es 360 hardware instruction

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Installation

1. General information

ES360 Hardware InstructionService Instruction

Printed Matter Number : 2946 1453 00

Appl icable to : Compressors

Preliminary Operations: :

Safety Instructions : General

Persons Required : 1

Special Tools :

Consumables :

2. Document overview

This document describes the following:

1. General information ............................................ .................................................... ....................................................1

2. Document overview ................................................. ....................................................... ............................................1

3. ES device....................................................................................................................................................................3

3.1. Overview ................................................. ........................................................ .......................................................3

3.2. Specifications ....................................................... ....................................................... ...........................................3

General box layout.............................................................................................................................................................3

Display buttons .................................................... ........................................................ ......................................................4

Enclosure & mounting........................................................................................................................................................4

Thermal..............................................................................................................................................................................4

Compliance ..................................................... ........................................................ ...........................................................4

3.3. Mechanical mounting .................................................... .................................................................... .....................5

3.4. Electrical connectivity.............................................................................................................................................5

Service diagram .................................................... ..................................................... ........................................................5

Power connection ...................................................... ....................................................... .................................................5

I/O ................................................ .................................................... ................................................................... ...............6

Digital inputs ............................................... ........................................................ ...............................................................6

Digital outputs ...................................................... ........................................................ ......................................................7

Extension IO blocks .................................................. ........................................................ .................................................9

3.5. Maintenance.........................................................................................................................................................10

Battery..............................................................................................................................................................................10

Compact Flash.................................................................................................................................................................10

4. Pressure measurement.............................................................................................................................................11

5. Machine communication ........................................................ ................................................................... ................11

Compressor/dryer communication (CAN) ............................................... ................................................................... ......11

6.

Field bus communication .................................................... ...................................................................... ................12

7. Data upload communication .................................................... ................................................................ .................12

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Ethernet ....................................................... ....................................................... .............................................................12

Analogue modem................................................... ........................................................ ..................................................12

GSM/GPRS modem.........................................................................................................................................................13

8. Initial ES configuration ................................................ .................................................... ..........................................14

Touch screen calibration..................................................................................................................................................14

Date-Time-Timezone settings ..................................................... .................................................................... .................14

IP address & settings ....................................................... ..................................................................... ...........................14

IP speed & full/half duplex................................................................................................................................................14

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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, dryersand other measurement equipment.

Compressors and dryers must be connected to the ES device by means of a CAN or ethernet network. Per airnet, one ormultiple 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

The device consists of the following primary electrical components:

Industrial PC with celeron M 600 MHz processor, 256MB L2 cache, 256 MB RAM

Industrial 12.1 TFT screen with resistive touch

I/O module 8AI, 4DI and 4 DO relays

24VDC power supplies: 4A control power supply + 1A sensor power supply

Optional modem

Optional Combox

All above are installed in a NEMA-12/IP54 compliant enclosure.

In the bottom, ten conduit routings closed with nuts allow to insert cables into the enclosure. Ten matching cable glands areprovided.

NOTE: The glands are in metric dimensions. An adapter is necessary when using 1/2 inch conduits.

General box layoutAn A610 touch screen is mounted onto the door.

The box consists of 3 parts:

Upper part:

optional Combox (Combox E A501, Combox P A502, Combox-S A501),

optional data upload modem (analogue modem T800, quadband GSM/GPRS modem T801),

terminal clamps (X200) for distribution of the 24VDC control voltage.

Middle part:

power supplies T111A and T111B,

industrial PC A500, control voltage fuse F111.

Lower part:

IO block K010, relays K101 to K104,

line safety switch F110,

terminal clamps (X100) for distribution of the 110-240 VAC,

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, thesebuttons are not to be used. If desired, the contrast/colour etc. of the screen can be adjusted though the menu.

Enclosure and mounting

The material for the enclosure is sheet steel. The enclosure is built according to the NEMA 12/IP54 standard. Actualcertification tests are not performed.

The ES is only fit for indoor usage. Keep the door closed during operation.

The ES is wall-mountable. Overall dimensions are 500mmW x 600mmH x 210mmD. Overall weight is about 27 kg,depending on the options ordered.

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

See also dimension drawing (AC PN 1623 3462 00)

Select the place on the wall to mount the ES, taking into account the maximum cable length of the CAN and/or ethernetnetworks and a maximum length of 1000 m to the pressure transmitters.

4 mounting brackets are included in the ES. Use appropriate fasteners to fix the unit to the wall. See dimension drawing fordimensions.

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 isconnected 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. Thedigital 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 24V three-wire interface (24V, GND, input)

Input voltage range Low= -3V to +5V, high: +15V to +30V

Isolated 2 kV to each port and to the system

Input filter 5 ms = 200Hz

Input protection 8 kV to ESD

Input impedance Minimum 1.5k ohm, maximum 6k ohm at 30V

Powered 24V +- 10% not protected

Protection Voltage: max 30V, current max 40 mA for all ports

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 somecases, but may behave unexpectedly. When using mechanical switches, 2 wires suffice.

Connections:

2-wire : connect + and input

3-wire : connect + and - to power, and input to the signal

Digital outputs

4 DIGITAL OUTPUTS

Contact type three-wire interface (24V, GND, output)

Switching voltage 24V DC

Switching current 0.5A

Switching delay time Ton = 10 ms, Toff = 10 ms

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 relayscan 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 goodoperation of your installation.

4 RELAY OUTPUTS (OPTIONAL)

Contact type 3 connection points per output: one of which refers to normally open, and one to normallyclose. Dual use possible.

Actuating voltage 24V DC

Nominal switching capacity AC: 250 VAC: 10A

DC: 30V DC: 10A, 110V DC: 0.25A, 220V DC: 0.12A

The power is not to be supplied by the ES control box.

The relays are used for signalling or controlling external devices based on certain states of the software. They are designed for usein UL Class 2 circuits.

The digital outputs should only be used to control or monitor functi onal 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 five-wire interface (input+, input-, shield, GND, 24V)

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


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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 CANconnector on the IO block K010.

Available IO blocks:

block with 8 analogue inputs, 4 digital inputs and 4 digital outputs

block with 16 digital inputs and 16 digital outputs

Specifications: as described above.

Using these optional IO blocks, the ES can connect to up to maximum 100 digital outputs, 100 digital inputs and 16analogue inputs.

The address of each I/O block is configured through 8 DIP switches on its left side. The first address 00000000 is used bythe 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 thedipswitches 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 machineCAN 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. Unpower the ES.

2. Remove the cables/caps from connectors X3, X12 and X13.

3. Remove the four front plate retaining screws.

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 withthe 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. Connect the pressure transmitters preferably:

to an air receiver to avoid pressure pulsations (vibrations should also be avoided)

via valves, allowing the pressure transmitter to be removed after isolating and depressurising it

in vertical position to avoid influence of condensate.

2. 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 coolof the air.

3. Connect the transmitters to the analogue inputs of the ES using double twisted pairs shielded 0.75mm cable. Themaximum 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 theES to prevent loop-currents in the system.

5. Machine communication

Compressor/dryer communication (CAN)

If the machines are equipped with an Elektronikon regulator of generation 4 or 5, a CAN bus has to be wired starting fromthe CAN0 (X13) and/or CAN1 (X12) connectors on the Industrial PC A500. Up to 30 machines can be connected per CANport.

Machines with an Elektronikon regulator of generation 5 have to be put into Mk5 communication mode for correctcommunication with the ES360.

The CAN cable is a three-wire shielded cable, two signal wires and one ground. CAN network cables have a maximumlength of 250 m.

Instructions on how to connect to a CAN network can be found in the CAN cabling instruction (Instruction nr: 9820 358200).

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6. Field bus communication

Some communication links on the compressor CAN network to the customers field bus system are possible:

Instructions on functionality of and how to connect to a Modbus network can be found in the instruction User Guide Mk4Modbus (Instruction nr: 9820 3582 02).

Instructions on functionality of and how to connect to a Profibus network can be found in the instruction User GuideMk4 Profibus (Instruction nr: 9820 3582 03)

Instructions on functionality of and how to connect to an Ethernet network can be found in the instruction?????? ***************

7. Data upload communication

In case data upload to the central data warehouse is needed, an internet connection is required. This can be a direct internetconnection (X9 connector on the industrial PC A500), or a connection over analogue modem (T800) or GSM/GPRS modem(T801). The modem is installed in the ES upon ordering the modem upload feature and connected to the X6 port of theindustrial PC. The GSM/GPRS modem is a quadband modem: 850, 900, 1800 and 1900 MHz.

The customer should provide access to the internet itself (internet provider, phone line, SIM card).

Ethernet

In case of a direct Ethernet connection, guide the Ethernet wire trough cable tray and cable gland and connect to X9connector on the industrial PC A500.

Analogue modemTo connect to an analogue modem, insert RJ11 phone line connector in the modem (T800) and guide wire trough cable trayand 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. Disconnect the power.

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 plasticfrom the edges.

4. Slide the SIM card into the holder with the contact surface towards the PCB. The angled corner must point towards theback of the PCB.

The device only supports 3 V SIM cards. For older SIM cards, please contact your GSM service provider.

5. Connect the antenna to the modem (T801).

6. Place the antenna outside the ES box. Make sure you can receive a good GSM signal on the location where this unitwill be placed.

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8. Initial ES conf iguration

Following can be adapted on the ES:

IP address & settings

Touch calibration

Boot without CF card to get into Windows to set these up.

Touch screen calibration

1. Double-click the KOM Touch calibrationlink on the desktop.

2. Follow the instructions.

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. Double-click the time on the status bar.

2. Set the time zone, date, time, enable/disable daylight savings.

3. PressApply.


NOTE: You must set the date-time-timezone correctly even if you have upload. The time synchronisation with the upload server is onlyapplied to the upload data points.

IP address & settings

Standard setting is DHCP on both Ethernet ports.

1. Go to Start -> Settings -> Network and dial up connections.

2. Right-click one of the Ethernet connections.3. Adjust the settings.

4. Close the settings windows.

5. Click Save registryon the desktop, press OK.


IP speed & full/half duplex

By default this is detected in the communication between switch and ES.

In the rare occasion that you have problems, theEthernetSettingstool on the desktop enables manual settings.

1. Double-click the EthernetSettings link on the desktop.

2. Adjust the settings.

3. Click Save registry and restart system.


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