es360 instruction book

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ES 360

Instruction book


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Atlas Copco

ES 360

Instruction book

Original instructions

Copyright Notice

Any unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.

This instruction book is valid for CE as well as non-CE labelled machines. It meets the

requirements for instructions specified by the applicable European directives as identified

in the Declaration of Conformity.

2010 - 01

No. 2920 1745 00

www.atlascopco.com


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Table of contents

1 Safety precautions..........................................................................................................3

1.1 SAFETYICONS...................................................................................................................................3

1.2 SAFETYPRECAUTIONSDURINGINSTALLATION...........................................................................................3

1.3 SAFETYPRECAUTIONSDURINGOPERATION..............................................................................................4

1.4 SAFETYPRECAUTIONSDURINGMAINTENANCEORREPAIR...........................................................................5

2 General description........................................................................................................7

2.1 INTRODUCTION...................................................................................................................................7

2.2 ES 360 FEATURES............................................................................................................................9

3 Installation.....................................................................................................................14

3.1 DIMENSIONDRAWING........................................................................................................................14

3.2 MOUNTINGINSTRUCTIONS..................................................................................................................15

4 Operating instructions.................................................................................................20

4.1 PREPARINGTHEMACHINESTOBECONNECTEDTOTHEES SYSTEM...........................................................20

4.2 USERINTERFACE.............................................................................................................................20

5 Parts list.........................................................................................................................33

5.1 CUBICLEANDOPTIONS .....................................................................................................................33

5.2 CONTROLPANELANDADDITIONALPARTS .............................................................................................34

5.3 PRESSURESENSOR .........................................................................................................................35

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or

non-observance of the normal caution and care required for installation, operation,

maintenance and repair, even if not expressly stated, will be disclaimed by the

manufacturer.

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety

regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to

dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within

safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.

2. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction

duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.

3. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.

4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or

worn hoses. Distribution pipes and connections must be of the correct size and suitable for the workingpressure.

5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead

to internal fire or explosion.

6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.

7. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under

heat and that it is not in contact with or close to flammable materials.

8. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.

9. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is

remotely controlled and may start without warning.

The operator has to make sure that the machine is stopped and that the isolating switch is open and locked

before any maintenance or repair. As a further safeguard, persons switching on remotely controlled

machines shall take adequate precautions to ensure that there is no one checking or working on the

machine. To this end, a suitable notice shall be affixed to the start equipment.

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10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and

that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.

11. The electrical connections must correspond to the applicable codes. The machines must be earthed and

protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed

near the compressor.

12. On machines with automatic start/stop system or if the automatic restart function after voltage failure is

activated, a sign stating "This machine may start without warning" must be affixed near the instrument

panel.

13. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return

valves (check valves) must not be relied upon for isolating pressure systems.

14. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure

vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be

protected by a pressure-relieving device or devices as required.

15. Piping or other parts with a temperature in excess of 80C (176F) and which may be accidentally touched

by personnel in normal operation must be guarded or insulated. Other high-temperature piping must be

clearly marked.

16. For water-cooled machines, the cooling water system installed outside the machine has to be protected bya safety device with set pressure according to the maximum cooling water inlet pressure.

17. If the ground is not level or can be subject to variable inclination, consult the manufacturer.

Also consult following safety precautions: Safety precautions during operationand Safety

precautions during maintenance.

These precautions apply to machinery processing or consuming air or inert gas.

Processing of any other gas requires additional safety precautions typical to the application

which are not included herein.

Some precautions are general and cover several machine types and equipment; hence

some statements may not apply to your machine.

1.3 Safety precautions during operation




manufacturer.

Precautions during operation

1. Never touch any piping or components of the compressor during operation.

2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or

air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure

that a hose is fully depressurized before disconnecting it.

3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there

is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote

start equipment.

4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or

particles.5. Never operate the machine below or in excess of its limit ratings.

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6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to

carry out routine checks. Wear ear protectors when opening a door.

7. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)

shall wear ear protectors.

8. Periodically check that:

All guards are in place and securely fastened

All hoses and/or pipes inside the machine are in good condition, secure and not rubbing

There are no leaks

All fasteners are tight

All electrical leads are secure and in good order

Safety valves and other pressure-relief devices are not obstructed by dirt or paint

Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free

of wear or abuse

9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take

precautions against air pollution and possible contamination of the breathing air.

10. Do not remove any of, or tamper with, the sound-damping material.

11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressurevessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be

protected by a pressure-relieving device or devices as required.

Also consult following safety precautions: Safety precautions during installationand Safety

precautions during maintenance.

These precautions apply to machinery processing or consuming air or inert gas.





1.4 Safety precautions during maintenance or repair




manufacturer.

Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).

2. Use only the correct tools for maintenance and repair work.

3. Use only genuine spare parts.

4. All maintenance work shall only be undertaken when the machine has cooled down.

5. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting

equipment.

6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there

is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote

start equipment.7. Close the compressor air outlet valve before connecting or disconnecting a pipe.

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8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure

and relieve the entire system of pressure.

9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against

toxic vapours of cleaning liquids.

10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts

and exposed openings with a clean cloth, paper or tape.

11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely

purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify,

pressure vessels.

12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the

machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has

elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.

13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.

14. Make sure that no tools, loose parts or rags are left in or on the machine.

15. All regulating and safety devices shall be maintained with due care to ensure that they function properly.

They may not be put out of action.

16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that

they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been

reinstalled.

17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator

vessel for carbon deposits; if excessive, the deposits should be removed.

18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering

them, e.g. when steam-cleaning.

19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork

and in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by

genuine material from the manufacturer to prevent the sound pressure level from increasing.

20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.21. The following safety precautions are stressed when handling refrigerant:

Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use

breathing protection.

Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If

liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush

abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical

first aid.

Also consult following safety precautions: Safety precautions during installationand Safety

precautions during operation.These precautions apply to machinery processing or consuming air or inert gas.





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2 General description

2.1 Introduction

General view

General view of the ES 360 Central control system

Function

Today customers want more than just peace of mind. They want to continuously reduce their production costs

without jeopardizing the availability of compressed air. Moreover, environmental awareness calls upon

industrial facilities to limit CO2 emissions by reducing their energy consumption. Compressed air

installations, with their significant power needs, are an important area for improvement.

The Atlas Copco ES 360 central controller is the perfect solution to meet these needs by:

improving the efficiency of the complete compressed air system

reducing the life cycle cost to the absolute minimum

monitoring the operation of the compressed air system

meeting stringent environment legislation.

Description

The core of the installation is the ES device which retrieves and processes information coming from the

compressors, dryers and other measurement equipment. The ES can be connected to 3 pressure air nets and

a total number of 60 machines, of which max 30 compressors and max 30 dryers. Additionally, the ES 360

can be configured with lots of analog inputs and digital in- and outputs to connect to other auxiliary equipment.

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Compressors and dryers must be connected to the ES device by means of a CAN or Ethernet network. Over

this network, the ES is able to receive data from the dryers (monitoring) and receive data from and send

commands to the compressors (monitoring and control). Based on a set of rules, dryers or other auxiliary

equipment can be controlled through digital signals, to be hardwired between the equipment and the ES. Per

air net, one or multiple 4-20 mA pressure transmitters can be connected. A flow meter, dewpoint meter, etc

are optional.

CAN network

Ethernet network

In case the control feature is available, the ES regulates the net pressure of the connected air nets by starting/

stopping machines and selecting their operating points. The ES regulates the net pressure within a selectable

and changeable pressure band, applying a selectable optimization profile; see section Features. The ESdisplays the energy savings realized compared to if the machines are running in local control.

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The ES stores all machine and sensor data locally on the ES device (up to one month of data). This allows

the user to see graphs on the ES user interface.

In case the datawarehouse monitoring feature is available, the monitored information is uploaded to a central

Atlas Copco Airpower datawarehouse. The customer can consult his data via webbrowser and receive warning

and error notifications over SMS or email.

2.2 ES 360 features

Savings calculation

One of the main features of the ES is the energy savings that are realized when ES takes over the control of

the machines. The ES also calculates the actual savings compared to local control. To this extent, the ES

continuously simulates the behavior of the compressed air network as if all machines would be running in

local control. In this simulation, the ES applies the same external inputs as the real compressed air installation

(flow demand, machine shutdowns, valve positions etc).

On the main and air net screens the ES savings are displayed. In addition, the ES has a screen available

explaining in detail where the savings originate from.

Control

The ES can control and monitor compressors over either a CAN or an Ethernet connection. A maximum of

60 pieces of equipment can be connected and controlled over the CAN or Ethernet connection.

Out of the 60 machines, a maximum number of 30 compressors can be connected.

In case a compressor is controlled by ES, it is called integrated. In the other case, the compressor runs on

its own local control regulator and local pressure transmitter and is called isolated. In case a compressor is

isolated, the ES is still capable of monitoring that compressor.

With the proper user permissions, the user can integrate and isolate compressors as desired.

Out of the 60 machines, a maximum number of 30 dryers can be connected.

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In case a dryer is connected over CAN or Ethernet, it can be monitored by the ES.

Control of dryers is possible via rule-based control over digital outputs. In this case the ES digital outputs

need to be connected to the dryers digital inputs.

Data logging and data upload

The ES monitors all measured and calculated machine data, air net data and connected analog inputs. Data

of up to one month are logged. Graphs can be made of each logged datapoint on the ES user interface.

The ES can upload all data to an Atlas Copco datawarehouse over a direct internet connection, or over analog

or GSM/GPRS modem. This data can be consulted via a webbrowser from any PC. Warning and error

notifications can be sent by SMS or email.

Smooth pressure control

The ES regulates the load/unload compressors inside a narrow user-defined pressure band.

In case variable flow machines (VSDs, turbos etc) are connected to the system, the ES will regulate towardsthe airnet pressure setpoint. The regulation has a fast response without over- or undershoot.

In order to obey the rules and optimization profiles, the ES can decide to switch the compressors, i.e. start

one or more machines combined with also stopping one or more machines. In this case, the ES calculates the

optimal timing of the compressor commands to keep the pressure inside the pressure band and to minimize

the influence of the switch on the pressure.

Pressure transmitters

Per air net, multiple pressure transmitters can be used.

In case one pressure transmitter fails or in case the deviation with respect to the other transmitters is too large,

the system generates a warning but can continue regulating.

In case the deviation between the remaining transmitters is too large, the ES system will send all machines

of the affected air net(s) to local control in order to guarantee the pressure in these air net(s) by the local

control algorithm of the machines and their local pressure transmitter.

System pressure settings management

Per air net different sets of pressure bands and setpoints can be defined. The settings to be applied can be

chosen manually, can be time triggered, or can be selected by an external input such as a digital signal. With

the correct user permissions, the pressure settings can be selected or changed.

The ES regulates each air net to the specified pressure band and setpoint. When changing from one SystemPressure Setting (SPS) to another, the setpoint and pressure bands move smoothly to their new setting during

a short transition period.

For each pressure setting, also a low and high pressure warning level and a low and high pressure shutdown

level are defined. In case the air net pressure reaches a warning level, a warning message is generated. In case

the air net pressure reaches a shutdown level, a shutdown message is generated and all the machines of the

air net are sent to local control mode. The pressure in the air net is then regulated by the local control algorithm

of the machines and their local pressure transmitter. The local machine controllers are hence used as a

redundancy for the ES system and its pressure transmitters to guarantee air net pressure at all times.

Optimization profiles

The ES can regulate each air net with following optimization profiles:

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optimized energy savings

optimized cost savings

forced sequence

equal wear

group management

Optimized energy savings means that the ES selects the machines that can produce the requested flow demand

with the lowest energy cost.

Optimized cost savings means that the ES selects the machines that can produce the requested flow demand

with the lowest total cost, meaning energy cost plus machine maintenance cost.

Forced sequence means that the ES triggers the start and stop of machines according to a specified sequence.

Equal wear means that the ES keeps the running hours of the different machines within a programmable range.

Group management means that groups and subgroups can be made with the machines. In each of the

(sub)groups any of the above optimization profiles can be defined. Over the (sub) groups a forced sequence

or equal wear algorithm can be activated.

On top of this, on airnet level, a central stop or local control profile can be defined. Central stop means that

the ES stops all integrated machines. Local control means that the ES sends all integrated compressors to their

local control.

The optimization profile(s) for each air net are selected manually, or based on a timer, or based on a flow

demand. E.g. depending on the calculated flow demand, an air net can be automatically regulated into another

forced sequence profile.

Optimal operating point

The optimization profile determines which machines to run. On top of this, whatever the chosen optimization

profile is, the ES continuously regulates the running machines towards the most energy efficient operatingpoint.

For instance, a forced sequence determines which machines are to be turned on or off. The ES continuously

adapts the operating points of the running machines such that the flow is produced at the lowest possible

energy cost.

If desired, it is possible to define base load units which are not taken into consideration for operating point

optimization; see section Rules. These units will run at full load.

Load after shutdown

In the unfortunate event of a compressor shutdown, the ES does not wait for the pressure to dip down, but

instead starts a machine immediately and as such the ES minimizes the pressure influence of the event.

Spare capacity

Selecting a spare capacity means that the ES keeps on running one or multiple machines which have the

immediate possibility to produce extra flow. The amount of extra flow is defined as the spare capacity.

The spare capacity can reduce the pressure fluctuations in case of a compressor shutdown or a sudden large

increase in flow demand. In some particular installations, these pressure fluctuations could result in production

loss. For these installations the energy costs of having extra spare capacity available are justified.

Two types of spare capacity are possible:

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the spare capacity is to be foreseen by compressors running in unload. This option guarantees the

immediate availability of air to avoid pressure undershoot due to shutdown of one of the loaded

compressors.

the spare capacity can consist of the available upload flow of the loaded compressors. This option

guarantees the immediate availability of air to avoid pressure undershoot due to a sudden increase in the

flow demand.

Compressor timers and limitations

The ES takes all critical machine settings and limitations into account such as idling time, minimum stop time,

maximum motor speed, number of starts per day, etc.

Time controlled isolation

On some occasions the ES needs to send multiple machines at once to local control, e.g. when the central stop

control profile is selected, or when a pressure shutdown occurs on an air net. However, in case the ES would

send all compressors at the same time to local control, they would be started simultaneously. The timecontrolled isolation option takes care that the running compressors (loaded and unloaded) are isolated first,

and then all stopped compressors are isolated one by one with a set time between the isolation events.

Rule based control

Following rules are predefined:

baseload compressors:

Baseload compressors take care of the baseload flow by running fully loaded. The operating points of

these compressors are not optimized with the energy optimization algorithm.

backup compressors:

Backup compressors are standby and only to be used in case one or more specified compressors becomeunavailable. In other words, as long as the specified compressors are available, the backup compressors

are the last to be started.

Customer specific programming of the digital outputs is possible. The digital outputs can be triggered

based on a combination of timers, machine states, measurement values and digital inputs (PLC logic). In

this way, the ES can control auxiliary machines or alarms with digital control inputs.

Inputs/Outputs

The standard ES device has eight analog 4-20 mA inputs, four digital inputs and four digital relay outputs.

Using extension IO blocks, the ES can connect to up to 100 digital outputs, 100 digital inputs and 16 analog

4-20 mA inputs.

At least one analog input per air net is preserved for pressure sensing, the remaining I/O are free for customer

specific use.

The analog and digital input measurements can be:

used in the programming of digital output rules

displayed on the air net or main screens (actual value, up to 4 measurements per air net)

viewed in the graph screens (data graph of last month)

uploaded to the datawarehouse

Field bus connectivity

Some field bus connectivity to read out parameters or select settings is available. Contact Atlas Copco toknow the possibilities for your field bus.

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Valves & multiple air nets

The ES can control up to 3 air nets.

The ES can only handle machines that produce air in one air net at the time. The ES can handle the switches

of a machine between air nets. Therefore the open/close digital signals of the valves need to be wired to the

ES.

Automatic functions

If desired, the ES can automatically reintegrate compressors after an event-triggered isolation.

Following automatic functions are available:

automatic integration after voltage failure.

At a voltage failure of the ES, the compressors start regulating in local control. After the voltage failure,

the ES reboots. In case this option is enabled, the ES will re-integrate previously integrated compressors.

The behavior of this function can be influenced with the value of a digital input, a delay timer and a

maximum ES down time. automatic integration after communication failure.

When a communication error between the ES and a machine occurs, the machine starts regulating in local

control. When the communication problem is solved and in case this option is enabled, the ES will re-

integrate the machine.

automatic integration after not responding.

Under ES control, the ES monitors whether the machines react as expected. At unexpected behavior, the

machine will be sent to local control. In case this option is enabled, the ES will try to re-integrate the

machine. The behavior of this function can be influenced with a delay timer and a maximum number of

retries in a set period.

automatic integration after LAN selection.

In case the machines are switched from LAN to local control on the local compressor regulator, the

machine starts regulating in local control. In case this option is enabled, the ES will automatically re-

integrate the machine when it is put back in LAN mode.

automatic integration after pressure shutdown.

In case the pressure should exceed the pressure shutdown levels, the ES will send all machines to local

control. In case this option is enabled, the ES will try to re-integrate the compressors. The behavior of this

function can be influenced with a delay timer and a maximum number of retries in a set period.

User management

All settings and control actions that influence the ES regulation are protected by user permissions. The ES

will prompt for login at such actions. Only users with the required permission are allowed to execute the

requested change.

Users can be created and assigned with any combination of the following permissions:

integrate/isolate machines

select or edit pressure settings

select optimization profile settings

select central stop

edit spare capacity settings

enable/disable rules

edit automatic function settings

edit user settings

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3 Installation

3.1 Dimension drawing

Dimensions

Dimension drawing, ES 360

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3.2 Mounting instructions

Procedure

The ES consists of a generic enclosure containing electrical components.

On the bottom of the enclosure, ten conduit routings closed with nuts allow to enter cables. Ten matching

cable glands are provided. Note that the glands are in metric dimensions and that an adapter is necessary in

case of use of 1/2 inch conduits.

The ES is wall mountable, the overall weight is about 27 kg, depending on the ordered options.

Select the place on the wall to mount the ES taking into account the maximum cable length of the CAN and/

or Ethernet networks and a maximum length of 1000 m to the pressure transmitters.

Four mounting brackets are included in the ES. Use appropriate fasteners to fix the unit to the wall. See section

Dimension drawingfor the dimensions.

Stick labels on the control panels of the machines connected to the ES as well as on anobvious place inside these machines, warning the operator that the machine is remotely

started and stopped by a separate controller. These labels must warn the operator that, also

after voltage failure, the ES can remotely start and stop the machine.

Pressure transmitters

The pressure transmitters should preferably be connected :

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

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

in vertical position to avoid influence of condensate.Isolate and depressurize that part of the air net to which the pressure transmitters will be connected.

The pressure transmitters have a working temperature limit from 30 C to 125 C (-22 F to 257 F). Use

an extension pipe for high temperatures to cool off the air.

Connect the transmitters to the analog inputs of the ES using double twisted pairs shielded 0.75 mm2cable.

The maximum allowable length of the cables is 1000 m.

In case the pressure transmitters have a fixed cable with shielding attached, the shielding

must not be connected to the shielding of the ES to prevent loop-currents in the system.

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Compressor/dryer communication (CAN)

In case the machines are equipped with an Elektronikon regulator of generation 4, a CAN bus needs to be

wired starting from the CAN0 and/or CAN1 connectors on the ES regulator A500. Up to 30 machines can be

connected per CAN port.

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

Compressor/dryer communication (Ethernet)

In case the machines are equipped with an Elektronikon regulator of generation 5, an Ethernet network needs

to be wired starting from the ETH0 connector on the ES regulator A500.

The Ethernet cable is an industrial Cat5e S-FTP cable. Ethernet network cables have a maximum length of

100 m.

Datawarehouse uploadIn case data upload to the central datawarehouse is needed, an internet connection is required. This can be a

direct internet connection (ETH1 connector on the ES regulator A500), or a connection over analog modem

(T800) or GSM/GPRS modem (T801). The modem is installed in the ES upon ordering the modem upload

feature. The access to the internet itself (internet provider, phone line, SIM card) is a responsibility of the

customer.

Service diagram

Connect a 110-240 VAC, 50/60 Hz power supply to terminals L1 and L2 of the ES controller.

Make sure the earthing cable is connected to terminal PE.

Provide a branch circuit protection and a disconnect possibility.

Inputs/Outputs

The ES device has an I/O block K010 with eight 4-20 mA analog inputs, four digital inputs and four digital

outputs. The digital outputs can be further wired to four relays: K101, K102, K103 and K104.

Electrical connections should be done by qualified personnel and according to the local

standards.

Technical data of the I/O:

Digital inputs:

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Input type 24V three-wire interface (24V, GND, input)

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

Isolated 2 kV to each port and to the system

Input filter 5 ms = 200HzInput protection 8 kV to ESD

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

Powered 24V +- 10% not protected

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

Switching time Max 100 ms

Input current 6.6 mA at 24V

Digital outputs (optional)

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

Switching voltage 24V DC

Switching current 0.5A

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

Isolation 2 kV process to system

Debouncing no

Relay outputs

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Contact type 3 connection points per output: one of which refers to normal open, and one

to normal closed. Dual use possible.

Actuating voltage 24V DC

Nominal switching capacity AC:

250 VAC: 10ADC:

30V DC: 10A

110V DC: 0.25A

220V DC: 0.12A

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

The relays are used for signalling or controlling external devices based on certain states

of the software. They are designed for use in UL Class 2 circuits.

Analog inputs, 4-20 mA

Input type 5 three-wire interface (24V, GND, input+, input-, shield)

Load Max load current per channel is 120mA with a max total of all 8 channels of

600 mA

Ranges Current: 4-20 mA

Resolution 10 bit

Accuracy


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ES commissioning

Contact the Atlas Copco service engineer to commission the ES system.

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4 Operating instructions

4.1 Preparing the machines to be connected to the ES system

Description

The ES can be connected to compressors and dryers equipped with an Elektronikon generation 4 and 5.

In order to be able to take control, the Elektronikon regulators of the connected machines must be set to LAN

control and an individual node address must be programmed in the regulator (consult the relevant instruction

book of the machine).

It is not necessary to stop machines in order to integrate them into ES control.

4.2 User interface

Description

The ES has a 30 cm (12 in) color touch screen. A contemporary user interface allows the user to navigatethrough all available system information and to change the system settings.

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Menu and navigation

On top of each screen on the left a navigation dock is displayed.

In the standard position it shows the navigation to the current screen.

Clicking on this dock will open the screen and allow to navigate to any other screen.

In addition to the navigation menu, most parts of each screen are shortcuts to related

screens (e.g. when clicking on a compressor in the air net screen, the device screen of

that compressor will be shown ). The navigation menu always shows the navigation to the

current screen, independent of whether it was obtained by using the menu or a shortcut.

On the top right of the screen 3 buttons are available:

The logout button is used to log out.

The settings button is a link to all system settings.

The system status shows the warnings and errors when they occur.

When no warnings are present, the system displays an OK icon:

Warnings of machines or air nets (e.g. service warning, low pressure warning) are indicated by a triangle:

Shutdowns of machines or air nets (e.g. emergency stop pressed, high pressure shutdown) are indicated by a

stop sign:

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Main screen

When the ES controls multiple air nets (up to 3), the main screen shows an overview of all most important

values of all air nets: the pressure graphs with air net pressures and pressure settings, the ES savings and

several measured and calculated data points.

The measured and calculated data points to be shown are selected at commissioning time.

The ES savings are the savings the ES has realized compared to a situation in which all machines are running

in local control. The savings displayed on the main screen, are the savings realized over all air nets.

In case the ES controls only one air net, this screen is missing and the air net screen becomes the main entry

of the user interface.

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Air net screens

For each air net, the ES has a dedicated air net screen showing :

the pressure graph indicating the pressure, the pressure settings and the selected ES optimization profile

the ES savings for that air net compared to a situation in which all machines are running in local control

some measured and calculated data points, to be selected at commissioning time

the used capacity bar, indicating the used capacity compared to the total available capacity for that air net(sum of all available compressors)

the machines connected to the air net, indicating the name, machine type, integration status icon

(integrated/isolated) and the actual status of the machine (loaded, unloaded, stopped, not available,

unknown). The compressors also have a capacity bar indicating how much air the machine delivers

compared to its maximum.

When a machine becomes unavailable to an air net because of valve settings, the machine is greyed out on

the user interface. All controls are still available, but only from the air net screen to which the machine belongs

at this time.

In case an error or warning is valid for a machine, an icon appears over the machine icon:

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A question mark is shown in case the warning is ES related, for instance when there is no

communication between the ES and the machine, or when the machine does not react as

expected.

An exclamation mark is shown in case the warning is machine related, for instance when

one of the internal machine sensors has reached a warning level.

A service key is shown in case the service interval of the machine has expired.

A stop sign is shown in case the machine is shut down, for instance when the emergency

stop button is pressed.

More detailed information about the error or warning is also available in the status bar on top.

The integration status icon indicates whether the ES is controlling the machine:

The machine is Isolated, meaning that the machine is at this time not controlled by the ES. The machine

is controlled by its local controller to its local settings based on the local pressure transmitter.

Pressing the button will integrate the machine and the icon changes into:

This can be done by any user with the required permissions.

The machine is Integrated, meaning that the ES is controlling this machine, based on the ES settings and

ES pressure transmitters.

Pressing the button will isolate the machine and the icon changes into:

This can be done by any user with the required permissions.

The machine is isolated and can not be integrated (e.g. the Elektronikon regulator is not set to LAN control).

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Measurement point screens

From any measured or calculated data point, a graph is available. The data is stored up to one month ago. The

graph time frame can be selected.

Savings screen

The ES continuously simulates the complete compressed air installation with machines running in local

control. With the simulated data, the savings per air net and of the complete installation are calculated anddisplayed on the air net screens and main screen.

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The savings screen gives more detailed information about where these savings are originating from.

Device screens

For each machine connected over the CAN or Ethernet network, a more detailed data view is available. All

measured and calculated values of the machine are shown, including all measured values from its internal

sensors.On this screen also the warning symbols and a button to switch the integrate/isolate status of the machine are

available. The symbols and actions are the same as explained in the section Air net screens.

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Log screen

The log screen gives an overview of setting changes, warnings and errors in the system, for the ES system as

well as for the connected machines.

Log-in dialog

Whenever changing system or air net settings, the user needs to log in by selecting the user name and entering

the correct password. The user permissions are checked to see whether the user is allowed to perform the

requested change.

The user can log out by the log out button on the menu bar:

The user is automatically logged out after a period of inactivity.

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Settings

By pressing the settings button, tab pages with the settings appear:

Pressure Settings

In this screen, an existing set of pressure settings or a timer mode can be modified and pressure settings can

be added or edited by users with the right permissions.

Pressure settings are managed per air net.

For more detailed information on the ES pressure regulation, see section ES features.

Changing the pressure settings has consequences to the net pressure and should only be

done by qualified personnel.

Optimization profile settings

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In this screen, an optimization profile, a timer mode or a selection based on flow demand can be activated by

users with the right permissions.

Optimization profiles are managed per air net.

For more detailed information on the ES optimization profiles, see section ES features.

Changing the optimization settings has consequences on the regulation and should only be

done by qualified personnel.

Rules

In this screen, regulation rules can be enabled or disabled by users with the right permissions.

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For more detailed information on the rule based control, see section ES features.

Changing the rules settings has consequences on the regulation and should only be done by

qualified personnel

Automatic functions

In this screen, automatic functions can be enabled or disabled by users with the right permissions.

For more detailed information on the available automatic functions, see section ES features.

Changing the automatic function settings has consequences on the regulation and should

only be done by qualified personnel.

Be aware that some of the automatic functions will cause machines to start automatically.

Stick labels on the control panels of the machines connected to the ES as well as on an

obvious place inside these machines, warning the operator that the machine is remotely

started and stopped by a separate controller. These labels must warn that, also after a voltage

failure, the ES can remotely start and stop the machine, depending on the air demand and

programmed values.

User management

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In this screen, users can be created and assigned any combination of following permissions:

integrate/isolate machines

select pressure settings

edit pressure settings

select profile settings

select central stop

enable/disable rules

edit automatic function settings

edit user settings

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System Preferences

In this screen, some system wide settings such as the measurement units, language, default time frame of the

graphs and savings can be selected.

Version and licensing information

This screen shows the ES version and license information.

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5 Parts list

5.1 Cubicle and options

Ref. Part number Qty Name Remarks

Cubicle

1 010 1623 4026 00 1 Cubicle box

Cubicle options

2 010 1089 9620 01 Analog modem T800

2 020 1089 9620 07 GSM/GPRS modem T801

2 030 1089 9620 06 GSM/GPRS Antenna T801

2 040 8092 2482 54 COMBOX-S A503

2 050 8092 2495 75 COMBOX-P A502

2 060 1900 0711 71 COMBOX-E A501

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5.2 Control panel and additional parts


ES box parts

1 010 1089 9544 02 1 Power supply 4A T111A

1 015 1089 9544 07 1 Power supply 1A T111B

1 020 1081 0421 02 1 Fuse 2A F110

1 025 1081 0421 01 1 Fuse 4A F111

1 030 1623 4027 00 1 I/O block K010

1 035 1089 9537 02 1 Relay

K101, K102,

K103, K1041 040 1089 9620 01 1 Analog modem T800

1 045 1089 9620 07 1 Quadband GSM/GPRS modem T801

1 050 1089 9620 06 1 Quadband GSM/GPRS modem T801

1 055 8092 2482 54 1 Combox-S Kit A503

1 060 8092 2495 75 1 Combox-P Kit A502

1 065 1900 0711 71 1 Combox-E Kit A501

1 075 0981 0405 11 1 CF card /

1 085 0985 3200 00 1 Screen A610

1 090 1624 0956 00 1 Mounting brackets /

ES box additional parts

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8104 0115 00 1 COM1 Service kit

1089 9404 20 1 Modbus Card

1088 0017 28 1 Connector

1088 0017 27 1 Connector

5.3 Pressure sensor


1 010 Pressure Transmitter

1089 0492 59 0-1 bar(e)

1089 0492 55 0-1.6 bar(e)

1089 0492 56 0-2.5 bar(e)

1089 0492 50 0-4 bar(e)

1089 0492 54 0-6 bar(e)

1089 0492 51 0-10 bar(e)

1089 0492 52 0-16 bar(e)

1089 0492 57 0-25 bar(e)

1089 0492 63 0-35 bar(e)

1089 0492 62 0-45 bar(e)

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1089 0492 53 0-60 bar(e)

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o.

2920174500/2010-01

What sets Atlas Copco apart as a company is our conviction that

we can only excel in what we do if we provide the best possible

know-how and technology to really help our customers produce,

grow and succeed.There is a unique way of achieving that - we simply call it the Atlas

Copco way. It builds on interaction, on long-term relationships

and involvement in the customers process, needs and objectives.

It means having the flexibility to adapt to the diverse demands of

the people we cater for.

Its the commitmentto our customers business that drives our

effort towards increasing their productivity through better

solutions. It starts with fully supporting existing products and

continuously doing things better, but it goes much further, creating

advances in technology through innovation. Not for the sake of

technology, but for the sake of our customers bottom line and

peace-of-mind.

That is how Atlas Copco will strive to remain the first choice, to

succeed in attracting new business and to maintain our position

as the industry leader.

es360 instruction book

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