compressor basics

21st MAY , 2003 AIF-TRAINING 1

COMPRESSORBASICS - ELECTRIC

Compressor Basics - Electric


CompressorBasic

Electrics



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)

VoltageUdc

Time

Voltage is polarised with + and -• Examples : Batteries

Rectified power supplies ; 12….24 V• Applications : Electronic instrument supplies

Control equipmentSupply 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 PhaseCharacteristic : Voltage and current regularly changes strength and direction in a sinusoidal variationApplication : General use



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 Safe for personnel

> 24 V is dangerousTerminology : < 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 systemPhase 1Phase 2Phase 3

NeutralGrounding

1-Phase

3-Phase Y 3-Phase Delta

L1L2L3

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 ()

ZX

R

Power factor - cos

Uac

X

R

Reactance

Resistance



Basic laws

Direct 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 with

I = Current in Ampere

U = Voltage in Volt

Z = Impedance in Ohm

= Sqrt (R² + X²) where X is the reactance• Power in a single phase system

P = U x I x cos

• Power in a three phase systemP = UL x IL x cosx 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

L2220 V

Measurement in V ac Between V and Com


Current : Measures current flow in a circuit Unit = Ampere

L1

L2PS

Measurement in A (of mA) between A and Com


Motor connection in Star

Terminal box

U1

U2

V1

V2

W2

W1

400 V400 V

400 V

230 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

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 HPat full load speed• Locked rotor torque• The minimum torque that a motor will developat 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 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 body’s 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 (

Loaded compressor

Unloaded compressorSpeed

Torque curve (Y

Speed : +/- 90-95 %



V Hz A KW cos t/m IA / In IP 55400 50 430 250 0,87 1488

+/- 10 %460 60 430 285 0,87 1784

KL 13 EN 60034 IEC 34-1SF : 1,1SF : 1,0

Weight : 1,3 tSFA : 470 ATemp rise : 105 K

S I E M E N S

1080 2846 42Nmax : 3000 RPM

3 f Mot 1LA8 315 4AB91 - Z

ROTOR SQU. CAGE

Temp rise : 80 KAmbient temp : 40°CAmbient temp : 55°C

MOTOR DATA PLATECompressor Basics - Electric


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 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 disturbs

6 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 vertical

3 Iden. as 2 but angle of 60°4 Water splashed against the

motor from any direction5 Against water jet6 Against condition on ship’s

decks7 Against the effect of immersion

Most frequently used are IP23, 44 and 54

Protection degree of electrical equipment : IP xyCompressor Basics - Electric



+/- 10 %460 60 430 285 0,87 1784

KL 13 EN 60034 IEC 34-1SF : 1,1SF : 1,0

Temp rise : 105 K

S I E M E N S

1080 2846 42Nmax : 3000 RPM

3 f Mot 1LA8 315 4AB91 - Z

ROTOR SQU. CAGE


Weight : 1,3 tSFA : 470 A



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



MOTOR TEMPERATURE RISE

Insulation class A E B F HAmbient temp °C 40 40 40 40 40Temp increase °C 60 75 80 105 125Thermal margin °C 5 5 10 10 15Max. final temp °C 105 120 130 155 180

INSULATION CLASSES

020406080

100120140160180200

A E B F H

Tem

p (°

C)

Ambient temp °C Temp increase °C Thermal margin °C



+/- 10 %460 60 430 285 0,87 1784

KL 13 EN 60034 IEC 34-1SF : 1,1SF : 1,0

Temp rise : 105 K

S I E M E N S

1080 2846 42Nmax : 3000 RPM

3 f Mot 1LA8 315 4AB91 - Z

ROTOR SQU. CAGE


Weight : 1,3 tSFA : 470 A



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

500Kg

1000Kg

1500Kg

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 RTD’s

• 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 protectionsAlarm and Trip



Motor protection

RTD’s = Resistance Temperature Detector

RTD’s 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 chart



TEMP

(°C) 0 1 2 3 4 5 6 7 8 9-10 960,9 964,81 968,72 972,63 976,54 980,45 984,36 988,27 992,18 996,090 1000 1003,9 1007,8 1011,7 1015,6 1019,5 1023,4 1027,3 1031,2 1035,110 1039 1042,89 1046,78 1050,67 1054,56 1058,45 1062,34 1066,23 1070,12 1074,0120 1077,9 1081,78 1085,66 1089,54 1093,42 1097,3 1101,18 1105,06 1108,94 1112,8230 1116,7 1120,57 1124,44 1128,31 1132,18 1136,05 1139,92 1143,79 1147,66 1151,5340 1155,4 1159,26 1163,12 1166,98 1170,84 1174,7 1178,56 1182,42 1186,28 1190,1450 1194 1197,84 1201,68 1205,52 1209,36 1213,2 1217,04 1220,88 1224,72 1228,5660 1232,4 1236,23 1240,06 1243,89 1247,72 1251,55 1255,38 1259,21 1263,04 1266,8770 1270,7 1274,52 1278,34 1282,16 1285,98 1289,8 1293,62 1297,44 1301,26 1305,0880 1308,9 1312,71 1316,52 1320,33 1324,14 1327,95 1331,76 1335,57 1339,38 1343,1990 1347 1350,8 1354,6 1358,4 1362,2 1366 1369,8 1373,6 1377,4 1381,2

100 1385 1388,79 1392,58 1396,37 1400,16 1403,95 1407,74 1411,53 1415,32 1419,11110 1422,9 1426,67 1430,44 1434,21 1437,98 1441,75 1445,52 1449,29 1453,06 1456,83120 1460,6 1464,36 1468,12 1471,88 1475,64 1479,4 1483,16 1486,92 1490,68 1494,44130 1498,2 1501,96 1505,72 1509,48 1513,24 1517 1520,76 1524,52 1528,28 1532,04140 1535,8 1539,53 1543,26 1546,99 1550,72 1554,45 1558,18 1561,91 1565,64 1569,37150 1573,1 1576,83 1580,56 1584,29 1588,02 1591,75 1595,48 1599,21 1602,94 1606,67160 1610,4 1614,12 1617,84 1621,56 1625,28 1629 1632,72 1636,44 1640,16 1643,88170 1647,6 1651,3 1655 1658,7 1662,4 1666,1 1669,8 1673,5 1677,2 1680,9180 1684,6 1688,3 1692 1695,7 1699,4 1703,1 1706,8 1710,5 1714,2 1717,9190 1721,6 1725,28 1728,96 1732,64 1736,32 1740 1743,68 1747,36 1751,04 1754,72200 1758,4 1762,07 1765,74 1769,41 1773,08 1776,75 1780,42 1784,09 1787,76 1791,43210 1795,1 1798,76 1802,42 1806,08 1809,74 1813,4 1817,06 1820,72 1824,38 1828,04220 1831,7 1835,35 1839 1842,65 1846,3 1849,95 1853,6 1857,25 1860,9 1864,55230 1868,2 1871,83 1875,46 1879,09 1882,72 1886,35 1889,98 1893,61 1897,24 1900,87240 1904,5 1908,12 1911,74 1915,36 1918,98 1922,6 1926,22 1929,84 1933,46 1937,08250 1940,7 1944,32 1947,94 1951,56 1955,18 1958,8 1962,42 1966,04 1969,66 1973,28260 1976,9 1980,5 1984,1 1987,7 1991,3 1994,9 1998,5 2002,1 2005,7 2009,3270 2012,9 2016,49 2020,08 2023,67 2027,26 2030,85 2034,44 2038,03 2041,62 2045,21280 2048,8 2052,37 2055,94 2059,51 2063,08 2066,65 2070,22 2073,79 2077,36 2080,93290 2084,5 2088,07 2091,64 2095,21 2098,78 2102,35 2105,92 2109,49 2113,06 2116,63300 2120,2

Resistance(in Ohm) of PT 1000 element as a function of the temperature



Sensor PT 1000

9001000110012001300140015001600170018001900200021002200

°C

Ohm



RTD’s Pt 100 and Pt 1000

RTD’s 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.

RTDElektronikon



RTD’s Pt 100 and Pt 1000RTD’s 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.

RTDElektronikon

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 numberTerminal row1 = Cubicle

2 = Elektronikon Master module3 = Consecutive module or component numbers Cables and wires



Basic symbols



Part of wiring diagramCompressor Basics - Electric


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 !

VOLT208220230380440460575

110220

TRANSFORMER CONNECTIONS

32-3831-35

1-37 & 31-21-36 & 32-21-35 & 33-2

3-4 & 5-64-5

PRIM

ARY

SEC

33-35 34-35



Part of wiring diagramCompressor Basics - Electric


Part of wiring diagram

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



Part of wiring diagram(for compressor supplied without starter)

Important

Take care of

interfacing connections

to be in phase with

ECB AIF 1133



Interfacing connections with Elektronikon

Auxiliary inputsRelay contactoutputs



Interfacing connections with Elektronikon

Relay outputsTemp inputs

Pt 1000Pressure sensor

inputs



Interfacing connectionsDevice connections

Pressure transducers3 - wire connection

Temp sensors Pt10002 - 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 DCFull scale = 4.5 Volt DC

Sensor must remain connected to Elektronikon



SERVICE DIAGRAM



[ l]

21

22 1 3 5

642

13

14

Q28

Fanmotor circuitonly for unitswithout compr. motor

M28PE

W 1 V1U1

M3

(T1) (T3) (T2)

[ l]

Remote/local press. sensingS 3 'Remote setpoint changeS 5 '

Remote start but tonRemote emergency stop button

S 1 'S 2 '

Compressor motor starterK2 1Undervoltage relay

CUSTOMER'S INSTALLATION

Overload relay compressor motorF6F2 1

3

To b e in stalled b y costu mer [n ]

0 3 /0 22

0 2 /0 1

3[b ]

Customer's installation

53

I>F 21

95

96

242

A2

A1K21

M1Compressor motor

M3

U<

F6

62

PE

[ f]

02/2

02/1

[ f]

F32

1

1 X4X

X

XX

1 X4X

X

XX

1

2

133

2

1 X4X

X

XX

230V

50Hz

[ e]

T1

30

F2F1F0L1

3231

L2L3

FANMOTOR CANOPYDRIVE MOTOR

1 X3

[b ]

1 X3

[m]

LEGEND

CUBICLE

Start button

Programmed S top button

Elektron ikon RegulatorCOMPRESSOR CONTROL MODULE

Blocking relayAux. relay Y-con tactorAux. relay D-contactorAux. relay load/unloadAir Press.High/Air Press.Low relayDryer + fan startAutomatic operation relayGeneral alarm relayGeneral sh ut-d own relayPrinted circuitboard connectors

E1K0 1K0 2K0 3K0 4K0 5K0 6K0 7K0 8K0 92X1/12

MOTOR HEATER

[l] In case of High Voltage supp lyfor the drive motor, use aseparate 3-ph ase supply forthe fan motor and single-phase supply for the regulator.

Power supp ly to be connected forcounterclockwise rotation ofcompressor motor and- clockwise rotation fanmotor for ZR 300-750Rotation to be observed whilefacing the end shaft ofthe motor.

[b ]NOTES

When remote stop button is

terminals of 1X4 and 1X6.be removed on the correspondinginstalled, the br idges should

[g ]

4 : sealed with dummy

1 : supply voltage2 : ground3 : output

423 1

[ i] Pressure transducerpin configuration

metric thread size M10: 40Nm (29 lbft )C.P.E. = Customer Provided Equipment

For field wiring : USE COPPER WIRE ONLYmetric thread size M5 : 5Nm ( 4 lbft)metric thread size M8 : 20Nm (15 lbft)metric thread size M6 : 8Nm ( 6 lbft)tightening torque for bolts :

[ o]

To avoid Electro Magneticbe used and earthed.Interference : screened cable shall

[n ]

X

XXX

X

XXX

T N

R96

CT.0 3 .1 1 1 8 .0 0 A 0 0 0 0 0 0

M/s

. A

TL

AS

CO

PC

O I

ND

IA L

TD

.

Not

to b

e us

ed w

itho

ut t

he p

erm

issi

on o

f

Confi

dent

ial

Prop

erty

of

ATLA

S CO

PCO

IND

IA L

TD.

Appurtenant drawing s and doc uments .

R

Q

P

O

N

M

L

K

J

I

H

G

F

E

D

C

B

A

2019181716151413121110987654321

Note: Pos i tion: M odified fro m: Date: Intr/Appd:

FINISH :

00

9095 ---- 00DD/MM/YY

(1/1)

--

1 : 1

XA 125See drg. area

PARTNAME432

REVISIONAC 1356KAC 1356KAC 1350K

Transferred toATLAS COPCO (I) LTD

Kg.Kg. SheetDesignation

Replaces

CompareRef.no.

finished wt.

DateAppd.Prod.chd.

Blank wt.Blank no.

Design chd.Std.chd.

Drawn

Scale

3

2

Name

ClassClassClass

flame cuttingWelding

flame cutted holesSheet metalpunched holes

Mach.surf./dril ledaccording toTolerance if not indicated

A1

DN:PNA90000000

15119 00 005.S GK .

0 7 /0 2 /0 3

(1/2)

9096 3823 009823 1897 32

1 : 1

(FOR ZR 355 AIR COMPRESSOR.)WIRING DIAGRAM FOR CONTROL PANEL

PT100

R11 R13R12 R14 R16R15 R17 R19R18 R20 R22R21 R23 R25R24 R26 R28R27 R29 R31R30 R32 R34R33

temp. s ens orBearing N-end

te mp. s ens ortemp. s ens orM o tor winding 1U1 Bea ring D-endM otor winding 2W2

temp. s ens o rtemp. s ens o rM oto r wind ing 1V1 M otor winding 1W1

temp. s ens orM otor winding 2V2temp. s ens o r

M otor winding 2U2temp. s ens or

SpaceHeater

CT

A

415 VAC, 3PH, 50HZ, BHELLT LINE FROM THESAME FEEDER OFHT LINE

GEAR WITH NECESSARY INTERLOCKS.POWERED DIRECTLY FROM CUSTOMER'S HT SWITCH

[t ] MAIN ELECTRIC MOTOR SPACE HEATERS TO BE

(THIS IS NOT IN ACIL SCOPE.)

(PAC)FROM

LAPTOP.

230 VAG 3 PINSOCKET FOR S6

109

M1~ AIR DRYER

K11

F21B

(IAC)

(IAC)108 (DRYER)

1x1

110

VAC

T132

(F) 2

F2 1

415

v31

(F) 1

F1 2

L2L1

1X11X12

1X11

230VAC POWER SUPPLYFROM HT SWITCH GEAR

PANELTUBE LIGHT

VA A 21K14,15 VA A 11- (2N O,2NC)

Q28 MIN IATURE CIRCU IT BREAKER FOR FAN MOTORS

F21A OVERLOAD RELAY-FAN MOTOR-M28.

K21 POWER CONTACTOR FOR FAN MOTOR M28

EMERGENCY STOP

1X3 EARTH BOLT 1X1 TERMIN AL STRIPT2 TRANSFORMER 110V AC / 24 V ACT1 MAIN TRANSFARMERS6 SELECTOR SWITCHS2 MUSHROOM-SHAPED PUSH BUTTON

F21 OVERLOAD RELAY-MAIN MOTOR.

K13 AUX. RELAY FOR STARTER CONTROL (4NO+4N C) K11 AUXILIARY RELAY LOADINGF1/5 FUSE L INKS, CONTROL CIRCU IT

A AMMETER

CONT

ROL

CIRCU

IT.CU

STOM

ER H

.T. P

ANEL

HT S

W.GE

AR

K14 K15

(+)

START / STOP / TRIP SCHEME.

65

STOP/TRIP

1x11x163

START

COIL.CLOS ING

(-)

DOL HT STARTER WITH ALL MOTOR NTPC`S IN STALLATION

661x1

K13

641x1

S HUNTCOIL.

/TR IP

PROTECTION S.

K3 1 Time relay water shut-off valve

. . .

PT100

. ..

PT100

.. .. .. .. . . .. . . . .. . . . . . . .

PT100PT100P T100 P T100PT100

. . . . . .. .. . . . .. . . ...

( NTPC-RIHAND 3.3 KV )

BY CUSTOMER

: PE-VO-200-555- .

NATIONAL THERMAL POWER CORPORATION LTD.

PROJECT ENGINEERING MANAGEMENT,

: 1230-001-10PE-PVM-B- .NEW DELHI, INDIA.

BHELJOB NO.

NTPC DRG. NO.

: 200 BHELDRG. NO.

BHARAT HEAVY ELECTRICALS LTD.

RIHAND SUPER THERMAL POWER PROJECT.NTPC

2 x 500 M.W.



F1

(F)

F2(F)

(F)

1X12

1X1

T3

T1

8

81X1

1X1

1x19

24 VA

C

(E) 1

10 VA

C

1X16

1X16

1X16

39

6

6

1X11X1 1X17 7 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

3132

L1L2

2

33

1

1X1

110

VAC

1

7

40

Y1 K11 A1

A2

8

9

2X7

2X7

K04

17

18

2

1

2

1

1

F31

2

1(F)

F42

2(F)

F51

415

v

K2

HK1K2

K1

1KK2

S3

S10

YS1

16

15T31

1X199

1001x1

1314

2122

1X13

1X13

13

14

GREEN

OFFM1M1

A1

A2K13

RED

ON

3A2

K21A1

M1

YELLOW

TRIP

K31A1

A2

K15A2

A1

T2A2

T1A1

K14

A2

A1

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PROJECT ENGINEERING MANAGEMENT,

NATIONAL THERMAL POWER CORPORATION LTD.

JOB NO.

NTPC DRG. NO.BHEL

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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?What is the Elektronikon?

State of the art electronic controller that optimizes all aspects of compressor maintenance and operation



The Elektronikon monitorsThe 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 simplicityElektronikon elegant simplicityOlder 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 Elektronikon electronic precisionelectronic 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

sensor’s 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



Improvements compared to MkIII – 2 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 don’t 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



Improvements compared to MkIII – 3 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 New FeaturesFeatures

More 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 independently



Chapter 2

Hardware



Elektronikon MKIV The familyElektronikon 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

Elektronikon MKIV The familyElektronikon MKIV The family



Elektronikon MKIV The familyElektronikon MKIV The family •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



Elektronikon MKIV The familyElektronikon MKIV The family

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 • I²C 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 (17…30VDC)• No download • Low powerconsumption (mA)

• AIE3 : 1900 0710 61• 5x Pt100 for motorprotection (2bearings, 3 windings)• No supply• No download • Low powerconsumption (mA)

• AIE4 : 1900 0710 81• 5x Pt1000 for motorprotection (2bearings, 3 windings)• No supply• No download • Low powerconsumption (mA)



• DIOE : 1900 0710 71• 4 voltage Free contactsK01 … 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, -03To 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 SensorsDigital Inputs Relay Outputs

Extra Inputs,Outputs or both

24VacRS485 Converter on models B/Dattention software PROTOCOL defines converter typeAvailable : Siemens,ABB & Vacon

Updated ! 1622 0661 00



• Weidmüller & Phoenix screw terminals

• Sometimes became loose

• PartNr: 1088 0014 xx

• Wago ‘spring’ connectors

• Also mechanically better fixed

• PartNr: 1088 0031 xx

Improved connectorsImproved connectorsMk3Mk3 Mk4Mk4

1088 0031 00_ed1.pdf



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

I²C cables– To connect modules (lengths of 150/600/1100 mm)

ES002– To connect an E/P unit to CANES003 = ES002 + Combox-S– To connect an E/P unit via CAN to ES100/300



B

DIOE

StandardDigital InputsD1 = Emergency StopD2 = start/stopD3 = load/unloadD4 = local/remote pressureD5 = main motor overloadD6 = fan motor overload

Digital inputsOption CONDR

D7 = Cond. DrainOption FIKIT D8 = DD filterD9 = PD filterOption PHSR

D10 =Phase sequence

AIE1AIE1

StandardKavlicoinputsP1 = delivery air P2 = DP oil separatorPt1000 inputsT1 = element outletFeature MDVAR= FF T2 = Dryer LAT

T3 = not used

StandardDigital outputsK01 = LineK02 = StarK03 = DeltaK04 = Load/Unload SolenoidK05 = APH / APLK06 = FD Dryer ControlK07 = Automatic OperationK08 = General WarningK09 = General Shutdown

Digital InputsOption THERM

DI01 : Thermistor WarningDI02 : Thermistor

Shutdown

DI03 : QD Filter (not used)DI04 : not used

Digital Outputs DO1=CD dryer (not used)

DO2 : not usedDO3 : not usedDO4 : not used

Pt1000 inputsFeature COOL=WATER

T1: Water InT2 :Water Out

Pt1000 inputsOption ENREC

T1 = ER Water InT2 = ER Water

Out

AIE3

Pt100 inputsOption Bearings (not

used)T1 : D bearing

T2 : ND bearingOption Windings (not

used)T3 : U windingT4 : V windingT5 : W winding

Kavlico inputs

P1 : not usedP2 : not used

Kavlico inputs P1 : not

usedP2 : 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 controlsThe 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 protectsThe Elektronikon protects

Electronic precision scans all vital functions…shuts the compressor down if trouble exists...

Cooling fan motor

Compressor element

Drive motor



The Elektronikon advisesThe Elektronikon advises

System pressure

Compressor status and data Service requirements



Compressor controlThe 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 VSD’s) to be specified• Choice between local and remote control

Load/unload pressure control

VSDpressurecontrol



Compressor monitoringThe 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 VSD’s– “Running”/”Loaded”/”Module” hours – Number of motor starts– …

For details: see MkIV Instruction Books



Compressor protectionThe 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 4Special 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 Elektronikon MMultiple ultiple CCompressor ompressor CControlontrolNet pressure

Com

p 1

Com

p 2

Com

p 3

Typical overall pressure band 1.5

barAvg pressureWith 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

• In Q1 2003 a remote pressure sensor will be possible: with pressure transmitter (4-20 mA) and AIE2 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 customer’s 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 5The CAN network



Elektronikon MKIV Elektronikon MKIV CommunicationCommunication NetworkingNetworking

• 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



Elektronikon MKIV Elektronikon MKIV CommunicationCommunication

CAN

Conversion Box“Communication”

COM1

MkIII


MkI/MkII E-P and Competition

RS232 RS232Relay(s)/Wiring

CAN graphical network representationCAN graphical network representation

Combox ComboxES002

MKIV MKIV MKIV MKIV



CAN


COM1

MkIII


MkI/MkII Electro-Pneumatic and Competition

RS232 RS232

Relay(s)/Wiring

Combox ComboxES002

MKIV MKIV MKIV


Customer’s LAN

Combox

Other LAN graphical network Other LAN graphical network representationrepresentationElektronikon MKIV Elektronikon MKIV CommunicationCommunication



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

ElectroPneumatic

E/PHard 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 102x2x0.34mm²

Alternative : Belden3106A – AC p/nr : 1900 0707 92 (300M)

Updated !



The Compressor Network for Communication

Customer PLCe.g. Simatic S7

Profibus Network

System Bus(CAN)

Central Control UnitRS232C

E/P

Hard wired

COM-BoxLocate in any ofthe cubicle, or

outside

Mk1…3

COM box ES002


Updated !





The Compressor Network for Communication : Next Step

System Bus(CAN)

Central Control UnitRS232C

E/P

Hard wired

E-BoxLocate in any ofthe cubicle, or

outsideInternet Explorer

Commercial Modem or

Router

Outside WorldEthernet

Mk1…3


Updated !





Elektronikon MKIV Elektronikon MKIV CommunicationCommunication

• Local communicationMeans for communicationMeans 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 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.



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



Description Remarks

ComBox-Modbus Communication module that converts CAN toModbus protocolApplication software dependent load atcommmissioning

ComBox-Profibus Communication module that converts CAN toProfibus protocol

ComBox-Ethernet Communication module that converts CAN toEthernet protocol

ComBox-RS232 Communication module that converts RS232from COM1 to CANCan be used to connect an older generationElektronikon to the CANApplication software dependent load atcommmissioning

ComBox-DIOE Communication device that convertsdigital inputs to CANCan be used to connect an elpn regulatedcompressors or digital accessory to CANSeparate enclosed product similar to ES001

Elektronikon MKIV Elektronikon MKIV Communication modules Communication modules


CAN

“X”- bus

Customer DCS

ComBox



Description Remarks

e -Box I Device that allows an authorised user tomonitor a compressor installation overthe web from a remote PC. Applicationsoftware is imbedded in the device.

e -Box II Device that allows an authorised user toconnect a compressed air installation toAtlas Copco's World Wide Web e-services.

Cable Connects an expansion module to the master600 mm in overall length with end connectors

Cable Connects an expansion module to the master150 mm in overall length with end connectors

Instruction How to wire the CAN

Instruction MCC operation and instruction manual

Instruction ComBox instruction manuals, ModbusProfibus and Ethernet

Instruction e -Box instruction manual

Elektronikon MKIV Elektronikon MKIV Monitoring Monitoring

World Wide Web

CAN

e-Box

Modem



Chapter 6Flexibility + Remote monitoring +

Operating costs



Elektronikon comprehensive flexibilityElektronikon 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 monitoringElektronikon 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 Elektronikon lowers operating costoperating cost

Facts 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 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 7MK-IV REGULATOR

ENERGY SAVER



Elektronikon MKIV Elektronikon MKIV ES evolutionES evolution EEnergy nergy SSaver sequencingaver 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

Today Tomorrow

Product Use Product Use

ES100 Sequences 2 to 7 load/no load MCC Sequences 2 to 4 compressorscompressors load/no load with 1 VSD from MKIV

ES200 Sequences 2 to 8 compressors ES1000 Sequences an unlimted numbermix of load/no load and ZH of load/no load compressors

ES300 Sequences 2 to 16 load/no load ES2000 Sequences an unlimted numbercompressors of load/no load and VSD

compressors

ES3000 Sequences an unlimted numberof load/no load, VSD and ZHAtlas Copco compressors

ES4000 Sequences an unlimted numberof load/no load, VSD andturbo compressors of other mfrs



Elektronikon MKIV Elektronikon MKIV ES evolutionES evolution EEnergy nergy SSaver monitoringaver monitoringToday Tomorrow

Product Use Product Use

ES400 Monitors up to seven Atlas e -Box I Allows up to four compressorsCopco compressors over serial to be monitored. Web applicationconnection built in device

e -Box I I Allows up to four compressorsto be connected to the Atlas Copcoweb services of monitoring or PMservice by Atlas Copco reps

ES - X Local monitoring of installationbased on CRC hardware platform

ES - XX Internet monitoring of installationbased on CRC hardware platformAtlas Copco web services can beused

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 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 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



INSTRUMENTATION & ELECTRONICS•POWER 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

Documents

phase voltage

aiftraining r

machine compressor

phase ul

phase alternating current

ac single phase

phase delta

rated voltage