Neuron II Elgi Compressor

Neuron II Manual

21.0

Index

1.0 Technical Features 23.02.0 Controller terminal configuration 24.03.0 Main Menu Screen 25.04.0 Menu Structure 26.04.1 View 26.04.1.1 Operator 26.14.1.2 Fault Report 26.14.1.3 Day Report 26.24.1.4 Service Time 26.24.1.5 Cumulative Time 26.34.1.6 VFD 26.34.2 Operator 26.44.2.1 Machine 26.54.2.2 Schedule 26.74.2.3 Maintenance 26.74.2.4 Language 26.84.2.5 Change Password 26.84.3 Service 26.94.3.1 Calibration 26.94.3.2 Relay 26.104.3.3 Change Password 26.104.3.4 Maintenance 26.104.3.5 Clock 26.114.3.6 Self Test 26.114.3.7 Change Password 26.114.4 Factory menu 26.124.4.1 Machine 26.134.4.2 Change Password 26.144.4.3 Integrator Dryer 26.144.5 Customer care 26.145.0 Data Interface 27.05.1 Analog output 27.05.2 DCS Port 27.06.0 Construction & Dimension Drawing 28.07.0 Controller Identification 29.08.0 Revision Details 29.0

APPENDIX A: Mimic LED Table 30.0APPENDIX B: Short Cut Key Functions 31.0APPENDIX C 32.0APPENDIX-D 33.0

22.0

Technical Features

8 nos of Optically Isolated Digital Inputs of 24VDC

01 = Emergency Stop

02 = Differential Pressure Oil Filter - DPOF

03 = Reverse Rotation

04 = Differential Pressure Air Filter - DPAF

05 = Remote Start/Stop

06 = High Sump Pressure

07 = Cooler

08 = Main Motor Overload

8 nos of Output Relay (SPDT 250V AC 10A, 1,00,000 cycle electric life)01 = Main contactor

02 = Star contactor

03 = Delta contactor

04 = Load Valve

05 = Fan

06 = Auto Drain Valve

07 = Dryer (if Dryer is Connected- else Programmable -Load,Service, Standby, Warn, Trip, Remote, Ready)

08 = Programmable [Load, Service, Standby, Warn, Trip, Remote,Ready]

Technical Features

22.1

4 nos of Analog Input Channels1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure

1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature

1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure

1 no of RTD (Pt-100) channel, -50 to +90 degree C for Drier Dew Point orAmbient Temperature

2 nos of Analog Output Channels1 to 5 VDC, One for Discharge Pressure and One Programmable (SumpPressure, Discharge temp, Dew point/Ambient)

9 nos of Function keysUp, Down, Left, Right, Enter, Escape, Start, Stop and Reset.

1 no of Display128X64 White Backlight Graphical LCD

9 nos of LEDs for Visualization Alarm & Machine StatusAuto

Air Filter

Main Motor Overload

Reverse Rotation

Cooler

Pressure

Temperature

Differential Pressure Oil Filter

Differential Pressure Separator Element

1 no. of Dual LED for Start/Stop IndicationGreen for start and Red for stop

1 no. of Non Volatile MemoryFor storage of 30 Days reports & 99 Fault Reports

1 no. of Real Time ClockWith Battery life of about 10 years

4 nos of Communication Port (RS485, 2 wire)Serial Port 1: MODBUS-RTU or SCADA Port

Serial Port 2: Dedicated FPD Port (For future use)

Serial Port 3: Add-On I/O Interface Port (expansion possibility)

Serial Port 4: VFD Interface Port

1 no. of In System Programming (ISP) Port For program / Data down loadingand data uploading

Power Supply Input: 24VAC +/- 25%, 50Hz / 60Hz, 1A (In built Protectionpresent for Surge, Over Current)

22.2

Technical Features

Controller Terminals Configuration

23.0

X03: Main Motor RelaysConnector type: 4 pole combicon

Pin Function Id Active state

1 Common for Main, Star and Delta Common -contactors

2 Main Contactor Main Energised

3 Star Contactor Star Energised

4 Delta Contactor Delta Energised

X01: Power supplyConnector type: 3 pole combicon


1 24V AC Phase 24 VAC P -

2 Earth Earth -

3 24V AC Neutral 24 VAC N -

X02: RelaysConnector type: 10 pole combicon


1 Common - Load Relay Common

2 Load Relay L / UL Load whenEnergised

3 Common - Fan Relay Common

4 Fan Relay Fan Energised

5 Common - Auto Drain Valve Relay Common

6 Auto Drain Valve Relay ADV Energised

7 Common Dryer Relay Common

8 Dryer Relay/ programmable relay Dryer / Pr2 Energised

9 Common - Programmable Relay Common

10 Programmable Relay Pr1 Energised


23.1

X04: Digital InputsConnector type: 11 pole combicon


1 Digital Inputs Common 24VDC 24VDC -

2 Emergency Stop Emergency Fault if open

3 Differential Pressure Oil Filter DPOF Fault if open

4 Reverse Rotation Rev. Rot Fault if closed

5 Differential Pressure Air Filter DPAF Fault if open

6 Remote Start Stop Control Remote Stop if open/start on Closure

7 High Sump Pressure HSP Fault if open

8 Cooler Fault Input Cooler Fault if open

9 Main Motor Overload MMOL Fault if open

10 24V Supply Ground -24V DC (provision forcheck DI

voltage)

11 No Connection - -

X05: Analog InputsConnector type: 8 pole combicon

Pin Function Id Type Range

1 Discharge pressure Dis. Pr 4-20 ma 0 to 16 bar

2 15 to 24VDC 18V

3 Discharge Temperature Dis. Tr + KTY10 0 to 150C4 Discharge Temperature Dis. Tr -

5 Sump Pressure Sump Pr 4-20 ma 0 to 16 bar

6 15 to 24VDC 18V

7 Dryer or Ambient Pt100 + Pt100 -50 to +90Ctemperature

8 Dryer or Ambient Pt100 -temperature


23.2

X06: Analog Outputs and VFDConnector type: 5 pole combicon

X07: CommunicationConnector type: 6 pole combicon

Pin Function Id Type Protocol/Range

1 VFD Interface VFD A RS485A FC Protocol

2 VFD Interface VFD B RS485 B

3 Supply Ground For 5V 0VDC - -

4 Dis. Pressure Output AO1 Voltage(1-5V) 0 to 16 bar

5 Programmable Analog AO2 Voltage 0 to 160C /Output (1-5V) 0 to 16 bar /-

65 to 95C

Pin Function Id Type Protocol/Range

1 DCS Interface-ModbusRTU DCS A RS485 A Modbus-RTU

2 DCS Interface Modbus -RTU DCS B RS485 B

3 FPD Interface FPD A RS485 A ASCII

4 FPD Interface FPD B RS485 B

5 Add On Interface Add-On A RS485 A Modbus

6 Add On Interface Add-On B RS485 B

Main Menu Screen

24.0

Message 1: Based on the short cut keys pressed (refer APPENDIX B)

Message 2: Compressor Status or fault message

- Pressure schedule- If Blank Pressure schedule is disabled

- If PS Pressure schedule is enabled

- If PS blinking Waiting for pressure schedule acknowledgement

- Control Mode (*/$)

- *L Local, ON/OFF control from local keypad

- *R Remote, ON/OFF control from remote input

- *D DCS, Control is from DCS System

- $M Manual, Start command given after power failure

- $A Auto, Compressor will automatically restart after power failure

Dis. Pr : 6.0 bar

Dis. Tr : 32C

Message 1

Message 2

Warning

HH:MM:SS DD/MM1 2

1

2

Main Menu Screen

24.1

Message 2 - Compressor Status or Fault message

Status Description

Ready Ready for start

Star Motor running in Star

Run Motor running in Delta

Run load Compressor in load

Run unload Compressor in unload

Stop busy Stop sequence in progress

Idle When the controller is in idle, User interface will notfunction during this period for 5 seconds

Emergency stop Emergency Stop Push Switch is ON

Start inhibit xx.x During the start, if sump pressure is higher than theset sump pressure value for starting, this message isdisplayed XX.X denotes the live sump pressure value.The compressor starts only if the pump pressure valueis below the set value.

Start inhibit If the sump pressure is not used (Disabled) then the seconds controller will ensure a minimum of 60 seconds

delay between the stop and the start. Count stops ifSTOP key is pressed

Auto restart If the compressor is in Auto Mode, the controllerseconds will ensure a minimum delay (user set, e.g. 90 sec)

between the stop and the start operations. Count stopsif STOP key is pressed

Start ack wait This message is displayed when the compressor waitsfor user acknowledgement, after fault clearance. Bypressing START key user can acknowledge

Main Menu Screen

24.2

Status DescriptionPr. Probe failure Discharge pressure sensor probe failure

Tp. Probe failure Temperature sensor probe failure

Sump Pr. probe Sump pressure sensor probe failureFailure

HSP (A) Case 1: Sump pressure is enabled when the sumppressure exceeds the set high sump pressure value.

Case 2: Sump pressure is disabled when the dischargepressure exceeds the set high sump pressure value.

HSP (D) HSP digital input opens due to high sumppressure

Cooler Cooler digital input opens due to cooler fault

Main motor MMOL digital input opens due to main motoroverload overload.

Rev Rot / Ph fail If the Rev Rot input closes, when the motor is running,due to motor reverse rotation or phase failure.

Trip temperature Discharge temperature exceeds the set triptemperature value

Sump pressure This function is displayed when the sump pr sensor isnot developing activated. After the Start, the sump pressure should

be at least 1.0 bar in 10 seconds. If this isnot achieved fault may occurs.

Power failure Mains supply is interrupted for more than 30 msec

Low voltage Mains supply voltage is less than the 67% of ratedvoltage, compressor is tripped and the controlleroperation is stopped until the Mains supply returns tonormal (at least 75% of the rated)

Menu Structure

25.0

From the default screen, press shortcut keys to view the following (ReferAppendix B)

S Set load, unload, start sump & maximum differential pressure valuesT Current day reportW Warning messages (All warning messages can be viewed)X Current sump pressure, diff pressure & ambient temperature or dew pointPress Enter Key to display main menu

View

OperatorFault

Report

Day

ReportService

Time

Cumulative

TimeVFD

4.1 ViewNo password required.

On view parameters, the preset parameters like mode, pressure values,temperature values, timer settings, DCS parameters, last 99 fault reports, last30days report, remaining service hrs due, cumulative time details and VFDparameters can be viewed. The values cannot be altered through this menu.

Scroll up or down by using up and down keys to select the menu. Then pressEnter to enter the selected menu.

Dis. Pr : 6.0 bar

Dis. Tr : 32C StatusX View

Operator

Service

Factory

Customer Care

Main Menu

25.1

Menu Structure

4.1.1 Operator

View Operator Mode Control mode Local / Remote / DCSUnload mode Enable / DisableAuto restart ON/ OFFPressure unit PSI / BarTemperature unit Fahren / Centi

Pressure Unload pressure X X . X b or p (bar orpsi)

Load pressure X X . X b or pPr. schedule ON/ OFFStart sump pressure X X . X b or pMax .diff pressure X X . X b or p

Delay Warn RST delay X X X s(second)Star delay X X sDTR delay X X sRTS delay X X sStandby time Sby X X m minute)

St/Sp PH X XDCS port Type Modbus / SCADA

Compr. ID X XBaud rate 9600/19200Parity None / EvenLength 8 / 7Stop bit 2 / 1

Temperature Trip temperature X X X C or FWarn temperature X X X C or FFan temperature X X X C or FLow dew Pt X X C or FHigh dew Pt X X C or F

LEVEL 4LEVEL 1 LEVEL 2 LEVEL 3

4.1.2 Fault Report

LEVEL 1 LEVEL 2 LEVEL 3

View Fault report Fault code: XX, Message

Time: HH:MM:SS

Date: DD/MM/YY

Dis.Pr: X X .X

Dis.Tr: X X X

Status: Load/ UnLoad /OFF

Use S ,T to select the Fault record number (1 to 99).

Menu Structure

25.2

Fault Code:01 & 09 Reserved

02-Main motor overload, 03-Cooler, 04-HSP(Analog), 05Trip temperature, 06-Reverse rotation, 07-Pressure probe failure, 08-Temperatureprobe failure, 0A-HSP(Digital), 0B-Power failure( Short Power Interrupt), 0C-Sump pressure not developing , 0D-Sump pressure probe failure.

On the fault report, parameters such as line pressure, discharge temperature andstatus of compressor will be displayed. This will help to troubleshoot the failure.

4.1.3 Day ReportUse S ,T to select the Record number (1 to 30).

L- Load, St Stop, UL Unload, F- Fault, R- Run, Sby- Standby,STC Start Count, LDC Load Count

On the fault report, parameters such as line pressure, discharge temperatureand status of compressor will be displayed. This will help to troubleshoot thefailure.


View Day report Date: DD/MM/YY

L: X X Hours St: X X Hours

UL: X X Hours F: X X Hours

R: X X Hours Sby: X X Hours

STC: X X X LDC: X X X X X

4.1.4 Service Time

The remaining service hours for the consumable parts can be viewed and theservice due is completed. The countdown then will be shown in negative(- hrs).


View Service time Remaining AFCT: X X X X X X hours

Remaining OFCT: X X X X X X hours

Remaining OSCT: X X X X X X hours

Remaining OCT: X X X X X X hours

Remaining RGT: X X X X X X hours

Menu Structure

On this menu, the cumulative hours including number of start/stops, number ofload/unloads and percentage of utilization can be viewed. With this CumulativeTime feature, the Emergency stop hours will be accounted in stop hours, andnot under fault hours. This enables the user to view the real fault hours. Thesedetails will further guide for energy savings in compressed air.

4.1.6 VFDWhen the VFD is connected to the compressor, user can view the followingparameters of VFD on Neuron II.

1. Voltage in V

2. Current in A

3. Frequency in Hz

4. Power in KW

5. Run Hours

6. Kilowatt Hour (Multiply the value shown by 100 to get the real KWH)

7. Status of the VFD

4.1.5 Cumulative Time


View Cumulative time Load X X X X X X hrs: X X Min

Unload X X X X X X hrs: X X Min

Run X X X X X X hrs: X X Min

Stop X X X X X X hrs: X X Min

Fault X X X X X X hrs: X X Min

Standby X X X X X X hrs: X X Min

Start Count X X X X X X

Load Count X X X X X X X X X

Utilisation X X %

25.3

25.4

Menu Structure

4.2 OperatorPassword protected. The operator has to receive the password from thecompressor commissioning engineer

With this menu, the operator parameters can be adjusted to match therequirement. Minimum and maximum limits are fixed for all the value adjustmentparameters. When the setting exceeds these values, there will be an indicationof out of range.

Operator

Machine Schedule Maintenance LanguageChange

Password

Mode PressureSet

Delay

DCS

Port

Auto Drain

Valve

Set Dew

Point

25.5

Menu Structure

4.2.1 Machine# Item Min Max Option Default Unit1 Auto restart - - on / off off -2 Pr unit - - bar / psi bar -

3 Tr unit - - cen / fah cen -4 Control mode - - loc/rem/dcs loc -5 Unload mode - - en/dis dis -

6 Analog output 2 - - Tmp / Sp /Pt / off off -

Pressure7 Unload > load < max - 7.5 bar bar/psipressure pressure unload (Varied

+0.5 pressure according(bar) (bar) to pr

model)8 Load 4.0 (bar) < unload - 5.5 bar bar/psipressure pressure- (Varied

0.5 (bar) accordingto pr

model)Set Delay

9 Warn RST 90 300 - 90 second10 Star 6 10 - 6 second

11 DTR 10 60 - 10 second12 RTS 5 30 - 5 second

13 Standby 1 99 - 5 minute14 St/Sp per hr 3 10 - 5 -

DCS Port15 Type - - Modbus / modbus -

SCADA

16 ID 01 99 - 01 -17 Baud rate - - 9600/19200 9600 bps

18 Parity - - None /Even None -19 Length - - 8 / 7 8 -

20 Stop bit - - 2 / 1 2 -Auto Drain Valve

21 Off time 1 150 - 4 minute

22 On time 1 15 - 5 SecondSet Dew Point

23 Low dew point -6 C +2 C - -2 C C/F24 High dew point 6 C 12 C - 8 C C/F

25.6

Menu Structure

Important Function Keys:

Auto restart ON: Switches On the compressor automatically after a powerfailure. The internal timer counts the power Off period and the period whenpower resumes. The compressor starts after elapsing the set time by thisfunction, ensuring the compressor availability immediately after a power failure.On the screen A will be displayed and the Auto lamp is On, indicating that thecompressor can be automatically started. If it doesnt, M (manual) will bedisplayed. This mode indicates that a manual start is required after power failure.

Local: The compressor is switched On/ Off through the start and stop buttonsin the controller.

Remote: The compressor is switched On/Off only through Digital input (Remote),and cannot be operated through the controller push buttons.

DCS : The compressor is operated only through modbus.

In Remote and DCS modes, the compressor can be stopped through theEmergency stop. The Auto LED will glow, in both these modes, indicating thatthe compressor can be automatically started.

Unload mode: This key verifies the functions of the compressor with out loading.If this mode is selected, the relay out put (load / unload) will be de energized.During this mode, the compressor runs continuously in Unload mode. If thefunction is disabled, then the compressor operates as per the pressure set inthe controller.

Load pressure & unload pressure: The user can adjust these values withinthe limits of the factory. The value is set at a minimum load pressure of 4 bar.The maximum unload pressure is set as per the indication on the compressorname plate. The minimum differential is 0.5 bar.

Menu Structure

25.7

4.2.2 ScheduleEnable Pressure Schedule, and use %, % to select the schedule number(1 to 32).

Then Press Enter to set the following

Once the pressure scheduler is selected, PS blinks on the screen. Toacknowledge this, press START button. When pressed, the compressor startsand stops as per the pressure scheduler. The start / stop keys are not activatedin this mode, after the user acknowledges it.

The controller is designed to accommodate changes in the schedule in betweenperiods. It avoids the necessity of marking changes in schedules in an order.For example, consider the two periods: Monday schedule (1-4) and Tuesdayschedule (5-8). If the user wants to make changes to the Monday schedule, hecan enter the changes in the 9 schedule (that follows after the Tuesday schedule).

4.2.3 Maintenance

Once the consumable part is replaced, enter in to the maintenance menu. Typethe changed part as Yes. Set the remaining service hours as per the 100%service hours.

# Item Min Max Option Default Unit

1 AF changed - - no/yes no -

2 OF changed - - no/yes no -

3 OS changed - - no/yes no -

4 Oil changed - - no/yes no -

5 Re Grease - - no/yes no -

# Item Min Max Option Default Unit1 Day - - Sun to Sat /

-- (means noschedule) -

2 Action - - on / off - -3 Time HH 00 23 - - Hour4 Time MM 00 59 - - Minute5 Unload > Load < Max - bar/psi

Pressure Pressure Unload+0.5 Pressure(bar) (bar)

6 Load Pressure 4.0 bar < Unload - - bar/psiPressure 0.5 (bar)

25.8

Menu Structure

4.2.4 Language

The user language can be selected, Default is in English.

4.2.5 Change Password

Procedure for changing the password

1. Enter the old password

2. If old password is correct, next screen is displayed. If wrong, the controlcomes out of the change password screen

3. When the next screen is displayed, enter the new password

4. Re-enter new password

5. If new password matches both the entries, the password will be updated.If mismatch occurs, the control goes back to step 3.

Pressing Esc will bring the control back to the main menu screen

# Item

1 English

2 Hindi

3 Portuguese

Menu Structure

25.9

4.3 ServicePassword protected. Only Elgi Service engineers are authorized to change themenu.

4.3.1 CalibrationSelect the parameter needed for calibration using the %, %keys. Then PressEnter to calibrate.

Discharge Pressure/ Discharge Temperature/ Sump Pressure Calibration

Run the compressor. Measure the value using a standard and recently calibratedmeter, when the value is stable. Enter the meter reading in the set value fielddisplayed on the Neuron II. Set Value should not exceed +/- 1 bar and +/- 10 Cthe actual value.

Pt 100 Calibration

Measure the value using a standard and recently calibrated meter, when thedew point/ ambient temperature is stable. Enter the meter reading in the setvalue field displayed on the Neuron II. Set Value should not exceed +/- 3 C theactual value.

Note:

Calibration should be done when the compressor is switched Off , and ensurethe digital outputs (relay terminals) are disconnected from the controller.

Calibration for pressure should be done for the pressure sensor at 8 bar (in baronly), and at 100 Deg C (in Centigrade only).

(3.3k resistor=100Deg C)

Analog Output 1 & 2

Calibration for analog output is done for two values: one at zero and the otherat 8.0 bar / 80 degree C. These values are set by connecting a Variable Resistor(TRIM POT) to the analog input channel. Measure the analog output value (canbe viewed in the DCS/VFD / or any master unit where this output is connected).Enter this value in set pressure:

Service

Calibration RelayFan

Temp MaintenanceClock

Self

Test

,Menu Structure

25.10

4.3.2 RelaySelect the Programmable Relay 1 or 2 using the S,Tkeys. Then Press Enterto assign any of the following functions for the relay.

4.3.3 Change PasswordThe fan temperature set point is used to start the fan when set temperature isreached. Stop the fan when the temperature reaches 10 Deg C or lesser thanthe set temperature. This setting is used to control On / Off settings of the fan,based on the discharge oil temperature.

The maintenance due is fixed by Elgi Service Engineer based on the spareparts used.

4.3.4 Maintenance

# Item1 Warn

2 Load

3 Service

4 Standby

5 Trip

6 Remote

7 Ready

Default:

Relay 1 = Warn

Relay 2 = Trip

Note: If Dryer is enabled, the Programmable Relay2 is not user programmable. It is used for automaticdryer control.

# Item Min Max Option Default Unit1 Fan temperature 60 C 85 C - 85 C C / F

# Item Min Max Option Default Unit1 Set AFCT 000000 999999 - 001500H Hour

2 Set OFCT 000000 999999 - 001000H Hour

3 Set OSCT 000000 999999 - 004000H Hour

4 Set OCT 000000 999999 - 001000H Hour

5 Set RGT 000000 999999 - 001500H Hour

Menu Structure

25.11

4.3.5 Clock

The clock setting of the controller is not changed, if used in India. When usedoverseas, the time is set according to the local timings, at the time ofcommissioning

4.3.6 Self TestSelf Test for testing the Controller Display, Mimic Leds, Keys, Input/Output,Memory & Communication Ports working.

Follow the instructions displayed on the screen.

# Item Min Max

1 Hour 00 23

2 Minute 00 59

3 Second 00 59

4 Date 01 31

5 Month 01 12

6 Year 00 99

7 Day Sun/Mon/Tue/Wed/Thu/Fri/Sat

WarningSelf-Test should be conducted only after disconnecting the compressor fromthe controller. (Use connect power supply X01 3 pin connector) DO NOT performself-test when the controller is connected to the compressor. Doing so will causesevere damage to the compressor.

4.3.7 Change Password1. Enter the old password

1. Enter the old password




5. If new password matches both the entries, the password will be updated. Ifmismatch occurs, the control goes back to step 3.


4.4 Factory menuPassword protected. Only Elgi authorized persons are allowed to change thesetting.

Menu Structure

25.12

Factory

MachineChange

PasswordDryer

Compressor

InfoDPAF DPOF

Max.

Pressure

Settings

Temperature

Settings

4.4.1 Machine

Menu Structure

25.13

If the sump pressure sensor is enabled, the Star sump pressure and themaximum differential pressure values will function. In this mode, the highsump pressure is activated based on the sump pressure in the Air oilsump.


1 Rating - - 11 to 315 22 KW

2 Pressure - - LP/ 7.0to12.5 LP bar

3 Fab no Alpha:A Alpha:Z - AAAA -(10 digit) num:0 num:9 000000

4 DPAF - - on/off off -

5 DPOF - - on/off off -Max. Pressure Settings

6 Max UL > Unload Max < Max - 10.5 bar barpressure Unload Unload /psi

pressure pressure+0.5 +3

8 Sump - - enable/ disable -pressure disable

9 Start sump 0.0 bar 16.0 bar - 1.0 bar barpressure /psi

10 Max. 0.0 bar 2.0 bar - 1.5 bar bardifferential /psipressure

Temperature Settings

11 Trip 80 C 120 C - 110 C C / Ftemperature

12 Warn 70 C 110 C - 105 C C / Ftemperature

Menu Structure

25.14

4.4.2 Change Password1. Enter the old password




5. If new password matches both the entries, the password will be updated.

If mismatch occurs, the control goes back to step 3.


4.4.3 Dryer


1 Dryer mode - - on/off off -

2 Dryer Delay 2 10 - 3 Minute

This mode is enabled, if dryer is part of the compressor. The dryer is switchedon and off through the controller, provided the compressor is switched On.When the compressor is On, dryer is switched On; and the dryer is switchedOff when the compressor is on Off mode. The time interval between the stopand start operations is decided by dryer delay time setting, which enables thesafe operation of dryer and compressor.

4.5 Customer Care

Dis. Pr : 6.0 bar

Dis. Tr : 32oC

Status

Toll Free No

1800-425-3544

e-mail [email protected]

Neuron II has two types of Data Interface

N Analog output

N DCS Port

5.1 Analog outputTwo channels are available for analog output. The first channel will output thecurrent discharge pressure value from 0.0 -16.0 bar, converted from 1 - 5V.

The Second channel is programmable. User can select any one of the following

menu: Operator/ Machine/ Mode/ Analog output

a. Dis. Temperature 0 -160 C, converted from 1 - 5V

b. Sump Pressure 0 - 16.0 bar, converted from 1 - 5V

c. Pt100 Temperature -65 - 95 C, converted from 1 - 5V

Note: Analog output will be 0V, in case of probe failure.

5.2 DCS PortDCS port can be of Modbus RTU type to interface to Generic DCS system orSCADA type to interface to ELGI SCADA software.

User can select the Port type in menu Operator/ Machine/ DCS Port. TheID, Baud Rate, Parity, data Length, Stop Bit are also user settable. The Modbusdata table will be provided based on the request (A CD contains address tableand activation key)

Data Interface

26.0

Construction

27.0

N Corrosion & dust protected back cover

N IP65 polyethylene front keypad

N Inputs and outputs through terminal block, board to wires, disconnectable, screw terminals

N Front plate dimensions 260 x 145mm

N Enclosure dimensions 235 X 120 X 70 mm

N Operating temperature - 0C to +75C

N Relative humidity

Controller Identification

28.0

While Communicating to Elgi, please mention the following:

Type of controller

SL no

Batch NO

Revision Details

For any other clarification in the controller please contact ELGI

Toll Free No : 1800-425-3544

e-mail [email protected]

Version Date Changes

1.0 2 April 2009 Initial Draft

1.1 13 July 2009 Pilot Batch S/W Version 1.1

1.2 01.02.2010 Pilot batch SW version 1.1D

Appendix A

29.0

Mimic Led Table

# LED Description

1 Auto Indicates the machine is in Automaticon/off mode. LED glows in AmberColour when

1. Pressure Schedule is enabled (or)Auto Restart is enabled

2 Air Filter Glows in Amber colour when 1.Air Filter Service is due based onservice hours2. Air Filter Digital Input(DPAF) is Open & DPAF is enabled

3 Main Motor Overload Glows in Red when the Main MotorOverload Digital Input is Open.

4 Reverse Rotation Glows in Red when the ReverseRotation Digital Input is Closed

5 Cooler fault Glows in Red when the cooler DigitalInput is Open

6 Pressure Glows in Red when 1. HSP DigitalInput is Open 2. Analog PressureInput is Open (Probe Failure) Dis.Pressure is higher than set HSP

7 Temperature Glows in Red when 1. AnalogTemperature Input is Open (ProbeFailure) 2. Dis. Temperature is higherthan set Trip temp.

8 Differential Pressure Glows in Amber when 1. DPOFDigital Input is Open & DPOF isenabled Oil Filter Service is due

9 Differential Pressure Glows in Amber when 1. Oil SeparatorFilter Service is due 2. On HighDifferential Pressure (Only if SumpPressure enabled)

10 Start & Stop 1. Glows in Red when machine isstopped / idle 2. Glows in Greenwhen machine is running

Appendix B

30.0

APPENDIX B: Short Cut Key Functions

Note1: All shortcut key functions only when the display is on Main Screen.Note2: On every press of the key NEXT message is displayed.

WWWWWLEFT Warning messages

Warning DescriptionDPAF Differential Pressure Air Filter Due For

Service

DPOF Differential Pressure Oil Filter Due ForService

Dryer Probe Failure Pt100 Sensor Probe Failure

Low Dew Point Live Dew Point less than the Set LowDew Point

High Dew Point Live Dew Point greater than the Set HighDew Point

High Differential pressure Difference Between the Sump & DischargePressure is greater than the set maxDifferential Pressure value.

Warn Temperature Discharge Temperature exceeds the setWarn value

Change Air Filter Air Filter Due For Service

Change Oil Filter Oil Filter Due For Service

Change Oil Separator Oil Separator Due For Service

Change Oil Oil Change Due For Service

Change Grease Re Grease Due For Service

Start Stop Exceeded No. of Start and Stop per hour exceeded

XXXXXRIGHT - Live analog values1. Live differential pressure2. Live sump pressure3. Live Pt100 temperature

SSSSSUP Set analog values1. Set load pressure2. Set unload pressure3. Set start sump pressure4. Max differential pressure

dddddDOWN Today report1. Date2. Load and stop hours3. Unload and fault hours4. Run and standby hours5. Start count and load count

Appendix B

30.1

Appendix C

31.0

APPENDIX C: Modbus Table [Function Code: 0x03(Read) & 0x10(Write)]# Data Address Type Bytes Example/ Access

Description Format

Cumulative Time & Count Registers

1 Load Hours 1010 BCD 4 HHHHHH:MM R

2 Unload Hours 1012 BCD 4 HHHHHH:MM R

3 Run Hours 1014 BCD 4 HHHHHH:MM R

4 Stop Hours 1016 BCD 4 HHHHHH:MM R

5 Fault Hours 1018 BCD 4 HHHHHH:MM R

6 Standby Hours 101A BCD 4 HHHHHH:MM R

7 No of Start 101C BCD 4 NNNNNNNN R

8 Load Count 101E BCD 6 NNNNNNNNNNNN R

9 Utilization % 1022 BCD 2 XXXX R

Service Remaining Time Registers

10 Rem AFCT 1029 ULong 4 H800927BF = RMinutes -599999

11 Rem OFCTMinutes 102C ULong 4 H800927BF = R

-599999

12 Rem OSCT 102F ULong 4 H800927BF = RMinutes -599999

13 Rem OCT 1032 ULong 4 H800927BF = R Minutes -599999

14 Rem RGT 1035 ULong 4 H800927BF = R Minutes -599999

Mode Registers

15 Control Mode 1040 BCD 2 0001-DCS0002-Local

0003-Remote R/W

16 Unload Mode 1041 BCD 2 0001-Disabled0002-Enabled R/W

17 Auto Restart 1042 BCD 2 0001-OFF0002-ON R/W

18 Pr Unit 1043 BCD 2 0001-BAR0002-PSI R/W

# Data Address Type Bytes Example/ AccessDescription Format

19 Tr unit 1044 BCD 2 0001-Centi0002-Farhen R/W

20 Pr. Schdl 1045 BCD 2 0001-OFF(on/off) 0002-ON R

Analog Registers

27 Dis. Pressure 104A BCD 2 1200 (/100) =12.0 bar R

28 Dis. 104B BCD 2 1100 (/10) =Temperature 110 C R

29 Dew Point /AmbientTemperature 104C BCD 2 MSB 01 = +

MSB 02 = -LSB = 30 R

30 Sump Pressure 104D BCD 2 1200 (/100) =12.0 bar R

31 Diff Pressure 104E BCD 2 0100 (/100)=1.0 bar R

32 Set Unload 104F BCD 2 0120 (/10)Pressure = 12.0 bar R/W

33 Set Load 1050 BCD 2 0080 (/10) =Pressure 8.0 bar R/W

34 Set Diff 1051 BCD 2 0010 (/10) = R/WPressure 1.0 bar

35 Trip Temp 1052 BCD 2 0110 = 110 C R

36 Warn Temp 1053 BCD 2 0105 = 105 C R/W

37 Low Dew Point 1054 BCD 2 MSB 01 = +MSB 02 = -LSB = 30 R/W

38 High Dew Point 1055 BCD 2 MSB 01 = +MSB 02 = -LSB = 30 R/W

39 Fan Temp 1056 BCD 2 0070 = 70 C R/W

Appendix C

31.1

Appendix C

31.2

# Data Address Type Bytes Example/ AccessDescription Format

21 Auto Restart 1060 BCD 2 0100 R/WDelay (Sec)

22 Star Delay (Sec) 1061 BCD 2 0005 R/W

23 DTR Delay (Sec) 1062 BCD 2 0010 R/W

24 RTS Delay (Sec) 1063 BCD 2 0010 R/W

25 Standby Time 1064 BCD 2 0005 R/W(Min)

26 Max. No of Start 1065 BCD 2 0005 R/Wper hour

RTC Registers

40 Hour 106A BCD 2 0023 R

41 Minutes 106B BCD 2 0059 R

42 Seconds 106C BCD 2 0059 R

43 Date 106D BCD 2 0031 R

44 Month 106E BCD 2 0012 R

45 Year 106F BCD 2 0009 R

46 Day 1070 BCD 2 0001Sunday -1 RStatus Registers

47 General Status 1071 UInt 2 Refer table R

48 Warning Status 1072 UInt 2 Refer table R

49 Fault Status 1073 UInt 2 Refer table R

Function Code: 0x01(Read Coil) & 0x05(Write Coil)0x01 Read Coil (Start / Stop)

0x05 Write Coil (Start / Stop)

Frame Type ID Function Address Quantity of DataCode coils

Request XX 01 2000 0001

Response XX 01 Byte count: 01 ON 0x01OFF 0x00

Frame Type ID Function Address Quantity of DataCode coils

Request XX 01 2000 0xFF00 Start0x0000 Stop

Response XX 01 2000 0xFF00 Start0x0000 Stop

Appendix C

31.3

Note: Function Code 0x10 (Write), 0x05 (Start/Stop) and 0x01 (read Start/Stop)will function only if Control Mode is set to DCS. Refer: Operator/Machine/Mode (Chapter 5.2.1)

On improper master request, any one of the following exception responseis sent

Code 01: Illegal function

Code 02: Illegal data address

Code 03: Illegal data value

Status Register Bit Definition:

Bit Position General Warning Fault

0 Ready DPAF HSP

1 Star DPOF Cooler

2 Run Dryer probe failure Main motoroverload

3 Run load Low dew point Reverse rotation

4 Run unload High dew point Pressure probefailure

5 Stop busy High differential Temperature probepressure Failure

6 Idle Warn temperature Trip temperature

7 Emergency Change air filter Sump pressure notstop developing

8 Start inhibit Change oil Sump pressure filter probe failure

9 Start Change oil Power failureack wait separator

10 Standby Change oil Reserved

11 Reserved Change grease Reserved

12 Reserved Reserved Reserved




Appendix C

31.4

Appendix-D Flow charts (Start, Stop, Load /unload /standbysequence)

Start Sequence:

STAR

ON

MAIN ON

NO. OF. START

INCREMENT

DELTA ON

STAR OFF

Return

Delay for 100msecs

(Fixed)

STAR TO DELTA delay x sec

(Star delay)

Delta to run delay x sec

(DTR)

Start Sequence

Appendix D

32.0

32.1

Appendix D

Is

STAR ON?

LOAD OFF

DELTA & MAIN

OFF

(RTS delay)

Run to stop x sec

IDLE delay for 5 secs

Fixed delay

READY

Yes

No

Stop

Is

MAIN ON?Return

Yes

No

Stop Sequence:

RUN LOAD/UNLOAD/STANDBY

IsDeltaON?

Load ON

Return

Load OFF

IncrementLoad Count

IsDIS Pr

< Load pr

pr.Is

DIS>UL pr

Return

NO

Yes

NO

Yes

No

Yes

Standby mode: In unload mode, if the pressure exceeds the set load pressurein the preset standby time, and is less than number of start/stop cycles duringthat time, the compressor goes into the standby mode ( or the compressorstops as per the stop sequence).

In standby mode, if the pressure drops below the set load pressure, thecompressor starts automatically as per the start sequence.

32.2

Appendix D

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/Description > /Namespace [ (Adobe) (Common) (1.0) ] /OtherNamespaces [ > /FormElements false /GenerateStructure true /IncludeBookmarks false /IncludeHyperlinks false /IncludeInteractive false /IncludeLayers false /IncludeProfiles true /MultimediaHandling /UseObjectSettings /Namespace [ (Adobe) (CreativeSuite) (2.0) ] /PDFXOutputIntentProfileSelector /NA /PreserveEditing true /UntaggedCMYKHandling /LeaveUntagged /UntaggedRGBHandling /LeaveUntagged /UseDocumentBleed false >> ]>> setdistillerparams> setpagedevice

Neuron II Elgi Compressor

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