According IEC 34-5)

States how an electrical device is protected against contact and against waterCode : I P X Y Protection against water Protection against human contact and penetration by a solid object

Example : IP 55 Protected against water jet Protection against dustCompressor Basics - Electric

Values for x0 Open motors PROTECTED AGAINST 1 Bodies with a diameter > 50 mm2 Bodies with a diameter > 12 mm3 Bodies with a diameter > 2.5 mm4 Bodies with a diameter > 1 mm5 Dust can still penetrate, but not in such a quantity that it disturbs6 Full dust protection

Values for y0 No protection PROTECTED AGAINST1 Vertical dripping2 Water falling as a spray at an angle equal to or smaller than 15 with respect to vertical3 Iden. as 2 but angle of 604 Water splashed against the motor from any direction5 Against water jet6 Against condition on ships decks7 Against the effect of immersionMost frequently used are IP23, 44 and 54Protection degree of electrical equipment : IP xyCompressor Basics - Electric

Insulation classScope The toughness of winding insulation is influenced by The temperature of the winding The insulation class The maximum allowable temperature rise of the windings is defined by the insulation class The power delivered by a motor is limited by the temperature rise of the winding !!IMPORTANT REMARK :If the upper limit winding temperature is exceededby 10 C, the service life of the insulation is shortened by about half Compressor Basics - Electric

MOTOR TEMPERATURE RISE

Service factor !!!

Definition ???

When used on a motor name plate , a number that indicates how much above the name plate rating a motor can be loaded without causing serious de-gradation .

That is a motor with 1.15 S.F. can produce 15% more torque than one with 1.0 S.F.


Service factor ?

What ?? The service factor of an electric motor is :A multiplier which, when applied to the related power, indicates a permissible higher loading which may be carried out, on condition that the maximum ambient temperature limit of 40 C is not exceeded

Example : - Motor rated power : 100 KW - Service factor : 1,2 - Motor may be loaded to : 120 KW - If Ambient temp

Service factor ?

Used why ??

MARKET DRIVEN

Competitors even use higher service factors ATLAS COPCO POLICY

Only use service factor within the safe limits of the insulation class

the thermal margin ( see table of insulation class) is never used.Compressor Basics - Electric

1900191019201930194019501960197019801990 500Kg1000Kg1500KgDevelopment of the motor-weight (4-pole TOFC-motor 30 kW) from 1900 until todayCompressor Basics - Electric

Service factor

Criteria for Atlas Copco motor selection :

High efficiency No oversizing for efficiency and starting torque Class F winding High protection degree (IP55) Long life time for bearings and windings Minimum 40 000 hours Service factor

Motors are selected to work in the worst conditions within the SAFE AREA of the insulation class !!!Compressor Basics - Electric

Service factor

Motor power is influenced by :

Spreading of the compressor element performance Fouling of the coolers Tolerances on the nominal voltage

Atlas Copco is testing very thoroughly by :

Measurement of the electrical parameters on different voltages and power output Measurement of temperatures around the motor Measurement of DT winding temperatures on various voltages Compressor Basics - Electric

Motor protection

Possible protection based on the line current : FUSE : - Prevent sustained overcurrent while avoiding blow out on starting- For larger motors, mainly used as short circuit protection

THERMAL RELAY- A bimetallic element is heated by the line current, to actuate the protection mechanism Compressor Basics - Electric

Motor protection

MAGNETIC RELAY Respond to magnetic field set up by the line current Almost no time function

Above mentioned protections do not respond to :Over temperature caused by hot ambient conditions Blocked ventilation or coolingCompressor Basics - Electric

Motor protection

OPTIONAL TEMPERATURE RESPONSIVE PROTECTORS : THERMISTORS and RTDs

Integrated (embedded) in the motor windings to protect against dangerous overheating

Closely thermally coupled to the motor windings

Need additional conditioning equipment to interrupt the contactorCompressor Basics - Electric

Termistor protectorConditioning relayPTCPower supplyOutputs for controlAlarmTripRemarks : Thermistors can not be used for measuring Thermistors can be connected in series(R total cold < 1500 ohm) Same sensor can be used for protectionsAlarm and TripCompressor Basics - Electric

Motor protection

RTDs =Resistance Temperature Detector

RTDs used in Atlas Copco : Pt 1000 : used in almost all compressors Pt 100 : Sometimes used to measure motor winding temperaturesPt 1000 Resistance value - 1000 Ohm - at 0 C Platin based resistor Pt 100 : Resistance value of Pt 1000 divided by 10 for the same temperatureValues : See table and chartCompressor Basics - Electric

RTDs Pt 100 and Pt 1000

RTDs Can be connected to Elektronikon extension module without other conditioning amplifiers

Remark for trouble shooting :

Always disconnect both wires of a RTD for checking its value in case of troubles.RTDElektronikonCompressor Basics - Electric

RTDs Pt 100 and Pt 1000RTDs Can be connected to Elektronikon extension module without other conditioning amplifiersRemark for trouble shooting :Always disconnect both wires of a RTD for checking its value in case of troubles.RTDElektronikonReadings in OhmCompressor Basics - Electric

Cables and dimensions Low Voltage power cables and connections The cable connection points have to be connected in the correct way Loose connection points can be the source of mechanical damage to the compressor and will damage the cables Use cables with dimensions as specified in the A.C. instruction manual of each compressor. Cables with too small dimensions cause excessive voltage drop.


Cables and dimensions

Medium Voltage cables

Selection of M.V. cables is the work for electrically qualified people. Cable connections and insulation at both ends have to be done extremely carefulCompressor Basics - Electric

How to read a service diagram ? Symbols : ref condensed symbol list (details ref A.C. Standard E1282 K) Numbering of components Numbering of aux. Contacts circuit numbers on diagram Cross reference Terminal rows Ex: 1 X1- 74Terminal numberTerminal row1 = Cubicle2 = Elektronikon Master module3 = Consecutive module or component numbers Cables and wires Compressor Basics - Electric

Basic symbolsCompressor Basics - Electric

Part of wiring diagramCompressor Basics - Electric

Transformer for auxiliary powerImportant Always take out fuses F1,F2,F3 before commissioning Measure Uin and make primary connections acc table Put F1,F2 in place and measure Uout If Uout is correct, close F3; otherwise adjust connectionsF1F2F3UinUoutTable as example only !Compressor Basics - Electric

Part of wiring diagramCompressor Basics - Electric

Part of wiring diagramAttention :

Remark about the 24 Vac secondary :

Secondary 24 V ac may never be grounded secondary is protected by two circuit breakers

NEVER change this !!!Compressor Basics - Electric

Part of wiring diagram( for compressor supplied without starter)K02 and K03

can be used for

control of

Y - D starterCompressor Basics - Electric

Part of wiring diagram(for compressor supplied without starter)Important

Take care of

interfacing connections

to be in phase with

ECB AIF 1133Compressor Basics - Electric

Interfacing connections with ElektronikonAuxiliary inputsRelay contactoutputsCompressor Basics - Electric

Interfacing connections with ElektronikonRelay outputsTemp inputsPt 1000Pressure sensorinputsCompressor Basics - Electric

Interfacing connectionsDevice connectionsPressure transducers3 - wire connectionTemp sensors Pt10002 - wire connectionCompressor Basics - Electric

PRESSURE SENSORS BCAA = Ground (-)B = Supply voltage(+5 V)C = Signal (+)Measurement in Volts DCRange : Zero = 0.5 Volt DCFull scale = 4.5 Volt DCSensor must remain connected to ElektronikonCompressor Basics - Electric

SERVICE DIAGRAMCompressor Basics - Electric

ELECTRICITY ATTENTION !!! Something - INVISIBLE- POWERFULL- DANGEROUS !!

Something - SIMPLE forQUALIFIED PEOPLECompressor Basics - Electric

Elektronikon MkIVState-of-the-art compressor controlINSTRUMENTATION & ELECTRONICS

What is the Elektronikon?State of the art electronic controller that optimizes all aspects of compressor maintenance and operationINSTRUMENTATION & ELECTRONICS

The Elektronikon monitorsThe Elektronikon system continuously and accurately monitors all defined critical functions of the compressor packageThe Elektronikon display is clear and easy to readINSTRUMENTATION & ELECTRONICS

Elektronikon elegant simplicityOlder electro-pneumatic controlMany more components required than with Elektronikon regulationMore opportunity for failure due to complexity than with Elektronikon regulationMore involved trouble shooting than with Elektronikon regulationINSTRUMENTATION & ELECTRONICS

Elektronikon electronic precisionOlder electropneumatic controlAdvanced electronic controlElektronikon advanced electronic advantage in accuracy...Electronic sensors maintain setpoint with same accuracy throughout lifetimeA mechanical switch's setpoint can drift over its lifetimeElectronic sensors setpoint is easily adjusted through the Elektronikon faceplateA mechanical switch requires inaccurate manual adjustmentReaction of the Elektronikon system is very fast insuring tight system pressure band and assured compressor protection [ better response time ]The reaction of the control system to a process deviation is slow with electropneumatic controlDisplay versus switch readout of parameter has deviationThe process value readout is a function of the sensors electrical signalINSTRUMENTATION & ELECTRONICS

Chapter 1Differences with MkIIIINSTRUMENTATION & ELECTRONICS

Improvements compared to MkIII 1

Hardware related improvements:Better viewing angle of LCD screenNo more expansion modules for standard machines (except ZH)Expansion and communication modules DIN rail mounted => less wiring to cubicle doorNo more COM module for VSD compressorsKey switch integrated in softwareImproved hardware, better electrical connections to terminalsINSTRUMENTATION & ELECTRONICS

Improved LCDLCD glass has updated technology This allows for better reading in all conditions Viewing angle less restricted than in Mk3INSTRUMENTATION & ELECTRONICS

Improvements compared to MkIII 2 Software related improvements:Improved menu structureImproved troubleshootingE.g. to check module connectionHelp Screen for Service contact (e.g. web site, e-mail address)Readout in MPa possible2 pressure settings possibleAutomatic switching with a week timerManual switchingRemote switchingDigital input1 = pressure setting 10 = pressure setting 2INSTRUMENTATION & ELECTRONICS

Double Pressure SettingEach compressor can have 2 sets of pressure settings E.g. to have lower pressure during the weekend. You dont have to pump-up your compressor network. Selection can be madeby handbased on the timer functionTimer can start/stop compressor and change pressure bandINSTRUMENTATION & ELECTRONICS

Improvements compared to MkIII 3 Other improvements:Field programming simplifiedOnly master module has to be downloadedAll components in the CAN network can be downloaded from 1 pointMultiple Compressor Control (MCC) function as optionEnergy savings No more cascading => smaller pressure bandWith remote pressure sensor in the air net => better control of the net pressureEqual wearEasier networking: CAN does not require interfacesOnly 1 module required for external communicationINSTRUMENTATION & ELECTRONICS

New FeaturesMore intelligent user interface for improved navigationHelp screen for service contact2 sets of pressure settingsImproved LCD (better visibility)Relay Expansion Box is integratedHardware improvements in general resulting in neat professional lookImproved communication skills via Computer Automation Network or CANOptimised & modified menu to accommodate new functions3 languages (3rd=Dutch For factory use only)C/F and PSI/Bar can be defined independentlyINSTRUMENTATION & ELECTRONICS

Chapter 2HardwareINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV The familyPhysically the same size as Elektronikon IIUses symbols instead of textNo programming required, parameter set selection based on machine type at assemblyNo communication, options or expansions. No clock functions.Hardware I/O

1 PressureCompressor outlet2 TemperaturesElement outletLAT3 Digital Inputs Emergency stopMotor overloadRemote start/stopInputOutput

Star contactorLine contactorDelta contactorLoad/unload sol. ValveGeneral shutdownDryer controlController functions

DSSARAVFID controlService indicationCountersRemote start/stopProtectionsElektronikon IINSTRUMENTATION & ELECTRONICS

Physically the same size as Elektronikon ITwo out of a selection of 23 languages can be downloadedTwo pressure sets can be programmed, selected manually or timer basedFull expansion capability, up to eight modules per compressorTwo hardware versions, MKIV-IIA or MKIV-IIB4x16 back lit LCDHardware I/OVersion A1 pressure input2 RTD temp inputs8 digital inputs9 digital outputsNo RS485 (no VSD)CAN connectionI/O expansion portVersion B2 pressure input3 RTD temp inputs10 digital inputs9 digital outputsRS485 (VSD)CAN connectionI/O expansion portElektronikon IIElektronikon MKIV The familyINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV The familyPhysically larger than the Elektronikon I and IITwo out of a selection of 23 languages can be downloadedTwo pressure sets can be programmed, selected manually or timer basedFull expansion capability, up to eight modules per compressorTwo hardware versions, MKIV-IIIC or MKIV-IIID4x40 backlit LCDElektronikon IIIHardware I/OVersion C4 pressure input8 RTD temp inputs10 digital inputs9 digital outputsNo RS485 (no VSD)CAN connectionI/O expansion portVersion B4 pressure input10 RTD temp inputs10 digital inputs9 digital outputsRS485 (VSD)CAN connectionI/O expansion portINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV The familyMKIV regulator typeCompressors it is installed on as standardType IPack style GAs, GA 5-11C and SF 1-5Type IIAWorkPlace style GA 11-90C, GA 5-11C(optional) and SF Multi coreType IIBGA less than 90 VSDType IIICZT less than 55 kWType IIIDZR, ZVSD and all other AIF compressorsWhere the Elektronikon MKIVs are usedINSTRUMENTATION & ELECTRONICS

MkIV Master Module for AIFOn all AIF machines the D-controller is used:INSTRUMENTATION & ELECTRONICS

D-Controller The D-controller has following features:User Interface4 * 40 charactersHigher Quality LCD than MkIIIInputs and outputs:4 * pressure inputs (0-5 V)10* temperature inputs (PT1000)10 * digital inputs9 * digital outputs=> No expansion modules for standard machines (except ZH)RS485 connection for convertersCAN connection => communication without interface IC connection for I/O24 Vac power supply requiredINSTRUMENTATION & ELECTRONICS

Expansion modules All modules are DIN rail mounted (less wires to door)Some modules require 24 Vac power supplyExpansion modules are mainly used for machine-options (but are also available as sales kit)AIE1 = 2 * pressure inputs (0-5 V) + 2 * PT1000 inputsE.g. for delta p over integrated DD-filterAIE2 = 4 * 4-20 mA inputsE.g. for dew point meter on IMD or remote speed control on VSD machinesAIE3 = 5 * PT100 inputsE.g. for motor winding/bearing temperaturesAIE4 = 5 * PT1000 inputsE.g. for motor winding/bearing temperaturesDIOE = 2 * digital inputs + 2 * digital outputsE.g. for thermistors in motor windingsSPM 5/7 = for 5 or 7 SPM inputs (= NEW option)INSTRUMENTATION & ELECTRONICS

AIE1 : 1900 0710 41 2 Kavlico Pressure inputs 2 Jumo Temperature inputs No supply No download Low power consumption (mA)Mountable on DIN railINSTRUMENTATION & ELECTRONICS

DIOE : 1900 0710 71 4 voltage Free contacts K01 K04 4 digital inputs No download 24Vac 50/60Hz supply consumption 9VAMountable on DIN rail SPM : 1900 0711 11 I/O for7 SPM channels No supply consumption not known COM Box : MODBUS to CAN 1900 0711 41 COM1(RS232) to CAN 1900 0711 41 PROFIBUS to CAN 1900 0711 42 Communication with compressor network & customers system modbus, profibus, ethernet to be downloadedUpdated !INSTRUMENTATION & ELECTRONICS

Communication modules All modules are DIN rail mountedAll modules require 24 Vac power supplyCommunication modules are only available as sales kit: Combox-S (CAN to Serial)For external communication via ModbusTo connect old units (MkI/II/III and E/P) to the CAN networkTo connect ES100/300 to the CAN network Combox-P (CAN to Profibus)For external communication via Profibus Combox-E (CAN to Ethernet)For external communication via Ethernet Will also be used for the AIRmonitor (communication to Internet for Service contracts)INSTRUMENTATION & ELECTRONICS

A typical compressor controller= CABLE 1622 0661 01, -02, -03To be ordered seperately.3 lengths available.Number of modules is limited by Hardware24Vac(some module types require external power supply, others get there power from the Main Controller)P&T SensorsDigital InputsRelay OutputsExtra Inputs,Outputs or both24VacRS485 Converter on models B/Dattention software PROTOCOL defines converter typeAvailable : Siemens,ABB & VaconUpdated !INSTRUMENTATION & ELECTRONICS

Weidmller & Phoenix screw terminalsSometimes became loose PartNr: 1088 0014 xx Wago spring connectors Also mechanically better fixed PartNr: 1088 0031 xxImproved connectorsMk3Mk4INSTRUMENTATION & ELECTRONICS

Other hardware CAN connectorsTo connect modules to a CAN networkConnector 1 for single nodeConnector 2 for 2 nodes or laptop connection CAN repeaterFor longer CAN networks (2 * 250 m) MCC (Multiple Compressor Control) dongleHardware key to activate the MCC function IC cablesTo connect modules (lengths of 150/600/1100 mm) ES002To connect an E/P unit to CANES003 = ES002 + Combox-STo connect an E/P unit via CAN to ES100/300

INSTRUMENTATION & ELECTRONICS

BDIOEStandardDigital InputsD1 = Emergency StopD2 = start/stopD3 = load/unloadD4 = local/remote pressureD5 = main motor overloadD6 = fan motor overloadDigital inputsOption CONDRD7 = Cond. DrainOption FIKIT D8 = DD filterD9 = PD filterOption PHSR D10 =Phase sequenceAIE1AIE1StandardKavlicoinputsP1 = delivery air P2 = DP oil separatorPt1000 inputsT1 = element outletFeature MDVAR= FF T2 = Dryer LAT

T3 = not usedStandardDigital outputsK01 = LineK02 = StarK03 = DeltaK04 = Load/Unload SolenoidK05 = APH / APLK06 = FD Dryer ControlK07 = Automatic OperationK08 = General WarningK09 = General ShutdownDigital InputsOption THERM DI01 : Thermistor WarningDI02 : Thermistor Shutdown

DI03 : QD Filter (not used)DI04 : not usedDigital Outputs DO1=CD dryer (not used)DO2 : not usedDO3 : not usedDO4 : not usedPt1000 inputsFeature COOL=WATERT1: Water InT2 :Water OutPt1000 inputsOption ENRECT1 = ER Water InT2 = ER Water OutAIE3Pt100 inputsOption Bearings (not used)T1 : D bearingT2 : ND bearingOption Windings (not used)T3 : U windingT4 : V windingT5 : W windingKavlico inputs P1 : not usedP2 : not usedKavlico inputs P1 : not usedP2 : not usede.g. GA 55-90CINSTRUMENTATION & ELECTRONICS

Hardware data INTERESTING TO KNOW : Line Voltage Limits+ 40 % to - 30 % of the nominal supply voltage.Supply drop-outThe device will operate without disturbance with a supply voltage drop-out of 40 ms every second. Degree of Protection of Enclosure and Connectorsdegree of protection at the front of IP 55 and at the back of IP 23, both according to IEC 529. Other devices have an overall protection of IP 23.INSTRUMENTATION & ELECTRONICS

Chapter 3Main functionsINSTRUMENTATION & ELECTRONICS

ControlThe Elektronikon controlsThe Elektronikon regulates the compressor to maintain the desired system pressureSystem pressureSystem pressure is compared to the programmed pressure bandLoad/no load fixed speed machinesVariable Speed Drive, VSD, machinesorINSTRUMENTATION & ELECTRONICS

The Elektronikon protectsElectronic precision scans all vital functionsshuts the compressor down if trouble exists...Cooling fan motorCompressor elementDrive motorINSTRUMENTATION & ELECTRONICS

The Elektronikon advisesSystem pressureCompressor status and dataService requirementsINSTRUMENTATION & ELECTRONICS

Compressor controlThe MkIV has following control functions:Manual start/stop of the compressorEmergency stop is separate buttonChoice between forced unload and automatic control (= pressure control) Pressure controlFor load/unloadBy loading and unloading the compressor

For VSDBy speed control between min and max speed (in this zone the MkIV tries to reach the set point)By stop/start (and unload for Z VSD) < min speedRequired pressure band (and set point for VSDs) to be specifiedChoice between local and remote controlINSTRUMENTATION & ELECTRONICS

Compressor monitoringThe MkIV has following monitoring functions:Status of the compressorVoltage on/offLoaded/unloaded/stoppedWarnings and shutdownControl modeForced unload/automaticLocal/remote controlMeasured values Pressures/temperatures/Speed of the motor and accumulated volume for VSDsRunning/Loaded/Module hours Number of motor startsFor details: see MkIV Instruction BooksINSTRUMENTATION & ELECTRONICS

Compressor protectionThe MkIV has following protection functions:To stop the machine (shutdown)When an input indicates that the machine can be damagedE.g. element outlet temperature too high (HH)To give a shutdown warningWhen the machine comes close to a shutdownE.g. element outlet temperature high (H)To give a service warningWhen the machine needs serviceE.g. air inlet filter high (H)Delay second stop (DSS)To protect overheating of motor windingsMotor can only stop once every 20 minutes (if 3 starts per hour allowed by motor vendor)INSTRUMENTATION & ELECTRONICS

Converter controlEach VSD device has a frequency converterOur compressors can have 3 converters:For the main motorFor the dryer (in FF machines or behind the machine) For the fan motor (in air cooled machines)The converter controllers are linked with the MkIV; but the MkIV is the master controllerAdvantages:Only 1 User Interface (of the MkIV)Because of the integrated controlsMore stable dew point with MD VSD and ID VSDBetter fine-tuning of the main motor converterBigger operating range (higher max and lower min speed)More energy savings (lower energy consumption by fan-motor and ID-dryer)INSTRUMENTATION & ELECTRONICS

Chapter 4Special options (sales kits): sequencing + external communicationINSTRUMENTATION & ELECTRONICS

Multiple Compressor Control What ?

Multiple compressor Control (MCC)= sequencing = central control

PurposePressure band reduction => energy savingsEqual wear of the compressorsLimitationsMax. 4 compressorsOf the 4 compressors max. 1 can be a VSDWithout MCCWith MCCINSTRUMENTATION & ELECTRONICS

Elektronikon Multiple Compressor ControlNet pressureComp 1Comp 2Comp 3Typical overall pressure band 1.5 barAvg pressureTraditional cascade controlUp to four compressors can be controlled with MCC, one of which can be a VSDReduce system pressure band - save energy, reduce leakage and stabilize system pressureEqualize running hours of all compressors integratedINSTRUMENTATION & ELECTRONICS

Multiple Compressor Control How ?

Set-upCompressors to be connected in a CAN networkNo extra controller requiredThe sequencing software is installed in every MkIVHardware key (dongle) on 1 of the master modules to activate the sequencing software (=> 1 MkIV machine in the network is enough) Algorithm MCC keeps the pressure at the outlet of the master compressor in the require pressure bandIn Q1 2003 a remote pressure sensor will be possible: with pressure transmitter (4-20 mA) and AIE2 moduleIf present VSD controls the pressureCompressor with lowest running hours is started/loadedCompressor with highest running hours is stopped/unloadedHour counters can be initializedChange-over at regular intervals can be forcedWeek timer with 2 pressure bands INSTRUMENTATION & ELECTRONICS

External communication

There are 3 ways to go to the customers plant management system (DCS):Via Modbus with Combox-SVia Profibus with Combox-P Via Ethernet with Combox-E1 Combox is enough for a complete CAN networkCombox is sold as a sales kit (not a machine option)Functionality:Monitoring of all compressors in the network:compressor status all measured valuesControl of all compressors in the network:Start/stopForced unload/automaticChange of pressure band (and set point for VSD)Remote speed control (for VSD)For details => see User Guide on Elektronikon software marketINSTRUMENTATION & ELECTRONICS

Chapter 5The CAN networkINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV CommunicationNetworkingThe MKIV regulators use a field bus called CANController Area Network (CAN) is an ISO approved standard for a low cost real time communication protocol. It has a relatively high transmission speed (up to 1Mbps). It is a fault tolerant and robust system.CAN was initially developed by Bosch for in-vehicle data transfer and was defined in 1984INSTRUMENTATION & ELECTRONICS

Overview of the CAN networkINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV CommunicationCANConversion BoxCommunicationCOM1MkIIIConversion BoxCommunicationMkI/MkIIE-P and CompetitionRS232RS232Relay(s)/WiringCAN graphical network representationComboxComboxES002MKIVMKIVMKIVMKIVINSTRUMENTATION & ELECTRONICS

CANConversion BoxCommunicationCOM1MkIIIConversion BoxCommunicationMkI/MkIIElectro-Pneumatic and CompetitionRS232RS232Relay(s)/WiringComboxComboxES002MKIVMKIVMKIVConversion BoxCommunicationCustomers LANComboxOther LAN graphical network representationElektronikon MKIV CommunicationINSTRUMENTATION & ELECTRONICS

The Compressor Network for ControlSystem Bus(CAN)Central Control Unit Reduced & simpler wiring Simplification of software CAN = very reliable connection Every model of Elektronikon II or III can be directly connected to this network Max. length = 200M without CAN repeater Max. length = 500M with CAN repeater every 250MElectroPneumaticE/PHard wiredMk1..3RS232CCOM boxES002!! IMPORTANT !! : Never ADD/REMOVE any device from the network without disconnecting the power supplyCAN cable : LAPP cable UNITRONIC BUS-CAN AC p/nr : 0017 2610 10 2x2x0.34mmAlternative : Belden3106A AC p/nr : 1900 0707 92 (300M)Updated !INSTRUMENTATION & ELECTRONICS

The Compressor Network for CommunicationCustomer PLCe.g. Simatic S7Profibus NetworkSystem Bus(CAN)Central Control UnitRS232CE/PHard wiredCOM-BoxLocate in any ofthe cubicle, or outsideMk13COM boxES002!! IMPORTANT !! : Never ADD/REMOVE any device from the network without disconnecting the power supplyUpdated !CAN cable : LAPP cable UNITRONIC BUS-CAN AC p/nr : 0017 2610 10 2x2x0.34mmAlternative : Belden3106A AC p/nr : 1900 0707 92 (300M)INSTRUMENTATION & ELECTRONICS

The Compressor Network for Communication : Next StepSystem Bus(CAN)Central Control UnitRS232CE/PHard wiredE-BoxLocate in any ofthe cubicle, or outsideInternet ExplorerCommercial Modem or RouterOutside WorldEthernetMk13!! IMPORTANT !! : Never ADD/REMOVE any device from the network without disconnecting the power supplyUpdated !CAN cable : LAPP cable UNITRONIC BUS-CAN AC p/nr : 0017 2610 10 2x2x0.34mmAlternative : Belden3106A AC p/nr : 1900 0707 92 (300M)INSTRUMENTATION & ELECTRONICS

Elektronikon MKIV CommunicationLocal communicationMeans for communicationCommunication and control of the regulator is done by an operator locally at the face plate of the module by manipulation of the modules screens through its membrane switchesDigital communicationCommunication and control of the regulator is done remotely by digital, potential free, contacts or switches. An operator in a remote station can control the machine and see the status of the digital outputs that are free for use. Could also mean control or monitoring by a PLC or similar device.Network communicationCommunication and control of the regulator is done remotely over a computer local area network connection. This could mean central control using an Atlas Copco ES product, including the new MCC, or network monitoring using our standard protocol conversions modules or the new e-Box and monitor over the world wide web.INSTRUMENTATION & ELECTRONICS

How to wire a CAN network ?Components (compressors, etc.) are connected in a Daisy-chain = multi-dropCAN connector on each component in the networkE.g. 2 compressors + Modbus = 3 connectors2 types of wires possible:Lapp-cable Unitronix ( AC nr. 0017 2610 10)Belden 3106A (AC nr. 1900 0707 92)Limitations:Max. 30 components in the networkMax. 250 meter total lengthWith a repeater max. length = 500 meterMore details in the How to wire a CAN network instructionOn Lotus Notes=> Database called Elektronikon software market=> Programs => Technical NotesINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV Communication modulesConversion BoxCommunicationCANX- busCustomer DCSComBoxINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV MonitoringWorld Wide WebCANe-BoxModemINSTRUMENTATION & ELECTRONICS

Chapter 6Flexibility + Remote monitoring + Operating costsINSTRUMENTATION & ELECTRONICS

Elektronikon comprehensive flexibilityElectronic gearingTwo programmable pressure setsSimple modification of parameters at faceplateAdditional non standard inputs possibleMultiple language selections possibleTimer based control as standardRemote control and annunciation standardAutomatic restart after power failure as standardElektronikon platform used on AII and AIF compressors as well as AIQ dryersINSTRUMENTATION & ELECTRONICS

Elektronikon remote monitoringThe Elektronikon allows a compressor installation to be monitored over a computer networkModbusProfibusEthernetStandard protocols availableCustomized monitoring packages available, as part of standardized service plansMonitoring via your own PC over your network or the internetMonitoring via Atlas Copco trained engineers over the internetINSTRUMENTATION & ELECTRONICS

Saves energyElektronikon lowers operating costFacts about working pressure:For each bar reduction in working pressure a 7% energy savings is realizedFor each bar reduction in working pressure a 13% lower leakage rate is realizedElektronikon lowers operating pressure...Electronic precision - more accurateElectronic decision making - anticipatesElectronic decision making - DSS algorithmElectronic sophistication - Multiple Compressor Control, MCCSavings potential of up 30% in energy costs over conventional electropneumatic controlTwo programmable pressure bands - flexibleINSTRUMENTATION & ELECTRONICS

Chapter 7MK-IV REGULATORENERGY SAVERINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV ES evolutionEnergy Saver sequencingThe new ES Millennium series sequencersBased on the CRC hardware platform from Oil FreeCan be combined with monitoring, each is up gradable to the next series with softwareThree modes; Energy savings, Equal wear and forced sequenceINSTRUMENTATION & ELECTRONICS

Elektronikon MKIV ES evolutionEnergy Saver monitoringThe new ES Millennium series monitoringBased on the CRC hardware platform from Oil FreeCan be combined with sequencing, each is upgradable to the next series with softwareWeb services will be fee related based on level of services contracted with local customer centersINSTRUMENTATION & ELECTRONICS

DIDITAL CIRCUIT1] a switching circuit that has only two states : ON and OFF.2] a circuit that provides a step function3] contrasted with analog circuit

ANALOG CIRCUIT1] a circuit in which the signal can vary continuously between specified limits.2] a circuit that provides a continuous function3] contrasted with digital circuit


RS - 232 - C An EIA standard that specifies electrical , mechanical and functional characteristics for serial binary communication circuits in a point - to - point link.RS - 485 An EIA standard that specifies electrical characteristics of balanced -voltage digital interface circuits in a multi-point linkSCADA Supervisory Control And Data AcquisitionRTD Resistance Temperature Detector. A resistor for which the electrical resistivity is a known function of the temperature


INSTRUMENTATION & ELECTRONICSPOWER FACTORA measurement of the time phase difference between the voltage and current in an ac circuit. It is represented by the cosine of the angle of this phase difference. Power factor is the ratio of real power [ in watts ] to apparent power [ in volt-amperes ]

Time to have coffee ...Compressor Basics - ElectricINSTRUMENTATION & ELECTRONICS&

Atlas Copco is the worlds leading air compressor and compressed air treatment manufacturer.Our principal values of Innovation, Interaction and Commitment are the foundation on which our products and services are built.At the heart of most of our products is the Elektronikon regulator. The Elektronikon regulator is a state of the art electronic monitoring and control system. It continuously and accurately monitors and controls the Atlas Copco equipment that it is installed on to insure efficient and reliable operation.

The Elektronikon regulator monitors all critical parameters of the equipment simply and efficiently.All parameters are monitored to insure safe and reliable operation of the equipment.These parameters could be temperature, pressure, motor status and other safety inputs to the system depending on which piece of equipment that the Elektronikon is installed on. This could be an Atlas Copco air compressor or dryer.All of the critical parameters that an operator or service technician need access to are clearly displayed at the liquid crystal display. The different parameters can be selected for viewing by scrolling through the different screens with the simple touch of a button.The screens are logically laid out to minimize the key strokes required for an operator to quickly call up the information of interest. This ease of use and visual clarity, in the operators native language, make monitoring the equipment very effective. The screen logic and manipulation of parameters is so simple that training time for operators is minimal.Ease of use helps to insure that the equipment is monitored, operated and maintained in the most practical and efficient manner possible.

With older electropneumatic control schemes complexity is the operative word. Complexity in manufacturing, complexity in trouble shooting and complexity in maintenance.The Elektronikon regulator replaces on anywhere from six to sixteen control relays in one simple box. Instead of keeping thousands of Euros toied up in stocking spare relays a customer could stock one simple and economical Elektronikon regulator. That can be trouble shot and replaced in the time it takes a service technician to find the control schematic of the older control scheme and his power meter.Through the shear reduction in components the wiring connection reductions alone significantly improve overall reliability and ease of maintenance of the system.Savings on spares inventories, technician training and maintenance is dramatic.

Lets explore now the reasons why we think that electronic control is the best choice for compressor control than traditional electropneumatic controls.The first reason is clearly precision. Through the use of state of the art elctronics we feel that the Elektronikon offers more precise and therefore better control when compared to electropneumatic control.Electropneumatic control schemes depend on mechanical switches ofr inputs to the control system.Because of wear, dirt and heat over time the setpoint of a mechanical switch will naturally drift from its original factory setpoint. A mechanical switchs setpoint tolerance will also increase over time. When both of these facts are considered the precision of the compressors inputs can come into question over time. Which leads to inefficiency, higher working pressure for example which leads to more power consumption.The adjustment of a mechanical switch is very inaccurate compared to electronic sensors which are highly accurate. The electronic setpoint is easily adjusted at the faceplate of the Elektronikon.Reaction time with a switch is very slow compared to an electronic sensor which could cause the system pressure to deviate widely requiring more power to run than an electronic system. This slow reaction time could even cause damage to the compressor if the controls dont react quickly enough to process changes.The display of a parameter is more accurate with electronics because there is no long capillary tube from gauge to sensing device.

Atlas Copco realizes that one size does not fit all. Because or Elektronikon concept is specifically designed for our equipment it is extremely flexible and versatile.We do not need to rely on standard commercially available hardware that is designed to operate all kinds of industrial equipment. We have determined over the years exactly what is required to efficiently monitor, control and safeguard an air compressor.The Elektronikon is configured into three basic hardware platforms that address the needs of Atlas Copcos wide product portfolio from 5 kW oil injected screw compressors to 1100 kW turbo machines as well as all kinds of compressed air drying technologies.The first in the family is the Elektronikon MKIV type I regulator. This regulator is intended to be an extremely simple alternative to electro pneumatic control schemes. It is typically installed on equipment with limited requirements for input and output points.Although it is small it still is comprehensive and precise protection for smaller Atlas Copc producst.The principal difference to the other members of the Elektronikon family is that the display uses symbols instead of text to interact with an operator or service technician.The simple and clear symbols convey information to personnel in a manner that is both language and literacy level independent.

The next member of the Elektronikon family is the MKIV type II regulator. This regulator has more input and outputs than the type I regulator so it can be used on larger Atlas Copco products.It is physically the same size as the type I regulator.The type II regulator is alpha numeric based and not symbol based as is the type I regulator.The type II regulator is chock full of extra features such as flexible expansion capability, multiple pressure set programming, multiple language selection and remote networked communication possibilities with optional protocol conversion module and a built in network communication port to be used within the Atlas Copco local area network.Within the type II frame size there are two distinct hardware platforms. The A and the B regulator. The principle difference between the type IIA and IIB regulators is that the B regulator has an RS485 for communication to the frequency converter of the VSD.

And then finally we come to the big daddy of the MKIV family the MKIV type III regulator.The type III regulator is physically larger than the types I or II regulators and is also alpha numeric based.It has more input output connections so it can handle larger and more complex compressors that the other two regulator types.It has all the main features that the type II regulator has but with more capacity for larger compressor applications.Within the type III frame size there are two distinct hardware platforms. The C and the D regulator. The principle difference between the type IIIC and IIID regulators is that the D regulator has an RS485 for communication to the frequency converter of the VSD.

jhkjdsfhkjasdhfkjldshfjlkhasdkljfhajksdfhkjdashfkjasdhfkjasdhkjfhjaksdhfkjsdahjkfahlkjsdfhkjlasdhlkjfhdsajkhfjksdhaflkasdkjhfkjasdhfkjlasdhflkjsdahfkjlhsdjkfhkjThe Elektronion regulator efficiently controls the equipment that it is installed on.In the case of an air compressor this means that it controls the operation of the main drive motor and regulates the system pressure of the air net within a predefined and narrow pressure band or setpoint.Starting and stopping of the unit by an operator is easily accomplished by manipulation of the start and stop buttons on the faceplate of the elektronikon regulator.In the case of a fixed speed compressor this simply means starting or stopping the drive motor and opening or closing the inlet valve of the compressor to either compress air or unload the compressor.In the case of a variable speed drive compressor, vsd, this simply means starting or stopping the drive motor while varying its speed within its flow range to vary the compressed air supplied to match the compressed air demand of the air net.Its that simple, efficient and elegant.The objective that the Elektronikon regulator achieves so well is to keep the air net within a defined and narrow pressure band while using the least amount of electrical energy in the process.Keep in mind that the most efficient way to run an air compressor is to turn it off. This the Elektronikon through its electronic sophistication does better than any other control system available.

The Elektronikon regulator also protects the Atlas Copco equipment.The regulator will monitor all of the key points to be safeguarded and will warn an operator of impending danger and or will shut down the machine when a parameter reaches its safety limit.For an air compressor this would mean keeping an eye on the status of the motor overloads, drive and or cooling fan, the compressor element discharge temperatures and critical operating pressures such as oil pressure on a Z compressor.The Elektronikon does not wait for trouble. It is proactive. It will act and notify an operator before damage can occur to the equipment and cause costly downtime of our customer's process.It is comprehensive protection with simple electronic precision that insures peace of mind for our customer that his air compressor will operate safely and reliably for many years to come.

The Elektronikon regulator acts as a trusted advisor regarding the status of the equipment and process.At a glance all key parameters of the machine and process and can be quickly and easily viewed. Parameters are not spread out over the machine with multiple gauges at multiple locations. These parameters can even be consulted from remote locations through the use of optional electronic communication products.The Elektronikon lets you know how the process is doing, discharge pressure and temperature for example. The Elektronikon lets you know how the equipment is doing by advising on its functional status or a key safety parameter such as discharge temperature. The Elektronikon helps you maintain the equipment and even advises who to contact when service is required. Service of compressors is categorized in simple service plans that clearly outline actions to be taken at certain intervals to insure that your Atlas Copco equipment is maintained properly to give the longest operational life possible.The Elektronikon is so simple. It has been designed specifically for use on Atlas Copco equipment so each of its functions is there for a specific purpose. To insure that the equipment operates reliably, efficiently and optimally over its entire life cycle.

Traditional multiple compressor control schemes involve the cascaded settings of the pressure control band on each compressor attached to the compressed air network. Each compressor acts independently based on its own pressure band setting and control system algorithms and response time.To insure that the minimum system pressure is maintained this type of setup requires the overall system pressure band to kept artificially higher than it needs to be. The result is a compressed air network that requires more energy to operate, has significantly higher compressed air leakage and is unnecessarily unstable.The multiple compressor control, mcc, feature of the Elektronikon coordinates the control of all of the compressors attached into one master controller.Insuring that all of the compressors act in concert with each other. With the mcc control feature of the Elektronikon regulator the overall system pressure can be drastically reduced. This reduction in system pressure reduces energy consumption, compressed air leakage and results in a more stable system pressure for your customers process. For each bar reduction in the average system pressureyou save 7% in energy and compressed air leakage is reduced 13%. These two factors alone can easily account for a 10% annual savings in a compressed air plants electric bill.The MCC feature not only helps to save energy but it also can help to optimise the maintenance scheduling of the compressors in the plant. The MCC feature will equalise the run time for each compressor that is attached to an installation so that maintenance of the compressors can be easily scheduled.The benefits and cost savings of multiple compressor control continue to grow with the more compressors installed in an installation.

The evolution of the Elektronikon over the years has resulted in the simplest yet most comprehensive control scheme in the industry.No other compressor manufacturer has a controller that is better optimised for compressor as well as compressed air auxiliary control than does Atlas Copco with its Elektronikon MKIV regulator.Some of the main features that depict this comprehensive flexibility include:Electronic gearing. This means that to get various pressure out of the compressor you simply dial it in through manipulation of the buttons on the Elektronikon faceplate. With VSD compressors any discharge pressure between 4 and 13 bar can easily be selected. Two different pressure sets or pressure bands can be programmed in for flexibility. The customer may want to operate the compressor at two different pressure levels that can be changed manually or on a timer base. Simple and fast adjustment of all operating parameters is done at the Elektronikon faceplate. No need to bounce around the machine to various switch locations to adjust parameter settings. Additional sensors can be added to the Elkrtonikon system easily with a simple programming modification. No need to rewire or add additional control relays to the control panel. Any set of three languages can be selected out of a library consisting of 23 different languages is possible making it truly a universal controller for a global marketplace. The compressor can be programmed to turn on or off at various times during a week to allow one to accommodate standardised shift schedules. Remote digital control and status indication is standard to easily accommodate most remote control applications.The most significant feature of an electronic controller is its inhereeant ability to be integrated into networked remote monitoring applications.The Elektronikon MKIVcan not only be integrated into our custmers existing plant management system over his own network but it can also be connected to the world wide web.This flexibility affords a tremendous opportunity to improve the entire operation of an Atlas Copco compressed air installation.Through the use of our optional communication devices the compressor installation can feed information to key plant management personell as well as Atlas Copco service representatives. Decisions can then be made based on real data from the installation for sheduling service, ordering spare parts, diagnosing the health of the installation before things go wrong, making decisoins regarding plant air capacity or expansion. Ulitimately by taking advantage of the technology the compressed air installation can be optimally operated and maintained which will save money every day that the plant is operating.Immediate notification to key personnel, either plant or Atlas Copco, of pending trouble or shutdown of a compressor can be arranged via e-mail so that down time is significantly reduced.

The Elektronikon lowers operating costs. The most significant cost to operate an air compressor is the electricity to run it. In fact electricity accounts for over 70% of the total life cycle cost of a compressor.The higher the pressure that a compressed air installation installation is operated the more power it will require and therefore cost more to supply it with electricity.The precision, anticipation features and sophistication afforded by the Elektronikon controller allow a drastic reduction in over all pressure band that the compressor must supply to the compressed air installation. It is a well established fact the generation of compressed air can account for up to 20% of an industrial plants total electricity bill.The Elektronikon allows the pressure band to be narrowed, and ina a multiple compressor control installation it can be significantly reduced, and reduce the overall system pressure dramatically.The Elektronikon has a sophisticated control algorithm called delayed second stop or DSS which insures that the compressor drive motor runs only when needed. It looks not only at motor parameters, such as starting limitations, but it also considers history of how the plant air demand behaves as well as how fast the demand changes. It insures that the system pressure remains within the accepted pressure band while minimising the drive motor run time.

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