MANY0739A.GB – Metacentre DX Box User Manual bar
TM
DX Box
1.0 Introduction
1.1 Management System Connectivity
1.2 Basic Function
2.0 Operation
2.1 User Interface
2.2 Display
2.3 Status Symbols
2.4 Indications
2.5 Compressor Identification
2.6 Operation
2.7 Power Failure Auto-Restart
2.8 Failure Modes
2.9 Compressor Fault
2.10 DX Box Fault
2.11 Pressure Sensor Fault
3.0 Parts List
4.0 Technical Data
5.0 Wiring Connection Diagram
Refere to Section Indicated
Note
Important or Caution, Safety
Index
Metacentre DX Box
Health and Safety
Refer to Metacentre Safety Manual
Page 1
User Manual
1. INTRODUCTION
The DX Box is designed to connect two load/unload air compressors to a system management unit, using a 2-wire RS485 data cable up to 500m (1650ft) in length.
The DX Box is designed specifically to ‘group’ two compressors together as a single coherent unit. The system management unit will detect and manipulate the two compressors as a single multiple step or variable output compressor unit.
The DX Box is able to manipulate two identical capacity compressors to form a single ‘group’ that will act in an identical manner as a 3-step compressor. The DX Box is also able to manipulate two differential capacity compressors providing demand matched control and sequence to form a single ‘group’ that will act in an identical manner as a variable stepping output, compressor.
This functionality provides the ability to: a) Group two adjacent air compressors together as a single coherent unit. b) Combine two similar capacity compressors together to form a threestep variable output group acting as a single coherent variable output unit. c) Take advantage of a small or minimal capacity compressor, grouped together with a medium or higher capacity compressor, to form a high capacity, variable output, group acting as a single variable output ‘top-up’ compressor. d) Exceed the maximum compressor control capability of a system management unit by combining compressors together as one.
Two single pressure switch control type air compressors can be connected to the DX Box using a 6-wire cable and a compressor interface PCB (i-PCB). The ‘i-PCB’ connections are identical to an system management unit.
The DX Box also provides optional ‘local pressure sensor’ connections. The compressor delivery pressures, local system pressure and air treatment differential pressures can be displayed. The monitored local pressure is available on the system network and can be utilised by an system management unit for advanced pressure related functions.
Page 2
Any number of DX Boxes can be connected to an system management unit as long as the total number of single compressors and/or groups does not exceed the total number of compressors for the system management unit model.
1.1 Management System Connectivity
DX Box
1 2
#1 3 #2
The DX Box connects to an ystem management unit using an industrial two wire
RS485 data network (Multi485).
1.2 Basic Function
The DX Box is a ‘Duel unit eXtension’ to a system management unit providing the ability to group two individual air compressors together in to one duel ‘group’ acting as a single coherent unit.
The DX Box provides additional ‘i-PCB’ connectivity.
The DX Box can also be used to provide ‘i-
PCB’ connectivity at a remote location beyond the maximum distance specification of direct system management unit connection.
1.3 Operation
2.3.1 Timer Rotation Mode (Tr)
A #1 B #2
50% 50% = 100%
1 A B
2 B A
Timer Rotation should be used when the two compressors have the same (50:50), or very similar, output capacity. The DX Box will assign one compressor as ‘Duty’ and the other as ‘Standby’. The duty compressor will always be loaded first and the standby used as and when required to meet demand. The duty and standby assignment will be changed at every
‘Interval Time’ (adjustable).
1.3.2 Automatic Mode (Ar)
A #1
65%
B #2
35% = 100%
0% -
35% B
65% A -
100% A B
Automatic mode can be used when the compressor capacities are different. The DX
Box will utilise each compressor as required to match output to demand. This mode enables the compressor ‘group’ to behave in the same manner as a single (multiple step) variable output unit.
The set ‘Interval Time’ is ignored in this mode, the DX Box will continuously evaluated utilisation to match demand.
For example:
If demand can be satisfied by the smaller of the two compressors (demand < 36%) the DX
Box will utilise the lower capacity compressor
(B). If demand increases above the output capacity of the smaller compressor, but within the capacity of the larger capacity compressor, the DX Box will utilise the larger capacity compressor (A). If demand exceeds to capacity of the larger capacity compressor the
DX Box will load the larger compressor continuously and utilise the smaller capacity compressor to regulate as required.
1.3.3 Management System Integration
When integrated with a system management unit the DX Box compressor ‘group’ will respond in ‘Top-Up’ mode or ‘Base-Load’ mode as dictated by the management unit.
The assigned mode of response will change from time-to-time dependant on the set sequencing mode of the management unit.
In Top-Up’ mode the DX Box will allow variable capacity control (as described above) dependant on demand.
In ‘Base-Load’ mode the DX Box will fully load both compressors to provide full base-load capacity output.
Metacentre DX Box
The DX Box ‘group’ unit should be set as a variable output unit on the management system. The management system will fully utilise the variable output capacity capability of the DX Box ‘group’ and report the percentage of utilisation of the ‘group’ in the same manner as a single variable output compressor.
1.3.4 Percentage Capacity
The capacity of each compressor is expressed, and set, as a percentage of the combined output capacity of both compressors.
For example:
If the larger compressor #1 (A) has an output capacity of 13.0m
3
/min, and the smaller #2 (B) compressor an output capacity of 7.0m
3
/min, the total combined output of the DX Box
‘group’ equates to 20.0m
3
/min.
Total Capacity (20.0m
3
/min.) = 100%
Compressor #1 (A) = 65%
Compressor #2 (B) = 35%
1.3.5 Compressor Failure Mode
If one compressor in the DX Box ‘group’ suffers a shutdown failure, or is manually stopped, the DX Box will indicate an ‘Alarm’ condition. The remaining compressor will continue to function and the DX Box will continue to operate at reduced capacity.
If both compressors suffer a shutdown failure, or are manually stopped, the DX Box will indicate a shutdown ‘Trip’ condition.
Page 3
User Manual
2. OPERATION
5 9 2
6
BAR
3
7
4
8 1 10
2.1 User Interface
2)
3)
4)
No function (unit always ON)
No function
No function
6)
7)
9)
UP, PLUS Button
DOWN, MINUS Button
DX Box Active Indicator
2.2 Display
The upper display will continuously show the
The detected ‘System’ pressure and the lower display will show the percentage load of the
DX Box ‘group’.
Press UP and DOWN to view the status,
‘Delivery’ pressure (if enabled) and
‘Differential’ pressure (if applicable) for each compressor in the ‘group’.
When viewing the status or pressure information for a compressor the ‘network address’ and DX Box identification will be show on the upper display (for example,
“C.03.1” indicates that the compressor is connected to the DX Box as compressor #1 and the DX Box is represented on the system management unit as compressor number
“03”). The status of the compressor will also be show using the ‘Run’ and ‘Load’ symbols.
If the ‘Delivery’ pressure sensor option for a compressor has not been enabled the lower display line will not be shown and the
‘differential’ pressure item will not be available.
User Menu Iems:
P.-C>: ‘System’ Pressure. and % Output
C#1-P>: ‘Delivery’ pressure compressor #1
C#1- P: ‘Differential’ Pressure #1
C#2-P>: ‘Delivery’ pressure compressor #2
C#2- P: ‘Differential’ Pressure #2
2.3 Status Symbols
DX Box Status (C>):
Power Failure Auto Restart (always on)
Communicating with the System
Management Controller (Remote Mode)
Flashing - No Communications with the
System Management Controller (Local
Mode)
One, or both, Compressors are Loaded
One, or both, compressors are switched to ‘Service Maintenance’ mode.
One, or both, compressors have exceeded the set Pressure Limit
1: Compressor Alarm
2: Auxiliary Alarm input active
3: Delivery Pressure Sensor fault
(display “- - - -“)
1: Compressor Not Available
2: Auxiliary Trip input active
Page 4
Compressor Status:
Compressor On Load
Flashing - Not Responding, Compressor
Not Running When required to load.
Service Maintenance function active
Pressure Limit Exceeded
“)
1: Compressor Alarm
2: Auxiliary Alarm input active
3: Pressure Sensor fault (display “- - - -
1: Compressor Not Available
2: Auxiliary Trip input active
2.2 Indicators
Run Indicator (Green LED)
OFF DX Box Fault condition
ON Active
Fault Indicator (Red LED)
OFF – No fault
“)
1: Compressor Alarm
2: Pressure Sensor fault (display “- - - -
1: Compressor Not Available
Each compressor connected to the DX Box will have an assigned compressor identification number #1 or #2.
DX Box
1 2
#1 3 #2
The DX Box ‘group’ will also have a single unique system address identification and will be represented on the system management unit as a single entity using the ‘address’ identification number. The identification number will be unique for the system.
For example, “C.03.1” indicates that the compressor is connected to the DX Box as compressor #1 and the DX Box is represented
Metacentre DX Box on the system management unit as compressor number “03”.
2.4 Operation
The DX Box is always active (started) and cannot be stopped. The DX Box will automatically switch between ‘Remote’, when under system management unit control, or
‘Local’ mode.
2.5 Power Failure Auto-Restart
The DX Box will always automatically start when power is re-applied after a power supply disruption or failure.
If communications with the system management unit is disrupted, the DX Box will switch to ‘Local’ mode and pressure regulation control is maintained using the set pressure set points.
The DX Box will automatically switch back to
‘Remote’ mode when communications with the system management unit are re-established, or the DX Box fault is reset.
If a fault occurs with the DX Box, or power to the DX Box is disrupted, pressure regulation control is automatically transferred back to each compressor. The compressor(s) will continue to operate using the pressure settings programmed or set in the individual compressor controller(s).
The design of some air compressor control systems may inhibit automatic transfer of pressure regulation control to local operation mode. In this instance the compressor will not continue production of compressed air – consult the air compressor manual or your air compressor supplier / specialist for details before installing the DX Box unit.
If a compressor fault condition is detected the
‘status’ display will show an ‘Alarm’ condition.
The ‘status’ display associated with the compressor will also indicate a fault condition
(see Status Symbols). The DX Box ‘Fault’ indicator (10) will flash to attract attention.
Compressor fault conditions will also be communicated to the system management unit controller.
Page 5
User Manual
2.10 DX Box Fault
The DX Box has two ‘shutdown’ fault conditions:
E:0821
Short Circuit Condition Detected, check all DX Box controller inputs and outputs.
E:0135
BAR
System Pressure Sensor Fault.
If one of these fault conditions occur the DX
Box will switch ‘off. The ‘Run Indicator’ (9) will also switch off and the ‘Fault Indicator’ (10) will fast flash.
2.11 Pressure Sensor Fault (Option)
E:0115
BAR
Delivery #1 Pressure Sensor Fault.
E:0125
BAR
Delivery #2 Pressure Sensor Fault.
Page 6
3.0 Parts List
DX Box
Item Part No. Description
- Y07ENER10.00 Unit, DX Box
- Y07CM14.00
1 Y07CM20.00
2 Y05CM31.00
Manual, User CD
Controller, S1 DX
Unit, XPM-TAC24
3 KPY0617.00C PCB, Terminal EX
4 Y07CM49.00 Gland, Set - Pg13.5
Required For Each Compressor:
Item Part No. Description
5 Y04CM59.00 Unit,
Optional Accessories:
Item Part No. Description
6 Y04CM29.00 Sensor,
7 Y01ENER35.00 Module, Relay 24Vac
4.0 Technical Data
Dimensions 291mm x 241mm x 152mm
Weight 6.5kg (14lb)
Mounting
Enclosure
Supply wall, 4 x screw fixings
IP54, NEMA 12
230Vac +/- 10%
Power 50VA
Temperature 0°C to 46°C (32°F to 115°F)
Humidity 95% RH non-condensing
1
4
5 i-PCB
AirMaster S1
6
Metacentre DX Box
XPM
-TAC
24
2
3
7
21 11
24 14
22 12
A2 A1
Page 7
User Manual
5.0 Wiring Diagram
+ VDC
Ai1
+ VDC
Ai2
+ VDC
Ai3
A-G ND
Ao
L1
L2
C007
C008
C009
C010
C001
C002
C003
C004
C005
C006
C011
C012
C013
C014
C015
C016
C017
C018
C019
C028
C029
C026
C027
C020
C021
C022
C023
C024
C025
C032
C030
C031
C024
C025
C011
10k
C015
C016
C031
C023
C021
C029
10k
C013
C014
C022
C027
C009
C010
C007
C008
C006
C005
C004
C003
C002
C001
C011
C017
C018
C019
230Vac 10%
115Vac 10%
Page 8
L2
L1
L2
L1
Multi485
Multi485 not used
Ai3 4-20mA
System Press.
Ai2 4-20mA
Pressure #2
Ai1 4-20mA
Pressure #1
+C
Di6 Aux Fault #1
+C
Di7 Aux Fault #2 not used
R4 Aux Output
+20VDC
Di4 Ready/Run
Di5 Alarm/Serv.
GND
R3 LOAD
R1 SEQ
2
1
4
3
6
5
+20VDC
Di2 Ready/Run
Di3
-
Alarm/Serv.
GND
R2 LOAD
R1 SEQ
2
1
4
3
6
5
XPM-TAC24
BLUE
BROWN
RED
GREEN
BLACK
ORANGE
WHITE
VIOLET
IEC
5x20mm
1 2 3 4
X04
T3.15A
T1.6A
T1.6A
T1.0A
FH5 FH4 FH3 FH2
2
X03 X02
1 2
VOLTAGE SELECT
230V
115V
T1.0A
1 2 3 4
X01
N L E E
FH1
24Vac/2 earthed
24Vac/1 isolated N L E
1 2 3 4
230V +-10%
115V +-10%
Metacentre DX Box
Page 9
