Compressor Basics

21st MAY , 2003 AIF-TRAINING 1
COMPRESSOR
BASICS -
ELECTRIC
Compressor Basics - Electric
Compressor
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 measurements
ELECTRICITY - What ?
Something - INVISIBLE
- POWERFULL
- DANGEROUS !!

Something - SIMPLE for
QUALIFIED PEOPLE

TAKE CARE !!!
Power sources Direct Current (DC)
Voltage
Udc
Time

Voltage is polarised with + and -
Examples : Batteries
Rectified power supplies ; 12.24 V
Applications : Electronic instrument supplies
Control equipment
Supply for pressure transmitter, etc...
Safety : Voltages up to 24 VDC are safe, higher voltages can be
dangerous for people.
Ex: 12 Volt
Alternating Current (AC) - Single Phase
Characteristic : Voltage and current regularly changes
strength and direction in a sinusoidal variation
Application : General use
Alternating Current (AC) - Single Phase
Characteristic 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 Safe for personnel
> 24 V is dangerous
Terminology : < 50 V : extra low voltage
< 1000 V : Low voltage
1000 V < U < 10000 V : Medium voltage
> 10000 V : High voltage
Alternating Current (AC) - Three Phase
Characteristics :
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
other
Alternating current system
Phase 1
Phase 2
Phase 3
Neutral
Grounding
1-Phase
3-Phase Y 3-Phase Delta
L1
L2
L3
N
UL=Line voltage = UL1-UL2
Uf =Phase voltage = UL
3

UL
UL
UL
Uf
In a net 3 x 400 V UL = 400 V and Uf = 230 V
IL
Relation between Reactance (X) - Resistance (R) -
Impedance (Z) - Phase displacement (j)
Z
X
j
R
Power factor - cos j
Uac
X
R
Reactance
Resistance
Basic laws
Direct Current
Law of Ohm
I = U / R with I = Current in Ampere
U = Voltage in Volt
R = Resistance in Ohm
Absorbed power
P = U x I with U = Voltage in Volt
I = Current in Ampere
P = Power in Watt

Alternating Current
Law of Ohm I = U / Z with
I = Current in Ampere
U = Voltage in Volt
Z = Impedance in Ohm
= Sqrt (R + X) where X is the reactance
Power in a single phase system
P = U x I x cos j
Power in a three phase system
P = UL x IL x cosj x Sqrt (3) with
P = Power in Watt ( other units as stated above)
Units and measurements
Tension : Difference in potential between two
points
Unit = VOLT
Example :
L1
L2
220 V
Measurement in V ac Between V and Com
Current : Measures current flow in a circuit Unit = Ampere
L1
L2
PS
Measurement in A (of mA) between A and Com
Motor connection in Star
Terminal box
U1
U2
V1
V2
W2
W1
400 V
400 V
400 V
Power = Pn
3
W2 U2 V2
U1 V1 W1
Un
U v1-v2
= Un/root 3
Motor connection in Delta
W2 U2 V2
U1 V1 W1
Terminal box
U1
U2
W2 W1
V1
V2
400 V
400 V
400 V
Uw1-w2 = Un
Power = Pn
Un
TORQUE
A 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]torque
The maximum torque a motor can deliver continuously
Starting [breakaway] torque
The torque required to start a machine /
compressor from stand-still. It is always greater
than the torque required to maintain motion.

Full load torque
The torque necessary to produce the rated HP
at full load speed
Locked rotor torque
The minimum torque that a motor will develop
at rest for all angular positions of the rotor
[with rated voltage applied at rated frequency]
Pull-out torque
The maximum running torque of a
synchronous motor .

Pull-up torque
The torque required to accelerate the load from
standstill to full speed , expressed in % of
running torque.
Stall torque
The 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 +compressor
GD square = 4 X WK square

Torque curve for a short circuited, induction motor
Tstart Tmin Tmax
Tnom
RPM
Torque
Torque curve of a screw compressor - started in Star/Delta
Torque curve (D)
Loaded compressor
Unloaded compressor
Speed
Torque curve (Y)
Speed : +/- 90-95 %
MOTOR DATA PLATE
PROTECTION CLASS (According IEC 34-5)

States how an electrical device is protected
against contact and
against water
Code : 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 dust

Values for x
0 Open motors
PROTECTED AGAINST
1 Bodies with a diameter > 50 mm
3 Bodies with a diameter > 2.5 mm
5 Dust can still penetrate, but not
in such a quantity that it
disturbs
6 Full dust protection

Values for y
0 No protection
PROTECTED AGAINST
1 Vertical dripping
2 Water falling as a spray at an
angle equal to or smaller than
15 with respect to vertical
3 Iden. as 2 but angle of 60
4 Water splashed against the
motor from any direction
5 Against water jet
6 Against condition on ships
decks
7 Against the effect of immersion
Most frequently used are IP23, 44 and 54
Protection degree of electrical equipment : IP xy
MOTOR DATA PLATE
Insulation class
Scope
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 exceeded
by 10 C, the service life of the insulation is shortened
by about half
MOTOR TEMPERATURE RISE
MOTOR DATA PLATE
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 <= 40 C
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.
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990
500
Kg
1000
Kg
1500
Kg
Development of the motor-weight (4-pole TOFC-motor 30 kW) from 1900 until today
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 !!!
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
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

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 cooling
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 contactor
Termistor protector
Conditioning relay
PTC
Power supply
Outputs for control
Alarm Trip
Remarks :
Thermistors can not be used for measuring
Thermistors can be connected in series
(R total cold < 1500 ohm)
Same sensor can be used for protections
Alarm and Trip
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
temperatures
Pt 1000
Resistance value - 1000 Ohm - at 0 C
Platin based resistor
Pt 100 : Resistance value of Pt 1000 divided
by 10 for the same temperature
Values : See table and chart

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.
RTD
Elektronikon
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.
RTD
Elektronikon
Readings in Ohm
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 careful
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- 74
Terminal number
Terminal row
1 = Cubicle
2 = Elektronikon Master module
3 = Consecutive module or component
numbers Cables and wires
Basic symbols
Basic symbols
Part of wiring diagram
Transformer for auxiliary power
Important
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 connections
F1
F2
F3
Uin Uout
Table as example only !
Attention :

Remark about the 24 Vac
secondary :

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

NEVER change this !!!
Part of wiring diagram( for compressor supplied without starter)
K02 and K03

can be used for

control of

Y - D starter
(for compressor supplied without starter)
Important

Take care of

interfacing
connections

to be in phase with

ECB AIF 1133
Interfacing connections with Elektronikon
Auxiliary inputs
Relay contact
outputs
Interfacing connections with Elektronikon
Relay outputs
Temp inputs
Pt 1000
Pressure sensor
inputs
Interfacing connections
Device connections
Pressure transducers
3 - wire connection
Temp sensors Pt1000
2 - wire connection
PRESSURE SENSORS
B
C
A
A = Ground (-)
B = Supply voltage(+5 V)
C = Signal (+)
Measurement in Volts DC
Range :
Zero = 0.5 Volt DC
Full scale = 4.5 Volt DC
Sensor must remain connected to Elektronikon
SERVICE DIAGRAM
SG K.
SG K.
ELECTRICITY
ATTENTION !!!
Something - INVISIBLE
- POWERFULL
- DANGEROUS !!

Something - SIMPLE for
QUALIFIED PEOPLE
TAKE CARE !!!
Elektronikon MkIV
State-of-the-art
compressor control
INSTRUMENTATION & ELECTRONICS
What is the Elektronikon?
State of the art electronic controller that optimizes all aspects of
compressor maintenance and operation
The Elektronikon monitors
The Elektronikon system continuously and accurately monitors
all defined critical functions of the compressor package
The Elektronikon display is
clear and easy to read
Elektronikon elegant simplicity Older electro-pneumatic control
Many more components required than
with Elektronikon regulation
More opportunity for failure due to
complexity than with Elektronikon regulation
More involved trouble shooting than with
Elektronikon regulation
More simplified due to reduction of components
Advanced electronic control
More reliable and easier to troubleshoot
than electro-pneumatic regulation
Elektronikon electronic precision
Older
electropneumatic
control
Advanced electronic control
Elektronikon advanced electronic
advantage in accuracy...
Electronic sensors maintain setpoint with same
accuracy throughout lifetime
A mechanical switch's setpoint can drift over
its lifetime
Electronic sensors setpoint is easily adjusted through
the Elektronikon faceplate
A mechanical switch requires inaccurate
manual adjustment
Reaction 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 control
Display versus switch readout of parameter
has deviation
The process value readout is a function of the sensors
electrical signal
Chapter 1
Differences with MkIII
Improvements compared to MkIII 1
Hardware related improvements:
Better viewing angle of LCD screen
No more expansion modules for standard
machines (except ZH)
Expansion and communication modules DIN rail
mounted => less wiring to cubicle door
No more COM module for VSD compressors
Key switch integrated in software
Improved hardware, better electrical connections
to terminals
Improved LCD
LCD glass has updated
technology

This allows for better reading
in all conditions

Viewing angle less restricted
than in Mk3
Software related improvements:
Improved menu structure
Improved troubleshooting
E.g. to check module connection
Help Screen for Service contact (e.g. web site, e-mail
address)
Readout in MPa possible
2 pressure settings possible
Automatic switching with a week timer
Manual switching
Remote switching
Digital input
1 = pressure setting 1
0 = pressure setting 2
Double Pressure Setting
Each 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 made
by hand
based on the timer function
Timer can start/stop compressor and change
pressure band
Other improvements:
Field programming simplified
Only master module has to be downloaded
All components in the CAN network can be downloaded from 1
point
Multiple Compressor Control (MCC) function as option
Energy savings
No more cascading => smaller pressure band
With remote pressure sensor in the air net => better control of
the net pressure
Equal wear
Easier networking: CAN does not require interfaces
Only 1 module required for external communication
New
Features
More intelligent user interface for improved navigation
Help screen for service contact
2 sets of pressure settings
Improved LCD (better visibility)
Relay Expansion Box is integrated
Hardware improvements in general resulting in neat professional look
Improved communication skills via Computer Automation Network or CAN
Optimised & modified menu to accommodate new functions
3 languages (3rd=Dutch For factory use only)
C/F and PSI/Bar can be defined independently
Chapter 2
Hardware
Elektronikon MKIV The family
Physically the same size as
Elektronikon II
Uses symbols instead
of text
No programming required,
parameter set selection based on
machine type at assembly
No communication, options or
expansions. No clock functions.
Hardware I/O

1 Pressure
Compressor outlet
2 Temperatures
Element outlet
LAT
3 Digital Inputs
Emergency stop
Motor overload
Remote start/stop
Input Output

Star contactor
Line contactor
Delta contactor
Load/unload sol.
Valve
General
shutdown
Dryer control
Controller functions

DSS
ARAVF
ID control
Service indication
Counters
Remote start/stop
Protections
Elektronikon I
Physically the same size as Elektronikon I
Two out of a selection of 23 languages can be
downloaded
Two pressure sets can be programmed, selected
manually or timer based
Full expansion capability, up to eight modules per
compressor
Two hardware versions, MKIV-IIA or MKIV-IIB
4x16 back lit LCD
Hardware I/O Version A
1 pressure input
2 RTD temp inputs
8 digital inputs
9 digital outputs
No RS485 (no VSD)
CAN connection
I/O expansion port
Version B
2 pressure input
3 RTD temp inputs
10 digital inputs
9 digital outputs
RS485 (VSD)
CAN connection
I/O expansion port
Elektronikon II
Physically larger than the Elektronikon I and II
Two out of a selection of 23 languages can be
downloaded
Two pressure sets can be programmed, selected
manually or timer based
Full expansion capability, up to eight modules
per compressor
Two hardware versions, MKIV-IIIC or MKIV-
IIID
4x40 backlit LCD
Elektronikon III
Hardware I/O
Version C
4 pressure input
8 RTD temp inputs
10 digital inputs
9 digital outputs
No RS485 (no VSD)
CAN connection
I/O expansion port
Version B
4 pressure input
10 RTD temp inputs
10 digital inputs
9 digital outputs
RS485 (VSD)
CAN connection
I/O expansion port
MKIV regulator type Compressors it is installed on as standard
Type I Pack style GAs, GA 5-11C and SF 1-5
Type IIA
WorkPlace style GA 11-90C, GA 5-
11C(optional) and SF Multi core
Type IIB
GA less than 90 VSD
Type IIIC ZT less than 55 kW
Type IIID ZR, ZVSD and all other AIF compressors
Where the Elektronikon MKIVs are used
MkIV Master Module for AIF
On all AIF machines the D-controller is used:
D-Controller
The D-controller has following features:
User Interface
4 * 40 characters
Higher Quality LCD than MkIII
Inputs and outputs:
4 * pressure inputs (0-5 V)
10* temperature inputs (PT1000)
10 * digital inputs
9 * digital outputs
=> No expansion modules for standard machines (except ZH)
RS485 connection for converters
CAN connection => communication without interface
IC connection for I/O
24 Vac power supply required
Expansion modules
All modules are DIN rail mounted (less wires to door)
Some modules require 24 Vac power supply
Expansion modules are mainly used for machine-options (but are also
available as sales kit)
AIE1 = 2 * pressure inputs (0-5 V) + 2 * PT1000 inputs
E.g. for delta p over integrated DD-filter
AIE2 = 4 * 4-20 mA inputs
E.g. for dew point meter on IMD or remote
speed control on VSD machines
AIE3 = 5 * PT100 inputs
E.g. for motor winding/bearing temperatures
AIE4 = 5 * PT1000 inputs
E.g. for motor winding/bearing temperatures
DIOE = 2 * digital inputs + 2 * digital outputs
E.g. for thermistors in motor windings
SPM 5/7 = for 5 or 7 SPM inputs (= NEW option)
AIE1 : 1900 0710 41
2 Kavlico Pressure inputs
2 Jumo Temperature inputs
No supply
No download
Low power consumption (mA)
Mountable on DIN rail
AIE2 : 1900 0710 51
4x 4..20mA passive (2 wires)
Needs external power supply (1730VDC)
No download
Low powerconsumption (mA)
AIE3 : 1900 0710 61
5x Pt100 for motorprotection
(2bearings, 3 windings)
No supply
No download
AIE4 : 1900 0710 81
5x Pt1000 for motorprotection
(2bearings, 3 windings)
No supply
No download
DIOE : 1900 0710 71
4 voltage Free contacts
K01 K04
4 digital inputs
No download
24Vac 50/60Hz supply
consumption 9VA
Mountable 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
downloaded
Updated !
Communication modules
All modules are DIN rail mounted
All modules require 24 Vac power supply
Communication modules are only available as sales kit:
Combox-S (CAN to Serial)
For external communication via Modbus
To connect old units (MkI/II/III and E/P) to the CAN network
To 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)
A typical compressor controller
= CABLE 1622 0661 01, -02, -03
To be ordered seperately.
3 lengths available.
Number of modules is limited by
Hardware
24Vac
(some module types
require external
power supply, others
get there power from
the Main Controller)
P&T Sensors
Digital Inputs
Relay Outputs
Extra Inputs,
Outputs or both
24Vac
RS485 Converter on models B/D
attention software PROTOCOL defines converter type
Available : Siemens,ABB & Vacon
Updated !
Weidmller & Phoenix
screw terminals
Sometimes became
loose

PartNr: 1088 0014 xx
Wago spring
connectors

Also mechanically
better fixed

PartNr: 1088 0031 xx
Improved connectors

Mk3
Mk4
Other hardware
CAN connectors
To connect modules to a CAN network
Connector 1 for single node
Connector 2 for 2 nodes or laptop connection
CAN repeater
For longer CAN networks (2 * 250 m)
MCC (Multiple Compressor Control) dongle
Hardware key to activate the MCC function
IC cables
To connect modules (lengths of 150/600/1100 mm)
ES002
To connect an E/P unit to CAN
ES003 = ES002 + Combox-S
To connect an E/P unit via CAN to ES100/300

B
DIOE
Standard
Digital Inputs
D1 = Emergency Stop
D2 = start/stop
D3 = load/unload
D4 = local/remote pressure
D5 = main motor overload
D6 = fan motor overload
Digital inputs
Option CONDR
D7 = Cond. Drain
Option FIKIT
D8 = DD filter
D9 = PD filter
Option PHSR
D10 =Phase sequence
AIE1 AIE1
Standard
Kavlicoinputs
P1 = delivery air
P2 = DP oil separator
Pt1000 inputs
T1 = element outlet
Feature MDVAR= FF
T2 = Dryer LAT

T3 = not used
Standard
Digital outputs
K01 = Line
K02 = Star
K03 = Delta
K04 = Load/Unload
Solenoid
K05 = APH / APL
K06 = FD Dryer Control
K07 = Automatic
Operation
K08 = General Warning
K09 = General Shutdown
Digital Inputs
Option THERM
DI01 : Thermistor
Warning
DI02 : Thermistor
Shutdown

DI03 : QD Filter (not
used)
DI04 : not used
Digital Outputs
DO1=CD dryer (not used)
DO2 : not used
DO3 : not used
DO4 : not used
Pt1000 inputs
Feature COOL=WATER
T1: Water In
T2 :Water Out
Pt1000 inputs
Option ENREC
T1 = ER Water In
T2 = ER Water
Out
AIE3
Pt100 inputs
Option Bearings (not
used)
T1 : D bearing
T2 : ND bearing
Option Windings (not
used)
T3 : U winding
T4 : V winding
T5 : W winding
Kavlico
inputs
P1 : not used
P2 : not used
Kavlico
inputs P1 :
not used
P2 : not used
e.g. GA 55-90C
Hardware data
INTERESTING TO KNOW :
Line Voltage Limits
+ 40 % to - 30 % of the nominal supply voltage.
Supply drop-out
The device will operate without disturbance with a supply
voltage drop-out of 40 ms every second.
Degree of Protection of Enclosure and Connectors
degree 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.
Chapter 3
Main functions
Control
The Elektronikon controls
The Elektronikon regulates the
compressor to maintain the
desired system pressure
System pressure System pressure is
compared to the
programmed
pressure band
Load/no load
fixed speed
machines
Variable Speed
Drive, VSD,
machines
or
The Elektronikon protects
Electronic precision scans all vital functionsshuts
the compressor down if trouble exists...
Cooling fan motor
Compressor
element
Drive motor
The Elektronikon advises
System pressure
Compressor status and data Service requirements
Compressor control
The MkIV has following control functions:
Manual start/stop of the compressor
Emergency stop is separate button
Choice between forced unload and automatic control
(= pressure control)
Pressure control
For load/unload
By loading and unloading the compressor

For VSD
By 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 speed
Required pressure band (and set point for VSDs) to be specified
Choice between local and remote control
Load/unload
pressure control
VSD
pressure
control
Compressor monitoring
The MkIV has following monitoring functions:
Status of the compressor
Voltage on/off
Loaded/unloaded/stopped
Warnings and shutdown
Control mode
Forced unload/automatic
Local/remote control
Measured values
Pressures/temperatures/
Speed of the motor and accumulated volume for VSDs
Running/Loaded/Module hours
Number of motor starts

For details: see MkIV Instruction Books
Compressor protection
The MkIV has following protection functions:
To stop the machine (shutdown)
When an input indicates that the machine can be damaged
E.g. element outlet temperature too high (HH)
To give a shutdown warning
When the machine comes close to a shutdown
E.g. element outlet temperature high (H)
To give a service warning
When the machine needs service
E.g. air inlet filter high (H)
Delay second stop (DSS)
To protect overheating of motor windings
Motor can only stop once every 20 minutes (if 3 starts per hour
allowed by motor vendor)
Converter control
Each VSD device has a frequency converter
Our compressors can have 3 converters:
For the main motor
For 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 controller
Advantages:
Only 1 User Interface (of the MkIV)
Because of the integrated controls
More stable dew point with MD VSD and ID VSD
Better fine-tuning of the main motor converter
Bigger operating range (higher max and lower min
speed)
More energy savings (lower energy consumption by fan-
motor and ID-dryer)
Chapter 4
Special options (sales kits):
sequencing + external communication
Multiple Compressor Control What ?

Multiple compressor Control (MCC)
= sequencing
= central control

Purpose
Pressure band reduction => energy savings
Equal wear of the compressors
Limitations
Max. 4 compressors
Of the 4 compressors max. 1 can be a VSD
Without MCC
With MCC
Elektronikon Multiple Compressor Control
Net pressure
C
o
m
p

1

C
o
m
p

2

C
o
m
p

3

Typical overall
pressure band 1.5
bar Avg pressure
With MCC overall
system pressure
can be drastically
reduced
Traditional cascade
control
Up to four compressors can be
controlled with MCC, one of which
can be a VSD
Reduce system pressure band -
save energy, reduce leakage and
stabilize system pressure
Equalize running hours of all
compressors integrated
Multiple Compressor Control How ?

Set-up
Compressors to be connected in a CAN network
No extra controller required
The sequencing software is installed in every MkIV
Hardware 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 band
I n Q1 2003 a remote pressure sensor will be possible:
with pressure transmitter (4-20 mA) and AI E2 module
If present VSD controls the pressure
Compressor with lowest running hours is started/loaded
Compressor with highest running hours is stopped/unloaded
Hour counters can be initialized
Change-over at regular intervals can be forced
Week timer with 2 pressure bands
External communication

There are 3 ways to go to the customers plant management system (DCS):
Via Modbus with Combox-S
Via Profibus with Combox-P
Via Ethernet with Combox-E
1 Combox is enough for a complete CAN network
Combox is sold as a sales kit (not a machine option)
Functionality:
Monitoring of all compressors in the network:
compressor status
all measured values
Control of all compressors in the network:
Start/stop
Forced unload/automatic
Change of pressure band (and set point for VSD)
Remote speed control (for VSD)
For details => see User Guide on Elektronikon software market
Chapter 5
The CAN network
Elektronikon MKIV Communication
Networking
The MKIV regulators use a field bus called CAN
Controller 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 1984
Overview of the CAN network
CAN
Conversion Box
Communication
COM1
MkIII
Conversion Box
Communication
MkI/MkII
E-P and Competition
RS232
RS232
Relay(s)/Wiring
CAN graphical network representation
Combox Combox
ES002
MKIV MKIV MKIV MKIV
CAN
Conversion Box
Communication
COM1
MkIII
Conversion Box
Communication
MkI/MkII
Electro-Pneumatic and Competition
RS232 RS232
Relay(s)/Wiring
Combox Combox
ES002
MKIV MKIV MKIV
Conversion Box
Communication
Customers LAN
Combox
Other LAN graphical network
representation
The Compressor Network for Control
System 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
250M
Electro
Pneumatic
E/P
Hard wired
Mk1..3
RS232C
COM box
ES002
!! IMPORTANT !! : Never ADD/REMOVE any device from the
network without disconnecting the power supply
CAN cable : LAPP cable UNITRONIC BUS-CAN AC p/nr : 0017 2610 10
2x2x0.34mm
Alternative : Belden3106A AC p/nr : 1900 0707 92 (300M)
Updated !
The Compressor Network for Communication
Customer PLC
e.g. Simatic S7
Profibus Network
System Bus
(CAN)
Central
Control Unit
RS232C
E/P
Hard wired
COM-Box
Locate in any of
the cubicle, or
outside
Mk13
COM box ES002
Updated !
2x2x0.34mm
The Compressor Network
for Communication : Next Step
System Bus
(CAN)
Central
Control Unit
RS232C
E/P
Hard wired
E-Box
Locate in any of
the cubicle, or
outside
Internet
Explorer
Commercial
Modem or
Router
Outside World
Ethernet
Mk13
Updated !
2x2x0.34mm
Local communication
Means for communication
Communication 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 switches
Digital communication
Communication 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 communication
Communication 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.
How to wire a CAN network ?
Components (compressors, etc.) are connected in a Daisy-
chain = multi-drop
CAN connector on each component in the network
E.g. 2 compressors + Modbus = 3 connectors
2 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 network
Max. 250 meter total length
With a repeater max. length = 500 meter
More details in the How to wire a CAN network
instruction
On Lotus Notes
=> Database called Elektronikon software market
=> Programs => Technical Notes
Elektronikon MKIV Communication modules
Conversion Box
Communication
CAN
X- bus
Customer DCS
ComBox
Elektronikon MKIV Monitoring
World Wide Web
CAN
e-Box
Modem
Chapter 6
Flexibility + Remote monitoring +
Operating costs
Elektronikon comprehensive flexibility
Electronic gearing
Two programmable
pressure sets
Simple
modification of
parameters at
faceplate
Additional non standard
inputs possible
Multiple language
selections possible
Timer based
control as standard
Remote control
and annunciation
standard
Automatic restart
after power failure
as standard
Elektronikon platform used on
AII and AIF compressors as
well as AIQ dryers
Elektronikon remote monitoring
The Elektronikon allows a compressor
installation to be monitored over a computer
network
Modbus
Profibus
Ethernet
Standard protocols available
Customized monitoring packages available,
as part of standardized service plans
Monitoring via your own PC over your network
or the internet
Monitoring via Atlas Copco trained engineers
over the internet
Saves energy
Elektronikon lowers
operating cost
Facts about working pressure:
For each bar reduction in working pressure a
7% energy savings is realized
For each bar reduction in working pressure a
13% lower leakage rate is realized
Elektronikon lowers operating pressure...
Electronic precision - more accurate
Electronic decision making - anticipates
Electronic decision making - DSS algorithm
Electronic sophistication - Multiple Compressor Control, MCC
Savings potential of up 30% in energy costs
over conventional electropneumatic control
Two programmable pressure bands - flexible
Chapter 7
MK-IV REGULATOR
ENERGY SAVER
Elektronikon MKIV ES evolution
Energy Saver sequencing
The new ES Millennium series sequencers
Based on the CRC hardware platform from Oil Free
Can be combined with monitoring, each is up gradable
to the next series with software
Three modes; Energy savings, Equal wear
and forced sequence
Elektronikon MKIV ES evolution
Energy Saver monitoring
The new ES Millennium series monitoring
Based on the CRC hardware platform from Oil Free
Can be combined with sequencing, each is upgradable
to the next series with software
Web services will be fee related based on
level of services contracted with local
customer centers
DIDITAL CIRCUIT
1] a switching circuit that has only two states : ON and OFF.
2] a circuit that provides a step function
3] contrasted with analog circuit

ANALOG CIRCUIT
1] a circuit in which the signal can vary continuously between specified
limits.
2] a circuit that provides a continuous function
3] 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 link
SCADA
Supervisory Control And Data Acquisition
RTD
Resistance Temperature Detector. A resistor for which the electrical resistivity
is a known function of the temperature


POWER FACTOR
A 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 ]

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21st MAY , 2003 AIF-TRAINING 1

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