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NEURON II
User Manual
Version 1.1 13 July 2009
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INDEX
# Chapter Page1.0 Salient Features 1
2.0 Technical Features 3
3.0 Input Output Description 44.0 Main Screen 6
5.0 Menu Structure 8
5.1 View 8
5.1.1Operator 9
5.1.2 Fault Report 10
5.1.3 Day Report 10
5.1.4 Service Time 10
5.1.5 Cumulative Time 11
5.1.6 VFD 11
5.2 Operator 11
5.2.1 Machine 12
5.2.2 Schedule 13
5.2.3 Maintenance 135.2.4 Language 13
5.2.5 Change Password 14
5.3 Service 14
5.3.1 Calibration 15
5.3.2 Relay 15
5.3.3 Change Password 16
5.3.4 Maintenance 16
5.3.5 Clock 16
5.3.6 Self Test 17
5.4 Factory menu 17
5.4.1 Machine 18
5.4.2 Change Password 19
5.4.3 Integrator Dryer 195.5 Customer care 19
6.0 Controls 20
6.1 Start Sequence 20
6.2 Stop Sequence 22
6.3 Fan Control 23
6.4 ADV control 24
6.5 Dryer Control 24
7.0 Data Interface 25
7.1 Analog output 25
7.2 DCS Port 25
8.0 Construction & Dimension Drawing 26
9.0 Revision Details 27
10.0 Appendix 28
APPENDIX A: MODBUS Table 28
APPENDIX B: Mimic LED Table 32
APPENDIX C: Short Cut Key Functions 33
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1.0 Salient features
Saves Money
The Smart Logic of NEURON II automatically decides the start delay required to ensure minimum wait time
between successive starts of the compressor and dryer thereby increasing their l ifetime.
Start Inhibit till sump pressure is within safe limits to enhance the life of the compressor
Low Voltage & Short time Power Interrupts detection to enhance the life of the contactors
Automatic Display Back-light Control to increase the Display Lifetime
Data validation of critical parameters for protecting the compressor from improper usage.
Saves Energy
Automatic Dryer ON/OFF Control to reduce power wastage
Automatic Fan ON/OFF Control based on temperature to reduce power wastage
Pressure Scheduling to allow user to plan for air requirements and avoid power wastage
Dedicated VFD interface port for synchronized operation of integrated compressor with VFD
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Saves Time
Easy User Interface thro 8 line Graphical Display and intuitive menu navigation keys
Multi Language menu & message display: English, Hindi, Selective European Languages
Mimic LED indication for fault diagnosis
Easy to read Fault and Warning message display
Cumulative Hours Display for Load, Unload, Run, Stop, Fault, Standby
Total No of Start/Stop and Load/Unload Cycle Display
Compressor Utilisation Display
Service Remain Hours Display
Dryer or Ambient Temperature (Pt100 sensor) Display
Different Control Modes: Local, Remote & DCS
Unload Mode for Service
Pressure & Temperature Units Selectable PSI or Bar, Centigrade or Fahrenheit
30 Day Report includes Date, Load, Unload, Run, Stop, Standby, Fault hours
99 Fault Report includes Fault Code along with the Date, Time, Pressure, Temperature and Run Status
MODBUS RTU protocol for monitoring the compressor through DCS interface (BAUD 9600 / 19200)
Analog Output for Pressure (Channel1), Temperature/Sump Pressure, Pt100 (Programmable on Channel2)
Programmable Relay for Load, Warn, Trip, Standby, Service, Ready, Remote
Easy Firmware update using a handheld programming device or a laptop
Optional Features
Optional add-on Fault Predictive Device
o Eliminate the need for the customer to call for service or repair
o Compressor life could be increased by regular monitoring for problems
o Production can be maximized due to the minimal downtime
Optional Add-on IO card further extends Input and Output
o 4 nos of Isolated Digital Input
o 4 nos of Relay Output
o 2 nos of Analog Input, 4-20ma
o 2 nos of Analog Input, RTD
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2.0 Technical Features
8 nos of Optically Isolated Digital Inputs of 24VDC01 = Emergency Stop02 = Differential Pressure Oil Filter - DPOF03 = Reverse Rotation
04 = Differential Pressure Air Filter - DPAF05 = Remote Start/Stop06 = High Sump Pressure07 = Cooler08 = Main Motor Overload
8 nos of Output Relay (SPDT 250V AC 10A, 1, 00,000 cycle electric life)01 = Main contactor02 = Star contactor03 = Delta contactor04 = Load Valve05 = Fan06 = Auto Drain Valve07 = Dryer (if Dryer is Connected) else Programmable
08 = Programmable [Load, Service, Standby, Warn, Trip, Remote, Ready]4 nos of Analog Input Channels
1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure1 no of RTD (Pt-100) channel, -50 to +85 degree C for Drier or Ambient Temperature
2 nos of Analog Output Channels0 to 5 VDC, One for Discharge Pressure and One Programmable
9 nos of Function keysUp, Down, Left, Right, Enter, Escape, Start, Stop and Reset.
1 no of Display128X64 White Backlight Graphical LCD
11 nos of LEDs for visualization alarm & machine status
AutoAir FilterMain Motor OverloadReverse RotationCoolerPressureTemperatureDifferential Pressure Oil FilterDifferential Pressure Separator ElementStart & Stop
1 no. of Dual led for start/stop indicationGreen for start and Red for stop
1 no. of Non Volatile MemoryFor storage of 30 Day & 99 Fault Reports
1 no. of Real Time ClockWith Battery life of about 10 years
4 nos of Communication Port (RS485, 2 wire)Serial Port 1: MODBUS-RTU or SCADA PortSerial Port 2: Dedicated FPD Port (For future use)Serial Port 3: Add-On I/O Interface Port (For future use)Serial Port 4: VFD Interface Port (For future use)
1 no. of In System Programming (ISP) portPower Supply Input: 24VAC +/- 25%, 50Hz, 1A (In built Protection present for Surge, Over Current)
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3.0 Input Output Description
X01: Power supplyConnector type: 3 pole combicon
Pin Function Id Active state1 24V AC Phase 24 VAC P -
2 Earth Earth -
3 24V AC Neutral 24 VAC N -
X02: RelaysConnector type: 10 pole combicon
Pin Function Id Active state
1 Common - Load Relay Common
2 Load Relay L / UL Load when Energised
3 Common - Fan Relay Common
4 Fan Relay Fan Energised
5 Common - Auto Drain Valve Relay Common
6 Auto Drain Valve Relay ADV Energised
7 Common Dryer Relay Common
8 Dryer Relay Dryer / Pr2 Energised
9 Common - Programmable Relay Common
10 Programmable Relay Pr1 Energised
X03: Main Motor RelaysConnector type: 4 pole combicon
Pin Function Id Active state
1 Common for Main, Star and Delta
contactors
Common -
2 Main Contactor Main Energised
3 Star Contactor Star Energised
4 Delta Contactor Delta Energised
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X04: Digital inputsConnector type: 11 pole combicon
X05: Analog InputsConnector type: 8 pole combicon
Pin Function Id Type Range
1 Discharge pressure Dis. Pr 4-20 ma
2 15 to 24VDC 18V
0 to 16 bar
3 Discharge temperature Dis. Tr + KTY10
4 Discharge temperature Dis. Tr -
0 to 150 C
5 Sump Pressure Sump Pr 4-20 ma
6 15 to 24VDC 18V
0 to 16 bar
7 Dryer or Amb temperature Pt100 + Pt100
8 Dryer or Amb temperature Pt100 -
-50 to +85 C
X06: Analog outputs and VFDConnector type: 5 pole combicon
Pin Function Id Type Protocol /Range
1 VFD Interface VFD A RS485 A
2 VFD Interface VFD B RS485 B
FC Protocol
3 Supply Ground For 5V 0VDC - -
4 Dis. Pressure Output AO1 Voltage 0 to 16 bar
5 Programmable Analog
Output
AO2 Voltage Programmable
Pin Function Id Active state
1 Digital Inputs Common 24VDC 24VDC -
2 Emergency Stop Emergency Fault if open3 Differential Pressure Oil Filter DPOF Fault if open
4 Reverse Rotation Rev. Rot Fault if closed
5 Differential Pressure Air Filter DPAF Fault if open
6 Remote Start Stop Control Remote Stop if open/ start on
Closure
7 High Sump Pressure HSP Fault if open
8 Cooler Fault Input Cooler Fault if open
9 Main Motor Overload MMOL Fault if open
10 24V supply ground GND24 -
11 No Connection - -
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X07: CommunicationConnector type: 6 pole combicon
Pin Function Id Type Protocol
1 DCS Interface DCS A RS485 A
2 DCS Interface DCS B RS485 B
Modbus
3 FPD Interface FPD A RS485 A
4 FPD Interface FPD B RS485 B
ASCII
5 Add On Interface Add-On A RS485 A
6 Add On Interface Add-On B RS485 B
Modbus
4.0 Main Screen
Dis. Pr : 6.0 bar
Dis. Tr : 32 C
Message1Message2
Warning
HH:MM:SS DD/MM
Message1: Based on the short cut key pressed (refer APPENDIX C)
Message2: Compressor Status or Fault message- Pressure schedule
- If Blank Pressure Schedule is Disabled
- If PS Pressure Schedule is Enabled
- If PS blinkingWaiting for Pressure Schedule Acknowledgement
- Control Mode
- L Local, ON/OFF Control from Local Keypad
- R Remote, ON/OFF Control from Remote Input
- D DCS, Control is from DCS System
- MManual, Start need to given after Power failure
- A Auto, Compressor will Automatically Restart after power failure
1 2
1
2
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Message 2 - Compressor Status or Fault message
Status Description
Ready Ready for Start
Star Motor Running in Star
Run Motor Running in Delta
Run Load Compressor in LoadRun Unload Compressor in Unload
Stop Busy Stop Sequence in Progress
Idle Controller in Idle condition, User interface will not work for this period
(5 Seconds)
Emergency Stop Emergency Stop Push Switch is ON
Start Inhibit xx.x During the Start, if the Sump Pressure is higher than the set start sump
pressure value, you will see this message. XX.X denotes the live sump
pressure value. The Compressor Starts only if the Sump Pressure valuegoes below the set value.
Start Inhibit
seconds
If Sump Pressure is Not used (Disabled) then the controller will ensure
minimum 60 seconds delay between the stop and the start. Count stops ifSTOP key is pressed
Auto Restart
seconds
If Compressor is in Auto Mode,
The controller will ensure minimum delay (user set, e.g. 90 sec) between
stop and start. Count stops if STOP key is pressed
Start ack wait This message is displayed after a fault is cleared and waiting for user
acknowledgement. By pressing RESET key user can acknowledge.
Fault Description
Pr. Probe Failure Discharge Pressure Sensor Probe Failure
Tp. Probe Failure Temperature Sensor Probe Failure
Sump Pr. Probe
Failure
Sump Pressure Sensor Probe Failure
HSP (A) Case 1: Sump Pressure is enabled
If Sump Pressure exceeds the set high sump pressure value.
Case 2: Sump Pressure is disabled
If Discharge Pressure exceeds the set high sump pressure value.
HSP (D) If the HSP Digital Input Opens due to High Sump Pressure
Cooler If the Cooler Digital Input Opens due to Cooler fault
Main Motor Overload IF the MMOL Digital Input Opens due to Main Motor Over Load.
Rev Rot / Ph Fail If the Rev Rot Input Closes when Motor Running due to motorreverse rotation or Phase failure.
Trip Temperature If the Discharge Temperature exceeds the set trip temperature value.
Sump Pressure Not
Developing
After the Start, The Sump Pressure should be at least 1.0 bar in 10
seconds. If this is NOT achieved this Fault occurs
Power failure If the Mains Supply is Interrupted for more than 50 msec
Low Voltage If the Mains Supply Voltage is less than the 67% of rated Voltage.
Compressor is tripped & All Controller Operation is Halted until the
Mains Supply Comes back to normal (at least 75% of the rated)
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5.0 Menu Structure
Press any one of the following keys,,and to enter main menu
Main Menu
Dis. Pr : 6.0 bar
Dis. Tr : 32 C
Status
View
Operator
ServiceFactory
Customer Care
5.1 View
View
Operator Fault
Report
DayReport
Service
Time
Cumulative
TimeVFD
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5.1.1 Operator
LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4
View Operator Mode Control mode Local / Remote / DCS
Unload Mode Enable / Disable
Auto Restart ON/ OFF
Pressure Unit PSI / Bar
Temperature Unit Fahren / Centi
Pressure Unload pressure X X . X b or p (bar or psi)
Load pressure X X . X b or p
Pr. Schedule ON/ OFF
Start Sump Press X X . X b or p
Max .Diff Pressure X X . X b or p
Delay Warn RST delay X X X s (second)
Star delay X X sDTR delay X X s
RTS delay X X s
Stanby TimeSby X X m(minute)
St/Sp PH X X
DCS port Type Modbus / SCADA
ID X X
Baud 9600/19200
Parity None / Even
Length 8 / 7
Stop Bit 2 / 1
Temperature Trip Temperature X X X C or F
Warn Temp X X X C or F
Fan Temp X X X C or F
Low Dew Pt X X C or F
High Dew Pt X X C or F
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5.1.2 Fault Report
Use, to select the Fault Record number (1 to 99).
LEVEL 1 LEVEL 2 LEVEL 3
View Fault report Fault code: XX, Message
Time: HH:MM:SS
Date: DD/MM/YY
Dis.Pr: X X .X
Dis.Tr: X X X
Status: Load/ UnLoad /OFF
Fault Code:
01 & 09 Reserved
02-Main Motor Overload, 03-Cooler, 04-HSP(Analog), 05Trip Temperature, 06-Reverse Rotation, 07-Pressure Probe Failure, 08-Temperature Probe Failure, 0A-
HSP(Digital), 0B-Power Failure( Short Power Interrupt), 0C-Sump Pressure Not
Developing , 0D-Sump Pressure probe Failure.
5.1.3 Day Report
Use, to select the Record number (1 to 30).
LEVEL 1 LEVEL 2 LEVEL 3
View Day report Date: DD/MM/YY
L: X X Hours St: X X Hours
UL: X X Hours F: X X Hours
R: X X Hours Sby: X X Hours
STC: X X X LDC: X X X X X
L- Load, St Stop, UL Unload, F- Fault, R- Run, Sby- Standby, STC Start Count,LDC Load Count
5.1.4 Service Time
LEVEL 1 LEVEL 2 LEVEL 3
View Service time Remaining AFCT: X X X X X X hours
Remaining OFCT: X X X X X X hours
Remaining OSCT: X X X X X X hours
Remaining OCT: X X X X X X hours
Remaining RGT: X X X X X X hours
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5.1.5 Cumulative Time
LEVEL 1 LEVEL 2 LEVEL 3
View Cumulative time Load X X X X X X hrs: X X Min
Unload X X X X X X hrs: X X Min
Run X X X X X X hrs: X X MinStop X X X X X X hrs: X X Min
Fault X X X X X X hrs: X X Min
Standby X X X X X X hrs: X X Min
Start Count X X X X X X
Load Count X X X X X X X X X
Utilisation X X %
5.1.6 VFDIf VFD is connected to the compressor and VFD port is connected, user can view the
following parameters of VFD in Neuron II.
1. Voltage in V2. Current in A3. Frequency in Hz4. Power in KW5. Run Hours6. Kilowatt Hour (Multiply the value shown by 100 to get the real KWH)7. Status of the VFD
5.2 OperatorPassword required.
Operator
Machine Schedule Maintenance Language Change
Password
Mode Pressure Set
Delay
DCS
PortAuto Drain
Valve
Set Dew
Point
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5.2.1 Machine
# Item Min Max Option Default Unit
Mode
1 Auto Restart - - on / off off -
2 Pr Unit - - bar / psi bar -3 Tr Unit - - cen / fah cen -
4 Control
mode
- - loc/rem/dcs loc -
5 Unload
mode
- - en/dis dis -
6 Analog
output
- - Tmp / Sp /
Pt
Tmp -
Pressure
7 Unload
Pressure
> load
pressure+0.5
(bar)
< max unload
pressure (bar)
- 7.0 bar bar/psi
8 Load
Pressure
4.0 (bar) < unload
pressure-0.5(bar)
- 5.5 bar bar/psi
Set Delay
9 Warn RST 90 300 - 90 second
10 Star 6 10 - 6 second
11 DTR 10 60 - 10 second
12 RTS 5 30 - 10 second
13 Standby 1 99 - 5 minute
14 St/Sp per hr 3 10 - 5 -
DCS Port
15 Type - - Modbus
/SCADA
modbus -
16 ID 01 99 - 01 -
17 Baud - - 9600/19200 9600 bps
18 Parity - - None /Even None -
19 Length - - 8 / 7 8 -
20 Stop Bit - - 2 / 1 2 -
Auto Drain Valve
21 Off time 1 150 - 4 minute
22 On time 1 15 - 5 SecondSet Dew Point
23 Low Dew
point
-6 C +2 C - -2 C C/F
24 High Dew
point
6 C 12 C - 8 C C/F
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5.2.2 Schedule
Enable Pressure Schedule, and then use, to select the schedule number (1 to 32).
Then Press Enter to set the following
# Item Min Max Option Default Unit
1 Day - - Sun to Sat /
--- (means noschedule)
--- -
2 Action - - on / off off -
3 Time HH 00 23 - 00 Hour
4 Time MM 00 59 - 00 Minute
5 Unload
Pressure
> Load
Pressure
+ 0.5(bar)
< Max
Unload
Pressure(bar)
- 6.5 bar bar/psi
6 Load Pressure 4.0 bar < UnloadPressure
0.5 (bar)
- 4.5 bar bar/psi
5.2.3 Maintenance
# Item Min Max Option Default Unit
1 AF changed - - no/yes no -2 OF changed - - no/yes no -
3 OS changed - - no/yes no -
4 Oil changed - - no/yes no -
5 Re Grease - - no/yes no -
5.2.4 Language
# Item
1 English2 Hindi
3 Portuguese
Default is English.
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5.2.5 Change Password
Procedure for changing the password
1. Enter the old Password
2. If old password is correct, next screen is displayed. If wrong the control comes
out of the change password screen.
3. Enter the New password
4. Enter the New password again
5. If the new password matches both the times then new password is updated. If
mismatch the control goes back to step 3.
Pressing Esc will bring the control to the main menu screen
5.3 ServicePassword required.
Service
Calibration Relay ChangePassword
Maintenance Clock SelfTest
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5.3.1 Calibration
Select the parameter need to calibrated using the,keys. Then Press Enter to
calibrate.
Dis Pressure/ Dis Temperature/ Sump Pressure Calibration
Run the Compressor. When the value is stable at some point, measure the actual value
using a standard & recently calibrated meter and enter the meter reading in to the set
value field displayed in Neuron II. Set Value should not exceed +/- 1 bar, +/- 10 C.
Pt 100 Calibration
When the Dew point/ Ambient Temperature is stable at some point, measure the actual
value using a standard & recently calibrated meter and enter the meter reading in to the
set value field displayed in Neuron II. Set Value should not exceed +/- 3 C.
Analog Output 1 & 2Calibration for analog output should be done for two values one at zero and one at 8.0 bar
/ 80 degree C. These values are set by connecting a Variable Resistor (TRIM POT) in the
analog input channel. Measure the Analog output value (can be viewed in the DCS/VFD /
or any master unit where this output is connected). Enter this value in set pr:
Note: Calibration need to be done only when the compressor is in off condition and the
digital outputs (relay terminals) are disconnected from the controller.
Note: Calibration for Pressure will be only in bar and for temperature only in Centigrade.
5.3.2 Relay
Select the Programmable Relay 1 or 2 using the,keys. Then Press Enter to assign
the any one of the following functionality for the relay.
# Item
1 Warn
2 Load
3 Service
4 Standby
5 Trip
6 Remote
7 Ready
Default:Relay 1 = Warn
Relay 2 = Trip
Note: If Dryer is enabled then Programmable
Relay 2 is not user programmable.
It is used for automatic dryer control.
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5.3.3 Change Password
Procedure for changing the password
1. Enter the old Password
2. If old password is correct, next screen is displayed. If wrong the control comes
out of the change password screen.
3. Enter the New password
4. Enter the New password again
5. If the new password matches both the times then new password is updated. If
mismatch the control goes back to step 3.
Pressing Esc will bring the control to the main menu screen
5.3.4 Maintenance
# Item Min Max Option Default Unit
1 Set AFCT 000000 999999 - 002000H Hour
2 Set OFCT 000000 999999 - 002000H Hour
3 Set OSCT 000000 999999 - 004000H Hour
4 Set OCT 000000 999999 - 002000H Hour
5 Set RGT 000000 999999 - 002000H Hour
5.3.5 Clock
# Item Min Max
1 Hour 00 23
2 Minute 00 59
3 Second 00 59
4 Date 01 31
5 Month 01 12
6 Year 00 99
7 Day Sun/Mon/Tue/Wed/Thu/Fri/Sat
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5.3.6 Self Test
Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output, Memory &
Communication Ports working.
Follow the instructions displayed in the screen
Warning!!!
Self Test should be conducted only when the compressor wiring is totally disconnected
from the controller. Do NOT perform self test when the controller is connected to the
compressor. Doing so will cause severe damage to the compressor.
5.4 Factory menuPassword required.
Factory
Machine ChangePassword
Dryer
Compressor
Info
DPSE DPOF Max.
PressureSettings
Temperature
Settings
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5.4.1 Machine
# Item Min Max Option Default Unit
Compressor Info
1 Rating - - 11 to 315 22 KW
2 Pressure - - LP/ 7.0 to 12.5 LP bar3 Fab no A-Z 00000 A-Z
999999
- A00000 -
4 DPSE - - on/off off -
5 DPOF - - on/off off -
Max. Pressure Settings
6 Max UL
Pressure
> Unload
Pressure
< 13.5 bar - 7.5 bar bar
/psi
7 High Sump
Pressure
> Max
Unloadpressure +1
< Max
Unloadpressure
+3
- 10.5 bar bar
/psi
8 Sump
Pressure
- - enable/disable disable -
9 Start Sump
Pressure
0.0 bar 16.0 bar - 2.2 bar bar
/psi
10 Max.
Differential
Pressure
0.0 bar 2.0 bar - 1.5 bar bar
/psi
Temperature Settings
11 Trip
temperature
110 C 120 C - 110 C C / F
12 Warn
temperature
90 C 110 C - 105 C C / F
13 Fan
temperature
60 80 C - 70 C C / F
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5.4.2 Change Password
Procedure for changing the password
1. Enter the old Password
2. If old password is correct, next screen is displayed. If wrong the control comes
out of the change password screen.
3. Enter the New password
4. Enter the New password again
5. If the new password matches both the times then new password is updated. If
mismatch the control goes back to step 3.
Pressing Esc will bring the control to the main menu screen
5.4.3 Dryer
# Item Min Max Option Default Unit
1 Dryer Mode - - on/off off -
2 Dryer Delay 2 10 - 3 Minute
5.5 Customer care
Dis. Pr : 6.0 barDis. Tr : 32 C
Status
Toll Free No
1800-425-3544
e-mail
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6.0 Controls
6.1 Start SequenceExit loop
FAULT?
ON
Command
No
Yes
AUTO
mode
ON?
Dis. Pr.
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STAR
ON
MAIN ON
NO. OF. START
INCREMENT
DELTA ON
STAR OFF
Exit loop
Delay for 100msecs
(Fixed)
STAR TO DELTA delay x sec
(Star delay)
Delta to run delay x sec
(DTR delay)
Start Sequence
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6.2 Stop Sequence
Is
STAR ON
LOAD OFF
DELTA & MAIN
OFF
(RTS delay)
Run to stop x sec
IDLE delay for 5 secsFixed delay
READY
Yes
No
Stop
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6.3 Fan Control
Dis. Temp
> Set FANTemp
FAN ON
No
Yes
FAN
= ON?
Dis. Temp< (Set FAN
Temp 5 C)
FAN OFF
Exit Loop
No
Yes
No
Yes
Exit Loop
State = Run?
No
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6.4 ADV control
As per the User set On & Off time the Drain Valve is automatically controlled.
6.5 Dryer Control
Calculate elapsed time from
last stop
IsElapsed time>set
dryer delay ?
Dryer ON
No
Yes
Dryer ON command generates
internally when Compressormotor starts runnin
Dryer OFF when Compressor is stopped
On time
Off time
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7.0 Data Interface
Neuron II has two types of Data Interface
Analog output
DCS Port
7.1 Analog output
Two Channels are available as analog output. The First Channel will output the current
Discharge Pressure value 0.0 to16.0 bar, converted into 1 to 4.75V.
The Second channel is programmable. User can select any one of the following in menu
Operator/ Machine/ Mode/ Analog output
a. Dis. Temperature 0 to 150 C, converted into 1 to 4.75V
b. Sump Pressure 0 to 16.0 bar, converted into 1 to 4.75V
c. Pt100 Temperature -50 to 90 C, converted into 1.25 to 4.75V
Note: Analog output will be 0V in case of probe failure.
7.2 DCS Port
DCS port can be of Modbus RTU type to interface to Generic DCS system or SCADA
type to interface to ELGI SCADA software.
User can select the Port type in menu Operator/ Machine/ DCS Port. Also the ID,
Baud Rate, Parity, data Length, Stop Bit are user settable. The Modbus data table is
provided in the Appendix.
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8.0 Construction
Corrosion & Dust protected Back Cover
IP65 polyethylene front keypad
Inputs and Outputs through terminal block, board to wires, disconnect able, screw terminals
Front Plate Dimensions 260 x 145mm
Enclosure Dimensions 235 X 120 X 70 mm
Operating Temperature - 0C to +75C
Relative Humidity
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9.0 Revision Details
Version Date Changes
1.0 2 April 2009 Initial Draft1.1 8 July 2009 Pilot Batch S/W
Version 1.1
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10.0 Appendix
APPENDIX A: MODBUS TABLE [Function Code: 0x03(Read) & 0x10(Write)]
# DataDescription
Address Type Bytes Example / Format Access
Cumulative Time & Count Registers
1 Load Hours 1010 BCD 4 HHHHHH:MM R
2 UnloadHours
1012 BCD 4 HHHHHH:MM R
3 Run Hours 1014 BCD 4 HHHHHH:MM R
4 Stop Hours 1016 BCD 4 HHHHHH:MM R
5 Fault Hours 1018 BCD 4 HHHHHH:MM R
6 Standby
Hours
101A BCD 4 HHHHHH:MM R
7 No of Start 101C BCD 4 NNNNNNNN R8 Load Count 101E BCD 6 NNNNNNNNNNNN R
9 Utilization % 1022 BCD 2 XXXX R
Service Remaining Time Registers
10 Rem AFCT
Hours
1028 Int 2 H8063 = -99
(X10000)
Minutes 1029 ULong 4 H000927BF =
599999
R
11 Rem OFCT
Hours
102B Int 2 H8063 = -99
(X10000)
Minutes 102C ULong 4 H000927BF =599999
R
12 Rem OSCTHours
102E Int 2 H8063 = -99(X10000)
Minutes 102F ULong 4 H000927BF =599999
R
13 Rem OCTHours
1031 Int 2 H8063 = -99(X10000)
Minutes 1032 ULong 4 H000927BF =599999
R
14 Rem RGT
Hours
1034 Int 2 H8063 = -99
(X10000)
Minutes 1035 ULong 4 H000927BF =
599999
R
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Mode Registers
15 Control
Mode
1040 BCD 2 0001-DCS
0002-Local
0003-Remote
R/W
16 Unload Mode 1041 BCD 2 0001-Disabled0002-Enabled
R/W
17 Auto Restart
1042 BCD 2 0001-OFF
0002-ON
R/W
18 Pr Unit 1043 BCD 2 0001-BAR0002-PSI
R/W
19 Tr unit 1044 BCD 2 0001-Centi0002-Farhen
R/W
20 Pr.Schdl(on/off)
1045 BCD 2 0001-OFF0002-ON
R
Analog Registers
27 Dis. Pressure
104A BCD 2 1200 (/100) =12.0 bar
R
28 Dis.Temperature
104B BCD 2 1100 (/10) =110 C
R
29 Dew Point /Ambient
Temperature
104C BCD 2 MSB 01 = +MSB 02 = -
LSB = 30
R
30 Sump
Pressure
104D BCD 2 1200 (/100) =
12.0 bar
R
31 Diff Pressure 104E BCD 2 0100 (/100)
=1.0 bar
R
32 Set UnloadPressure
104F BCD 2 0120 (/10) =12.0 bar
R/W
33 Set Load
Pressure
1050 BCD 2 0080 (/10) =
8.0 bar
R/W
34 Set DiffPressure
1051 BCD 2 0010 (/10) =1.0 bar
R/W
35 Trip Temp 1052 BCD 2 0110 = 110 C R
36 Warn Temp 1053 BCD 2 0105 = 105 C R/W
37 Low Dew
Point
1054 BCD 2 MSB 01 = +
MSB 02 = -LSB = 30
R/W
38 High DewPoint
1055 BCD 2 MSB 01 = +MSB 02 = -
LSB = 30
R/W
39 Fan Temp 1056 BCD 2 0070 = 70 C R/W
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Delay Registers
21 Auto Restart
Delay (Sec)
1060 BCD 2 0100 R/W
22 Star Delay
(Sec)
1061 BCD 2 0005 R/W
23 DTR Delay
(Sec)
1062 BCD 2 0010 R/W
24 RTS Delay
(Sec)
1063 BCD 2 0010 R/W
25 Standby
Time (Min)
1064 BCD 2 0005 R/W
26 Max. No of
Start per hour
1065 BCD 2 0005 R/W
RTC Registers
40 Hour 106A BCD 2 0023 R
41 Minutes 106B BCD 2 0059 R42 Seconds 106C BCD 2 0059 R
43 Date 106D BCD 2 0031 R
44 Month 106E BCD 2 0012 R
45 Year 106F BCD 2 0009 R
46 Day 1070 BCD 2 0001
Sunday -1
R
Status Registers
47 General
Status
1071 UInt 2 Refer table R
48 Warning
Status
1072 UInt 2 Refer table R
49 Fault Status 1073 UInt 2 Refer table R
Start / StopFunction Code: 05Address : 1074
Value : 0xFF00 Start
0x0000 Stop
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Status Register Bit Definition:
Bit Position General Warning Fault
0 Ready DPSE HSP
1 Star DPOF Cooler
2 Run Dryer Probe Failure Main Motor Overload3 Run Load Low Dew Point Reverse Rotation
4 Run Unload High Dew Point Pressure Probe Failure
5 Stop Busy High Differentialpressure
Temperature ProbeFailure
6 Idle Warn Temperature Trip Temperature
7 Emergency Stop Change Air Filter Sump Pressure Not
Developing
8 Start Inhibit Change Oil Filter Sump Pressure probeFailure
9 Start ack wait Change Oil Separator Power failure
10 Standby Change Oil Reserved11 Reserved Change Grease Reserved
12 Reserved Reserved Reserved
13 Reserved Reserved Reserved
14 Reserved Reserved Reserved
15 Reserved Reserved Reserved
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APPENDIX B: MIMIC LED TABLE
# LED Description
1 Auto To indicate the machine is in automatic on/off mode. This Led
glows in Amber Colour on these conditions
1. When Pressure Schedule is enabled (or)2. When Auto Restart is enabled2 Air Filter Glows in Amber colour when
1. Air Filter Service is due based on service hours2. Air Filter Digital Input (DPAF) is Open
3 Main Motor
Overload
Glows in Red when the main motor overload Digital Input is
Open.
4 Reverse Rotation Glows in Red when the Reverse Rotation Digital Input isClosed and the machine is in Run state
5 Cooler Glows in Red when the cooler Digital Input is Open
6 Pressure Glows in Red when the
1. HSP Digital Input is Open2. Analog Pressure Input is Open (Probe Failure)3. Dis. Pressure is higher than set HSP
7 Temperature Glows in Red when the
1. Analog Temperature Input is Open (Probe Failure)2. Dis. Temperature is higher than set Trip temp.
8 Differential
Pressure Oil Filter(DPOF)
Glows in Amber when the
1. DPOF Digital Input is Open & DPOF is enabled2. Oil Filter Service is due
9 Differential
Pressure Separator
Element (DPSE)
Glows in Amber when the
1. DPSE Digital Input is Open & DPSE is enabled
2. Oil Separator Filter Service is due10 Start & Stop 1. Glows in Red when machine is stopped / idle
2. Glows in Green when machine is running
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APPENDIX C: Short Cut Key Functions
Note1: All shortcut key functions only when the display is in Main Screen.
Note2: On every press of the key NEXT message is displayed.
LEFT Warning messages
Warning Description
DPSE Differential Pressure Separator Element Due For
Service
DPOF Differential Pressure Oil Filter Due For Service
Dryer Probe Failure Pt100 Sensor Probe Failure
Low Dew Point Live Dew Point less than the Set Low Dew Point
High Dew Point Live Dew Point greater than the Set High Dew Point
High Differential pressure Difference Between the Sump & Discharge Pressure is
greater than the set max Differential Pressure value.
Warn Temperature Discharge Temperature exceeds the set Warn valueChange Air Filter Air Filter Due For Service
Change Oil Filter Oil Filter Due For Service
Change Oil Separator Oil Separator Due For Service
Change Oil Oil Change Due For Service
Change Grease Re Grease Due For Service
Start Stop Exceeded No. of Start stop per hour exceeded
RIGHT - Live Analog Values
1. Live Differential Pressure2. Live Sump Pressure
3. Live Pt100 Temperature
UP Set Analog Values
1. Set Load Pressure
2. Set Unload Pressure
3. Set Start Sump Pressure4. Max Differential Pressure
DOWN Today Report
1. Date
2. Load and Stop Hours
3. Unload and Fault Hours4. Run and Standby Hours
5. Start Count and Load Count