Quincy Compressor Net$ync II Conductor 4 Parts Manual

MANY0706A.GB – Net$ync II Conductor 4 Technical Manual
bar
Net$ync II
Conductor 4
Net$ync II Conductor 4
Index
1.0 Safety Precautions
1.1 Installation
1.2 Operational
1.3 Maintenance and Repair
2.0 Introduction
2.1 Compressor Connections and Control
2.2 Pressure Connection and Control
Refere to Section Indicated
Note
Important or Caution, Safety
3.0 Features and Functions
3.1 Pressure Control
3.2 Tolerance
3.3 Damping
3.4 System Volume
3.5 Sequence Control Strategies
3.6 Priority Settings
3.7 Prefill
3.8 Pressure Schedule
4.0 Installation
4.1 Unit Location
4.2 Power Supply
4.3 Pressure Sensor Location
4.4 Compressor Interface PCB
4.5 Auxiliary Input
4.6 Auxiliary Output
4.7 RS485 Communications
5.0 Commissioning
5.1 Physical Checks
5.2 Pressure Display
5.3 Unit Configuration
5.4 Optional Features and Functions
6.0 Menu Navigation
6.1 Menus
6.2 Menu Items
7.0 Operation
7.1 User Interface
7.2 Sequence Rotation
7.3 Unit Status
7.4 Compressor Status
7.5 Unit Functions
7.6 Information Displays
7.7 Manual Sequence Rotation
7.8 Compressor Identification
7.9 Stop
7.10 Start
7.11 Power Failure Auto Restart
7.12 Failure Mode
7.13 Reset
7.14 Fault Codes
8.0 Parts List
9.0 Technical Data
10.0 Wiring Connection Diagram
Page 1
Technical Manual
1. Safety Precautions
ALWAYS EMPLOY SAFE WORKING
PRACTESES AND PROCEDURES
WARNING: Risk of Danger
WARNING: Risk of Electric Shock
WARNING: Risk of High Pressure
WARNING: Consult Manual
When installing, commissioning, operating or
carrying out service or maintenance on a product,
personnel must use safe working practices and
observe all relevant local health and safety
requirements and regulations. Attention of users in
the UK is drawn to the Health and Safety at Work
Act, 1974, and to the Regulations and
Recommendations of the Institution of Electrical
Engineers (IEE).
Lethal voltages are used within the product. Use
extreme caution when carrying out electrical checks.
Isolate the power supply before starting any
maintenance work.
It is not possible to anticipate every circumstance
that might represent a potential hazard. If the user
employs an operating procedure, an item of
equipment or a method of working which is not
specifically recommended the user must ensure the
product will not be damaged or made unsafe and
that there is no risk to persons or property. Failure to
observe safety precautions or implement safe
working practises may be considered dangerous
practice or misuse of the product.
1.2 Installation
Installation work must only be carried out by a
competent person under qualified supervision.
A fused isolation switch must be fitted between the
main power supply and the product.
The product should be mounted in such a location
as to allow operational and maintenance access
without obstruction or hazard and to allow clear
visibility of indicators at all times.
If raised platforms are required to provide access to
the product they must not interfere with normal
operation or obstruct access. Platforms and stairs
should be of grid or plate construction with safety
rails on all open sides.
1.3 Operation
The product must only be operated by competent
personnel under qualified supervision.
Never remove or tamper with safety devices, guards
or insulation materials fitted to the unit.
The product must only be operated at the supply
voltage and frequency for which it is designed.
Page 2
When mains power is switched on, lethal voltages
are present in the electrical circuits and extreme
caution must be exercised whenever it is necessary
to carry out any work on the unit.
Do not open access panels or touch electrical
components while voltage is applied unless it is
necessary for measurements, tests or adjustments.
This work must only be carried out by a qualified
electrician or technician equipped with the correct
tools and appropriate protection against electrical
hazards.
All air compressors and/or other machine equipment
connected too, and controlled by, the product should
have a warning sign attached stating ‘THIS UNIT
MAY START WITHOUT WARNING’ next to the
display panel.
If an air compressor and/or other machine
equipment connected too, and controlled by, the
product is to be started remotely, attach warning
signs to the machine stating ‘THIS UNIT CAN BE
STARTED REMOTELY’ in a prominent location,
one on the outside of the machine, the other inside
the machine control compartment.
1.3 Service Maintenance and Repair
Service, maintenance, repairs or modifications must
only be carried out by competent personnel under
qualified supervision.
If replacement parts are required use only genuine
parts from the original equipment manufacturer, or
an alternative approved source.
Carry out the following operations before opening or
removing any access panels or carrying out any
work on the product :•
•
Isolate from the main electrical power supply.
Lock the isolator in the ‘OFF’ position and
remove the fuses.
Attach a label to the isolator switch and to the
product stating ‘WORK IN PROGRESS - DO
NOT APPLY VOLTAGE’. Do not switch on
electrical power or attempt to start the unit if
such a warning label is attached.
Ensure that all instructions concerning operation
and maintenance are strictly followed and that the
complete product, with all accessories and safety
devices, is kept in good working order.
The accuracy of sensor devices must be checked
on a regular basis. They must be renewed when
acceptable tolerances are exceeded. Always ensure
any pressure within a compressed air system is
safely vented to atmosphere before attempting to
remove or install a sensor device.
The product must only be cleaned with a damp
cloth, using mild detergents if necessary. Avoid the
use of any substances containing corrosive acids or
alkalis.
Do not paint the control facial or obscure any
indications, controls, instructions or warnings.
Net$ync II Conductor 4
2. INTRODUCTION
2.2 Pressure Detection and Control
The Net$ync II Conductor 4 a specialised
supervisory and control product designed to
provide energy efficient optimised pressure
and sequence management of up to 4 air
compressors operating on a common air
system. The Net$ync II Conductor 4 general
operating mode can be modified by a number
of adjustable parameters and priorities to
enable operation to be matched to site
requirements and characteristics.
The Net$ync II Conductor 4 utilises the signal
from an electronic pressure sensor that can be
mounted remotely from the Metacentre P4 in a
suitable location in the compressed air
system.
2.1 Compressor Connections and Control
As default the Net$ync II Conductor 4 set-up
for operation with a 16bar (232psi) pressure
sensor but can accept input from any 4-20mA
type pressure sensor with a range from 1.0bar
(14.5psi) up to 600bar (8700psi).
1
2
3
4
Each air compressor in the system can be
integrated with the Net$ync II Conductor 4 using an
interface module that is designed to enable
connection to almost any positive
displacement air compressor (regardless of
make or manufacturer) that operates using a
single pressure switch type control with a
control voltage between 12V to 250V, 50 or
60Hz.
The interface module is
installed within the
compressor control area
and connected to the
Net$ync II Conductor 4
using a sixwire cable.
Each air compressor must be equipped with a
load/unload regulation system and, if not
regulated with a single electro-mechanical
pressure switch, have a facility for a remote
load/unload control with the ability to accept a
volt free switching contact input for remote
load/unload.
Consult the air compressor manual or your
air compressor supplier/specialist for details
before installing the Net$ync II Conductor 4.
Page 3
Technical Manual
3. Features and Functions
3.1 Pressure Control:
The primary function of the Conductor 4’s pressure
control strategy is to maintain system pressure
between the ‘High Pressure’ set point (PH adjustable) and the ‘Low Pressure’ set point
(PL - adjustable) in conjunction with targeting
optimum achievable system energy efficiency.
The P4 calculates a ‘Target’ pressure level
(PT), the mid-point between the two set points,
which is used as the nominal ‘target’ pressure
level for the system.
a
If demand for air is abruptly, or significantly,
increased, and the capacity output of the
compressor loaded at the Low Pressure set
point (b) is insufficient, the pressure will
continue to decrease at a reduced rate.
The Conductor 4 will accommodate for this event by
loading an additional compressor.
The instance at which the additional
compressor is loaded (c) is dynamically
calculated and is determined by the rate of
pressure decrease (the urgency or time limit)
and the acceptable deviation of system
pressure (the ‘Tolerance’) from the normal
control limits.
PH
PT
b
a
PH
PL
PT
b
When system pressure increases to the High
Pressure set point (a) a compressor is
unloaded. Pressure is allowed to decrease to
the Low Pressure set point (b) before a
compressor is loaded again to add capacity
output and increase pressure. This process
will continue under a steady demand for air in
a continuous stable cycle.
For systems that consist of a variable capacity
(or variable speed) compressor, the
compressor must be set, or controlled, to
achieve and maintain the calculated system
‘Target’ pressure level (PT).
PH
PT
PL
Where abrupt, or significant, changes in air
demand, beyond the capacity scope of the
variable capacity compressor, are
experienced, the loading and unloading of
other compressors is implemented in exactly
the same way as described above.
Page 4
PL
c
The same method is implemented in reverse
(above the High Pressure set point) when an
abrupt, or significant, decrease for air demand
is experienced.
Rate of change of pressure, and the stability of
pressure control, is largely determined by
system volume and the scale, and/or
abruptness, of air demand fluctuations; these
characteristics will differ from installation to
installation. To accommodate for variations in
installation characteristics the ‘Tolerance’
pressure level (TO) and an influence on the
dynamic reaction time (or ‘Damping’) of the
Conductor 4 (DA) is adjustable.
-
Net$ync II Conductor 4
3.2 Tolerance:
3.3 Damping:
Tolerance is a pressure band above and
below the set pressure control levels that
accommodates for an exceptional instance of
abrupt and/or significant increase, or
decrease, in demand without compromise to
optimal energy efficient control.
In situations where the loading of an additional
compressor, at the PL pressure set point, is
inadequate to match a significant and/or
abrupt increase in air demand the additional
reaction of the Conductor 4, while pressure deviates
into the ‘tolerance’ limit, is dynamically calculated.
The time before an additional compressor is
loaded, to increase generation capacity
further, will vary in accordance with the
urgency of the situation.
PH + TO
TO
PH
PT
PL
TO
PL - TO
Tolerance (TO) is expressed as a pressure
defining the width of the tolerance ‘band’.
For example; a tolerance setting of 3psi
(0.2bar) means the Conductor 4 will implement
appropriate optimal energy efficient
response(s) during a deviation of pressure
3psi below the set PL pressure level. If
pressure ever deviates beyond the ‘tolerance’
limit the Conductor 4 will proportionally increment
an emergency response, abandoning optimum
energy efficiency, until pressure is returned to
normal levels.
If system volume is inadequate, and/or
demand fluctuations are significantly large, it is
advisable to increase the ‘Tolerance’ band to
maintain optimum energy efficiency, and
reduce over-reaction, during such transition
periods.
If system volume is generous, rate of pressure
change is slow and demand fluctuations are
insignificant and gradual, the ‘Tolerance’ band
can be reduced to improve pressure control
without compromise to optimum energy
efficiency.
The Conductor 4’s dynamic reaction algorithm is
pre-set by default to accommodate for the majority of
installation characteristics.
In some situations, of which the following are
examples, the rate of pressure change may be
aggressive and disproportionate:
a) Inadequate system volume
b) Excessive air treatment equipment
pressure differential
c) Inadequately sized pipe work
d) Delayed compressor response
In such instances the Conductor 4 may over-react
and attempt to load an additional compressor that
may not be necessary once the initial
compressor is running, loaded, and able to
contribute adequate additional generation
capacity. If an increase in the ‘tolerance’ band
is insufficient, the Conductor 4’s dynamic reaction
response can be influenced by increasing the
‘Damping’ factor (DA) reducing tendency to
over-react.
The ‘Damping’ factor is adjustable and scaled
from 0.1 to 10 with a default factor of 1. A
factor of 0.1 equates to 10 times faster than
default and a factor of 10 equates to 10 times
slower than default.
Page 5
Technical Manual
3.4 System Volume:
3.3.1 Fixed Cascade Mode
This mode is intended for special
applications and is not recommended for use
in normal situations. Avoid setting the damping
factor to ‘0.0’ unless the installation specifically
requires this mode of operation.
To implement fixed pressure set point
‘cascade’ mode adjust the ‘damping’ factor
(DA) to 0.0(zero). In this mode automated
single pressure band control is disabled and
each compressor is assigned fixed load and
unload pressure set points; simulating a
multiple pressure switch cascade system. The
set points are determined by the PH (unload)
and PL (load) pressure levels and are
‘cascaded’ below these settings at differentials
determined by the set ‘tolerance’ band (TO).
DA = 0
Comp ‘A’ Unload
TO
Comp ‘B’ Unload
TO
Comp ‘C’ Unload
TO
Comp ‘D’ Unload
Comp ‘A’ Load
TO
Comp ‘B’ Load
TO
Comp ‘C’ Load
TO
Comp ‘D’ Load
PH
PH - (1 x TO)
PH - (2 x TO)
PH - (3 x TO)
PL
PL - (1 x TO)
PL - (2 x TO)
PL - (3 x TO)
It is permissible for the ‘Unload’ and ‘Load’
levels to overlap if the ‘PH’ and ‘PL’ levels are
set close together.
Comp ‘A’ Unload
Comp ‘A’ Load
Comp ‘B’ Load
Comp ‘C’ Load
PH
Comp ‘B’ Unload
PH
Comp ‘C’ Unload
Comp ‘D’ Unload
Comp ‘D’ Load
The pressure set points are not dynamic
and remain fixed and unchanging. The
‘average’ system pressure will decrease
dependant on the number of compressor(s)
running as demand increases.
This is not an energy efficient focused
mode of operation.
Page 6
-
+
Pressure control of a system is a ‘feedback
loop’ response derived from increasing, or
decreasing, air generation output capacity. If
output capacity is greater than demand for air
the pressure in a system will increase, if
demand is greater than output capacity system
pressure will decrease. The rate of change of
pressure to changing generation and demand
capacity situations is largely dependant on
system volume. If system volume is small in
comparison to recommended size the rate of
change of pressure will be fast and abrupt
inhibiting effective control and compromising
optimum system energy efficiency. If system
volume is large the rate of change of pressure
will be slow and gradual. In this instance an
enhanced control of pressure can be
achieved, the system response times can be
reduced and optimum system energy
efficiency will generally be increased as a
result.
The rule below provides an approximation for
recommended minimum system volume:
1) For systems comprising of fixed capacity
output (or fixed speed) compressors:
m3 = (m3/min) / (bar.g – 1)
The approximation only works in metric
units; convert psi and ft3 to metric units first.
1.0 m3 1.0 m3/min
1.0 bar = 35.315 ft3
= 35.315 cfm
= 14.5 psi
Example: for a system that operates with a
maximum normal demand air flow of 36m3/min
at a nominal pressure of 7.0bar =
36m3/min / (7.0bar – 1) = 6.0 m3 (212 ft3)
2) For systems consisting of variable output
capacity (or variable speed) compressor(s) the
system volume should be doubled.
m3 = 2 x ((m3/min) / (bar.g – 1))
Net$ync II Conductor 4
3.5 Sequence Control Strategies:
The Conductor 4 provides three basic sequence
control strategies or modes. Each sequence control
strategy consists of two sub strategies:
1) The compressor ‘Rotation’ strategy
2) The compressor load ‘Control’
strategy
The ‘Rotation’ strategy defines how the
compressors are re-arranged, or re-ordered, in
to a new sequence at each routine ‘Rotation’
event. Rotation events are triggered by a
cyclic interval time, a set time of day each day,
or a set time of day once a week.
The compressor load ‘Control’ strategy
defines how the compressors are utilised in
response to variations in system pressure.
Compressor Sequence Arrangements:
Each compressor in a system is initially
assigned to the Conductor 4 with a fixed and
unchanging number reference, 1 to 4.
The ‘duty’ that a compressor is assigned in
any set ‘Rotation’ sequence arrangement is
defined by a letter, A to D.
A = the ‘Duty’ compressor, the first to be
utilised.
B = The ‘Standby’ compressor, the second to
be utilised.
C = The ‘Second Standby’ compressor, the
third to be utilised.
D = The ‘Third Standby’ compressor, the forth
to be utilised.
Compressor ‘duty’ assignments are reviewed,
and re-arranged as appropriate in accordance
with the selected rotation strategy, at each
rotation event.
Equal Hours Run Mode
The primary function of EHR mode is to
maintain a close relationship between the
running hours of each compressor in the
system. This provides an opportunity to
service all compressors at the same time
(providing the service interval times for all
compressors are the same or similar).
EHR is not an energy efficient focused
mode of operation.
Rotation:
Each time the rotation interval elapses, or the
rotation time is reached, the sequence order of
compressors is reviewed and re-arranged
dependant on the running hours recorded for
each compressor. The compressor with the
least recorded running hours is assigned as
the ‘duty’ compressor, the compressor with the
greatest recorded running hours is assigned
as the ‘last standby’ compressor. For systems
with more than two compressors, the
remaining compressor(s) are assigned in
accordance with there recorded running hours
in the same way.
Example: The compressors in a fourcompressor
system have the following
recorded running hours at the ‘Rotation’ time.
Compressor 1 = 2200 hrs
Compressor 2 = 2150 hrs
Compressor 3 = 2020 hrs
Compressor 4 = 2180 hrs
The new sequence order arrangement after a
rotation event would be:
Compressor 1 = D
Compressor 2 = B
Compressor 3 = A
Compressor 4 = C
Compressor 3, that has the least recorded
running hours, will now be utilised to a greater
extent in the new sequence arrangement;
potentially increasing the running hours at a
faster rate.
The Conductor 4 continuously monitors the running
status of each compressor and maintains a
record of the accumulated running hours.
These are available, and adjustable, in the
Conductor 4’s compressor running hour’s menu.
The Conductor 4 uses these values in EHR mode.
The Conductor 4’s running hours record should be
routinely checked, and adjusted if necessary, to
ensure a close match with the actual run hours
displayed on each compressor.
If a compressor is operated independently
from the Conductor 4 the running hours record may
not be accurately updated.
The running hours meter display on most
compressors are intended for approximate
service interval indication only and may
deviate in accuracy over a period of time.
Page 7
Technical Manual
Control:
Compressors are utilised, in response to
changing demand, using a ‘FILO’ (First In,
Last Out) strategy. The ‘duty’ compressor (A)
is utilised first followed by (B) if demand is
greater than the output capacity of (A). As
demand increases (C) is utilised followed by
(D) if demand increases further. As demand
reduces (D) is the first compressor to be
unloaded, followed by (C) and then (B) if
demand continuous to reduce. The last
compressor to be unloaded, if demand
reduces significantly, is (A). The compressor
assigned as (A) in the sequence is the first to
be loaded and the last to be unloaded.
First In First Out Mode
The primary function of FIFO mode is to keep
a compressor in a loaded condition for the
maximum amount of time, dependant on
demand fluctuations, while continuously
sharing regulation and utilisation among the
available compressors.
FIFO is not an energy efficient focused
mode of operation.
FIFO mode does not follow a fixed rotation
interval, or set rotation time. Compressors are
rotated at each load event. The ‘Rotation’
strategy also becomes the ‘Control’ strategy in
this mode.
Initially compressor 1 is loaded. As demand
increases compressor 2 is loaded. If demand
reduces compressor 1 is unloaded and
compressor 2 allowed to remain loaded for a
longer period. If demand increases again
compressor 3 is loaded followed by
compressor 4 as demand continues to
increase. If demand reduces compressor 2,
the compressor that has been loaded for the
longest period, is unloaded first followed by
compressor 3 if demand continuous to reduce.
If demand increases again compressor 1 will
be loaded, this strategy continuous in a cyclic
pattern.
1
2
3
4
ABCD
Page 8
DABC
DABC
CDAB
BCDA
BCDA
BCDA
ABCD
At each load event the compressor that has
just been loaded becomes (A), the
compressor that has been loaded for the
longest period becomes (D) and is the next
compressor to be unloaded if demand
decreases.
Timer Rotation Mode
The primary function of Timer Rotation mode
is to efficiently operate a compressed air
system consisting of fixed capacity output
compressors. The routine rotation
assignments can be modified using ‘Priority’
settings to accommodate for a differentially
sized or variable capacity output
compressor(s).
Rotation:
Each time the rotation interval elapses, or the
rotation time is reached, a sequence rotation
occurs and the sequence assignment for each
compressor is re-arranged. The compressor
that was assigned for duty (A) is re-assigned
as last standby (D) and all other compressor
assignments are incremented by one.
1
2
3
4
#1
A
B
C
D
#2
D
A
B
C
#3
C
D
A
B
#4
B
C
D
A
The sequence assignment pattern can be
modified by ‘Priority’ settings.
Tables; Priority Settings
Control:
Compressors are utilised, in response to
changing demand, using a ‘FILO’ (First In,
Last Out) strategy. The ‘duty’ compressor (A)
is utilised first followed by (B) if demand is
greater than the output capacity of (A). As
demand increases (C) is utilised followed by
(D) if demand increases further.
Net$ync II Conductor 4
As demand reduces (D) is the first compressor
to be unloaded, followed by (C) and then (B) if
demand continues to reduce.
The last compressor to be unloaded, if
demand reduces significantly, is (A). The
compressor assigned as (A) in the sequence
is the first to be loaded and the last to be
unloaded.
This feature is intended to allow the system to
react to changes in pressure target levels in a
smooth and energy efficient manner without
abrupt overreaction.
1
2
Tables:
The Conductor 4 operates in
accordance with settings that are
T01
programmed in to a number of
PH - - - menu ‘Tables’. Each table
PL - - - Pm - - - defines the operational
SQ - - - parameters and mode of
operation of the Conductor 4.
The Conductor 4 can be instructed to change from
one table to another at any time from an external
remote source or from settings in the real time
clock ‘Pressure Schedule’
This functionality enables the Conductor 4 to
switch from one set of operational parameters, and/or
from one mode of operation, to another at any
time without disruption to routine control.
Table Parameters:
Each table consists of the following
parameters; the parameters can be set
differently in each table.
1) PH: High pressure set point
2) PL: Low pressure set point
3) Pm: Minimum pressure warning level
4) SQ: Sequence rotation mode
5) 01: Compressor 1 Priority setting
6) 02: Compressor 2 Priority setting
7) 03: Compressor 3 Priority setting
8) 04: Compressor 4 Priority setting
The ‘maximum’ pressure fault level and the
rotation interval, or rotation time, are set
independently in a configuration menu and are
unchanging regardless of Table selected.
Pressure Change Time:
When pressure set points change, a change
from one ‘Table’ to another, the Conductor 4 will
increase, or decrease, the pressure target
levels towards the new table settings in a
gradual transition over a period of time.
PC
The time the system will take to complete the
transition from one pressure target to another
is determined by the ‘Pressure Change’ time
(PC). This value can be adjusted to
accommodate installation characteristics to
achieve the transition at optimal energy
efficiency.
If the Conductor 4 is able to achieve the transition
without compromising energy efficiency in a
shorter time than set, the pressure change
event time will be automatically reduced.
An aggressively short time setting will
compromise system optimal energy efficiency.
Sequence Rotation:
A sequence ‘Rotation’ event can be
automatically triggered on a routine basis
using a pre-determined interval, a predetermined
time each day or a pre-determined
day and time each week.
S01 04.01
RP
#1
18:00
Enter the rotation period menu item (RP); the
‘day’ setting will flash.
Select the ‘day’ or day function as
required:
#1 = Monday to #7 = Sunday
#8 = each working day of the week, excluding
Saturday and Sunday
#9 = each working day of the weeky.
#- (dash) = deactivate
Page 9
Technical Manual
Select the required hour and minutes of the
day(s) using the same method.
1
2
3
4
1
2
2
2
#1
A
B
C
D
#2
A
C
D
B
#3
A
D
B
C
#4
A
B
C
D
A day starts at 00:00hrs and ends at
23:59hrs (24hr clock system).
To define an interval time (more than
one rotation event a day) select ‘#t’ for the day
function and press Enter:
S01 04.02
RP
#t
12:00
2
An ‘intervals per day’ value will appear and
flash. Select the required number of rotation
events per day (1 to 96). The hour and
minutes display will now show the interval time
between each rotation event; 1 = every 24hrs
to 96 = every 15 minutes (example: 2 = every
12hrs).
Example 2:
For a four-compressor system, that includes a
compressor (for example compressor 4) that is
less efficient, or otherwise less desirable to
operate for other reasons, it may be
convenient to ensure the compressor is only
utilised as an emergency backup. To achieve
this assign compressor number 4 with a lower
priority.
Compressors 1 to 3 = priority 1
Compressor 4 = priority 2
The first automated rotation event each day
will occur at 00:00hrs and then every set
rotation interval time throughout the day.
3.6 Priority Settings:
Priority settings can be used to modify the
‘Rotation’ sequence assignment. Compressors
can be assigned a ‘priority’ of 1 to 4; where 1
is the highest priority. Any compressor can be
assigned any priority and any number of
compressors can have the same priority.
Example 1:
For a four-compressor system, that includes a
single variable speed compressor assigned as
compressor number ‘1’, it may be desirable to
ensure the variable speed compressor is
continuously utilised in any sequence
arrangement as the ‘duty’ or ‘top-up’ unit. To
achieve this assign compressor number 1 with
a higher priority than the remaining three fixed
speed compressors.
Compressor 1 (variable speed) = priority 1
Compressors 2 to 4 (fixed speed) = priority 2
Page 10
1
2
3
4
1
1
1
2
#1
A
B
C
D
#2
B
C
A
D
#3
C
A
B
D
#4
A
B
C
D
Example 3:
For a four-compressor system that includes a
variable speed compressor (compressor
number 1) and a fixed speed compressor that
is only required as an emergency backup
(compressor number 4) it may be desirable to
ensure the variable speed compressor is
always utilised first, and the backup
compressor utilised last, in any sequence
arrangement.
Compressor 1 (variable speed) = priority 1
Compressors 2 and 3 = priority 2
Compressor 4 (back-up) = priority 3
Net$ync II Conductor 4
3.7 Prefill:
1
2
3
4
1
2
2
3
#1
A
B
C
D
#2
A
C
B
D
#3
A
B
C
D
#4
A
C
B
D
Example 4:
Compressors can be separated in to rotation
groups. In this example compressors 1 and 2,
of a four-compressor system, have been set
as a high priority group and compressors 3
and 4 as a lower priority group. Compressors
1 and 2 will always be utilised first in any
sequence arrangement and will be rotated at
each ‘Rotation’ event. Compressors 3 and 4
will always be utilised as lower priority in any
sequence arrangement and will be rotated at
each ‘Rotation’ event.
1
2
3
4
1
1
2
2
#1
A
B
C
D
#2
B
A
D
C
#3
A
B
C
D
#4
B
A
D
C
The Prefill feature provides a controlled
and energy efficient method of increasing
pressure to normal operating levels at system
start. This feature avoids the inefficient
potential for all available system compressors
to start and load before pressure reaches the
normal operating level.
At system start (manual start or automated
start from standby) the Conductor 4 will only load
compressors that have been pre-set for prefill
operation, for a pre-set period of time. The
prefill time (PT) can be adjusted to suit system
characteristics. The aim is to increase
pressure to normal operational levels, using
only the pre-determined compressors, prior to
the prefill time expiring.
If normal operational pressure is reached prior
to the set prefill time, the prefill function will
automatically cease and normal operational
control begin. If normal operational pressure is
not reached by the end of the prefill time the
Conductor 4 will utilise as many available
compressors as required to achieve normal
operational pressure as quickly as possible. Normal
operational control will then begin.
Two prefill modes are available; both function
in the same way but differ in response to a
failure, or loss, of a prefill compressor.
Backup Mode: Compressor(s) can be preselected
as ‘Primary Prefill’ compressor(s) or
‘Backup Prefill’ compressor(s). If a primary
prefill compressor experiences a shutdown, or
is stopped, it is replaced by a pre-defined
backup compressor and prefill continues.
! X Standard Mode: If one or more of the
pre-defined prefill compressors experiences a
shutdown, or is stopped, the prefill function is
cancelled and normal operation begins.
To manually skip Prefill mode, press and
hold START for several seconds.
Page 11
Technical Manual
3.8 Pressure Schedule:
The Conductor 4 is equipped with a real time clock
feature and pressure schedule facility. The
‘Pressure Schedule’ function can be used to
provide automation of the system.
The pressure schedule consists of 28
individual settings that instruct the system to
change from one ‘Table’ to another, or put the
system in to ‘Standby’ mode, dependant on
time of day and day of the week. The pressure
schedule will cycle from 00:00 hours Monday
(day #1) to 23:59 hours on Sunday (day #7)
each calendar week.
P01 01.0#
01
# -
--:----
0# =
01
02
04
03
01) Day of the Week
#1 = Monday to #7 = Sunday
#8 = every working day of the week;
Monday to Friday, excluding Saturday and
Sunday.
#9 = every working day of the week.
Select “-“ (dash) and enter to delete a
setting from the schedule.
02) Hours; time of day (24hr format)
03) Minutes; time of day
04) The required table, T01 to T03, or
“-X-“ = Standby (unload all compressors).
Adjust the ‘day of the week’ sub-setting first
and then press ENTER to increment to the
next setting. Repeat until all item sub-settings
are entered. The complete ‘Pressure
Schedule’ item will not be set in Conductor 4
memory until the last sub-setting is entered. Press
ESCAPE to step back one sub-item if
required.
Page 12
Pressure Schedule menu item settings are
automatically arranged and presented in
chronological order (Monday to Sunday).
When an ‘empty’ item setting is set-up and
entered, the menu item number (01 to 28) may
automatically change; this is normal.
The ‘Pressure Schedule’ can be overridden, at
any time, from the remote input using the
auxiliary input facility or enabled/disabled from
a single User menu setting (PS).
Net$ync II Conductor 4
4. Installation
It is recommended that installation and
commissioning be carried out by an authorised
and trained product supplier.
4.1 Unit Location
The Conductor 4 is wall mounting using conventional
screw fixings. The Conductor 4 can be located remote
from the compressors but within 100m (330ft)
cable length from each compressor and within
100m (330ft) cable length from the system
pressure sensor.
System pressure will be lower than the set
‘generation’ pressure due to pressure
differential losses across air treatment
equipment. The nominal system pressure will
reduce as the air treatment differential
pressure increases.
System (Demand Side) Pressure Control:
P
P
1
4.2 Power Supply
2
A fused switching isolator must be installed to
the main incoming power supply, external to
the Conductor 4. The isolator must be fitted with
a fuse of the correct rating to provide adequate
protection to the power supply cable used (in
accordance with local electrical and safety
regulations).
P
1
P
XPM-TAC24
1
2
3
1
4
2
3
2
4
X04
N
L
E
E
VOLTAGE SELECT
X01
230Vac
N L E
1
2
3
4
X04
VOLTAGE SELECT
115Vac
Check the input voltage select link wires on
the Conductor 4’s power supply PCB, adjust if
necessary.
4.3 Pressure Sensor Location
The system pressure sensor (P) must be
located in a position that will continuously
experience pressure that is common to all
compressors.
Generation Side Pressure Control:
Ensure each compressor is equipped with
independent excess pressure shutdown; an
increase in pressure differential across air
treatment equipment can result in excess
compressor discharge pressure.
Regular routine monitoring of pressure
differential across air treatment equipment is
recommended.
4.4 Pressure Sensor Connection
The pressure sensor must be connected to
terminal X05 of the Conductor 4 using an earth
screened, two-core (0.5mm2 CSA minimum),
cable no greater than 100m (330ft) in length.
X05
-
26
25
+
P
1
2
P
+
4-20mA
P
Wire polarity is important.
Page 13
Technical Manual
4.5 Compressor Interface Q485
The ‘Q485’ is designed to interface a
compressor with the Conductor 4 using a 6-core,
earth shielded, cable no greater than 100m (330ft)
in length.
Each compressor in the system must be
assigned a unique identification number from
1 up to the number of compressors in the
system. The identification number should be
clearly indicated on each compressor for
operational reference.
For each compressor connected to the Conductor
4 utilising an ‘Q485,’ the signal wires must be
connected to the Conductor 4 terminals dedicated
for the assigned compressor reference number.
The ‘Q485’ uses a 12V to 250V input voltage
detection system and universal relay contact
control outputs (250V ‘CE’ / 115V ‘UL’ @ 5A
maximum). Integrated directly into the circuits
of an air compressor, the ‘Q485’ avoids the
need for additional relays or remote inputs.
The ‘Q485’ also acts as an electrical barrier
between the compressor and the Conductor 4
providing protection and voltage isolation.
3.5.1 Input Functions
The ‘Q485’ is fitted with a six-pin terminal C04
for compressor monitoring. The ‘Q485’ uses
two inputs (Ready and Run) to determine
compressor status. An Alarm input can be
used if compressor alarm indication is
available and required. The Alarm input is
optional and is not necessary for system
operation.
Ready Input:
C01
C02
Q485
C04
#1
C03
1
2 3
4
5
C05
6
The ‘Ready’ connection is intended to indicate
that the compressor is in a ‘started’ state, has
no operational inhibiting fault condition and is
ready to respond to Conductor 4 regulation without
manual intervention.
READY LAMP
LED 1
0V
LED 2
+V
X01
1 2
3
4
5
6
The ‘Q485’ is a DIN rail mountable module
designed to be installed within the compressor
control or switchgear area.
Each air compressor must be equipped with a
load/unload regulation system and, if not
regulated with a single electro-mechanical
pressure switch, have a facility for a remote
load/unload control with the ability to accept a
volt-free switching contact input for remote
load/unload.
Consult the air compressor manual or your
air compressor supplier/specialist for details
before installing the Conductor 4.
Page 14
ALARM
RUN
C04
READY
The READY input will accept 12V to 250V ac
(50/60Hz) or dc.
Do not connect a voltage greater than
250Vac/dc to this input.
This input must be connected to the terminals
of a ‘ready’ or ‘operational’ lamp, or other
circuit of the compressor control system, that
will be energised when the compressor is in a
started (standby or running) condition.
The voltage to this input must de-energise
when the compressor is stopped and
unavailable to produce air upon a load signal,
or the Emergency Stop button is pressed, or
when the compressor experiences a fault that
prevents the compressor from running.
Net$ync II Conductor 4
When the compressor ready lamp, or other
control circuit, is energised the ‘Q485’ will
detect the voltage and signal the Conductor 4 that
the compressor is ready and available to load and
produce air when a load request signal is
given.
Run Input:
MAIN (LINE) CONTACTOR
0V
+V
The ‘Q485’ input common terminal must
always be connected to the neutral, common
or 0V line of the applied input voltage.
Ready Input, Alternative Connection Method:
In instances where a convenient voltage signal
for a compressor ready condition is not
available the ‘Ready’ input can be connected
directly to a constant compressor control
system power supply voltage (12V to 250Vac
or dc). This will signal the Conductor 4 that the
compressor is ready and available at all times
when power is applied to the compressor. The
Conductor 4 has a built-in function to determine
when a compressor is not responding, or is in a
shutdown condition, regardless of a constant
ready signal. If the Conductor 4 requests a compressor
to run/load, but fails to detect a RUN signal
within 60 seconds, the Conductor 4 will regard the
compressor as ‘not ready’ and indicate the
compressor as not available. If a RUN signal
is detected at any time, the Conductor 4 will
automatically reset the compressor ‘not ready’
condition and re-establish control.
+Vac
ALARM
RUN
READY
C04
The RUN input will accept 12V to 250V ac
(50/60Hz) only (DC cannot be used).
Do not connect a voltage greater than
250V to this input.
12V to 250Vac must be applied to the ‘Run’
terminals when the compressor motor is
running.
This input can be connected to the control
terminals A1 and A2 (coil) of the main starter
contactor of the compressor. When the
compressor control system energises the main
contactor, the ‘Q485’ will detect the voltage
across the contactor coil terminals and signal
the Conductor 4 that the compressor is running.
Alternatively, if the main contactor coil voltage
is greater than 250Vac, a contactor auxiliary
switch can be used to apply a suitable voltage
to the ‘Run’ input terminals.
F1
MAIN (LINE) CONTACTOR
0Vac
+V
READY
Never connect the READY input positive
connection directly to the output of a control
system transformer, always connect after a
fuse or circuit breaker.
If a normally closed contact of an Emergency
Stop button is included in the compressor
power supply circuit, connect after the
Emergency Stop button contacts. This will
instantly indicate a compressor ‘not ready’
condition if the Emergency Stop button is
activated.
0V
+V
0V
AUXILIARY SWITCH
ALARM
RUN
READY
C04
In instances where a motor starter contactor is
not available or accessible, any part of a
compressor control circuit that is energised
when the compressor is running can be
monitored. For example: fan contactor or
voltage signal to a remote starter.
Page 15
Technical Manual
The ‘Q485’ input common terminal must
always be connected to the neutral, common
or 0V line of the applied input voltage.
Alarm Input (optional):
The ‘Q485’ is equipped with an alarm (or
warning) input that can be used to detect
alarm or warning conditions.
A fault, that stops the compressor, and/or
prevents the compressor from running, is
determined from the ‘Run’ and ‘Ready’ inputs;
Alarm detection is optional and is not a
requirement.
Alarm Lamp
0V
+V
3.5.2 Output Functions
The Conductor 4 will control the ‘Q485’ load/
unload relay outputs in accordance with the active
system load and unload pressure set points.
The ‘Q485’ load/unload relay contacts can be
used for compressor controllers that have
‘pressure switch’ load/unload regulation.
‘Q485’ Internal Output Circuits
C
OUT
NO
1
Load
C
Seq
IN
NO
OUT
C
IN
C
3
OUT
NC
2
SEQ
Relay
1&2
IN
NC
LOAD
Relay
3
Contacts :250Vac/dc @ 5A
maximum
C03
Alarm
Run
Ready
C04
SEQ LOAD
CONT UNL
The Alarm input will accept 12V to 250V ac
(50/60Hz) or dc.
Do not connect a voltage greater than
250Vac/dc to this input.
This input can be connected to the terminals of
an alarm lamp or other accessible part of the
control circuit that is energised when the
compressor is in an alarm condition.
If an alarm condition is experienced the
compressor alarm lamp, or alarm circuit, will
energise. The ‘Q485’ will detect the voltage
and signal the Conductor 4 that an alarm has
occurred. If the compressor has no accessible alarm
circuit, or this function is not required, the ‘Q485’
alarm terminals can be ignored.
The ‘Q485’ input common terminal must
always be connected to the neutral, common
or 0V line of the applied input voltage.
Page 16
GND
DI1
DI2
+20V
24Vac
The C01 and C02 terminal functions of the ‘Q485’
are intended to control load and unload
regulation of the compressor.
Pressure Switch Regulation:
For air compressors fitted with an electromechanical
pressure switch a six-pin terminal
C02 has been provided to enable connection
to a pressure switch that has a two wire or
three-wire connection.
When connected the pressure switch can be
switched in and out of circuit automatically. If
the Conductor 4 is stopped or experiences a
failure or loss of power, pressure control will
automatically revert back to the pressure
switch and the compressor will continue to
operate in ‘Local’ mode.
The local pressure settings of all
compressors in the system should be set in a
cascaded manner such that the system will
operate normally in the event of Conductor 4
inoperability.
Net$ync II Conductor 4
The NC (normally closed) and NO
(normally open) terminal references of the ‘Q485’
are related to internal connection
functions and should not be referenced to the
connections of a compressor pressure switch;
which will generally be in reverse order.
Remote Load/Unload Regulation:
Lethal voltages may be present on the
terminals of the air compressor pressure
switch. Isolate the air compressor power
supply before starting any work.
This terminal provides volt free contact closure
for load control and also provides volt free
contact closure for remote pressure control
enable.
Two Wire Pressure Switch Connections:
A remote load enable input provides the facility
to change the compressor load regulation from
internal control to a remote switching source.
For air compressors controllers fitted with
‘Remote/Local Pressure Regulation’ digital
inputs, a 4-pin connector C01 has been
provided.
Note: Compressors that use electronic
pressure detection but are not equipped with a
remote pressure control enable feature will not
automatically revert to local control if the Conductor 4
is stopped or experiences a fault or loss of
power.
0V
+V
LOAD
SOLENOID
Load and Sequence Connection:
C02
C
NC
NO
C
OUT
NC
NO
COMPRESSOR CONTROLLER
INPUTS
IN
Local/Remote
or
Remote Load Enable
Remote Load
Inputs Common
Three Wire Pressure Switch Connections:
LOAD
SOLENOID
0V
+V
OUT
C02
NC
C
NO
NC
C
NO
C
SEQ
C
RUN-ON
TIMER
LOAD
C01
Compressors that use electronic pressure
detection but are not equipped with a remote
pressure control enable feature will not
automatically revert to local control if the Conductor
4 is stopped or experiences a fault or loss of
power.
IN
Compressor controller inputs common
voltage may be 0V or +V.
Page 17
Technical Manual
The local/remote pressure regulation input
and/or remote load input logic of some
electronic pressure sensor type controllers are
reversed, in this instance the ‘pressure switch’
outputs (terminal C02) can be used to
establish alternative logic control connections.
For Example:
If the compressor controller ‘Local/Remote
Pressure Control’ input is a normally open
type; remote when closed, but the ‘Remote
Load’ input is a normally closed type; load
when open, the ‘Q485’ pressure switch
terminal contacts can be used to achieve the
correct switching logic.
C02
NO
OUT
C
NC
NO
IN
C
Local/Remote
common
Remote Load
common
NC
Examine the ‘Q485’ internal output circuit
diagram to establish any desired switching
logic that may differ from normal practise.
Do not attempt to utilise ‘Digital Pressure
Regulation Control’ (terminal C01) and the
‘Pressure Switch Control’ (terminal C02)
output connections at the same time for
different products. These two output functions
are internally connected and a short circuit
condition and/or malfunction may result.
The ‘Q485’ connection examples shown in
this manual are intended to provide a guide
for the majority of compressor control
systems in use. Some compressors have
variations in operation and/or function;
consult your compressor
supplier/specialist for advice.
Page 18
Service Maintenance Switch:
The ‘Q485’ is equipped with a volt-free input
(terminal C05) that can be used to remove the
compressor from Conductor 4 control, without
generating a fault condition, during short-term
maintenance or servicing periods.
C05
1
2
When the ‘Service Maintenance Switch’ input
terminal pins are connected together, using a
volt-free switching contact, the Conductor 4 will
indicate that the compressor is not available but
will not generate an Alarm, Trip or Shutdown
condition. The Conductor 4 will also remove the
compressor from the sequence strategy and
substitute with an alternative available
compressor if necessary. When the ‘Service
Maintenance Switch’ inputs are open circuit
again the compressor will automatically be
accepted back in to the sequence strategy and
will be utilised as and when next required.
The use of a ‘key switch’ is recommended for
this purpose in order to prevent the switch
contacts being inadvertently left in the closed
circuit condition after service maintenance is
complete.
DO NOT connect any external voltage
source to the pins of terminal C05.
Net$ync II Conductor 4
4.6 Auxiliary Input (Option)
4.8 RS485 Communications
The Conductor 4 is equipped with an auxiliary input;
terminals 31 and 32 (X07).
The Conductor 4 is equipped with an RS485
network communications capability using the
protocol. This facility can be used for remote
connectivity to optional networked units and
modules with Multi485 communications
capabilities.
The function of the input is menu selectable
and can be adapted for differing application
requirements.
Menu Items – S02:AI
X07
32
31
The input is designed to detect a remote ‘voltfree’
switching contact (rated for a minimum
24VDC @ 10mA).
4.7 Auxiliary Output (Option)
The Conductor 4 is equipped with a remote relay
contact output; terminals 33 and 34 (X08).
The function of the output is menu selectable
and can be adapted for differing application
requirements.
Menu Items – S02:AO
X08
R6
34
33
The remote output relay contacts are rated for
240V ‘CE’ / 115V ‘UL’ @ 5A maximum.
X06
L1
L2
L1
L2
30
29
28
27
RS485
RS485 data communications and other
low voltage signals can be subject to electrical
interference. This potential can result in
intermittent malfunction or anomaly that is
difficult to diagnose. To avoid this possibility
always use earth shielded cables, securely
bonded to a known good earth at one end. In
addition, give careful consideration to cable
routing during installation.
a) Never route an RS485 data
communications or low voltage signal cable
alongside a high voltage or 3-phase power
supply cable. If it is necessary to cross the
path of a power supply cable(s), always cross
at a right angle.
b) If it is necessary to follow the route of power
supply cables for a short distance (for
example: from a compressor Conductor 4 to a
wall along a suspended cable tray) attach the
RS485 or signal cable on the outside of an
earthed cable tray such that the cable tray
forms an earthed electrical interference shield.
c) Where possible, never route an RS485 or
signal cable near to equipment or devices that
may be a source of electrical interference (for
example: 3-phase power supply transformer,
high voltage switchgear unit, frequency
inverter drive module, radio communications
antenna).
Page 19
Technical Manual
5. COMMISSIONING
5.3 Unit Configuration
Commissioning Procedure
Before successful basic operation can be
established the following items must be set (in
the order shown) to suit installation
requirements.
When commissioning the Conductor 4, carry out
the following procedures before attempting to
start.
It is recommended that an authorised and
trained product supplier carry out
commissioning.
5.1 Physical Checks
Before applying power to the Conductor 4 ensure
that the power supply connections are correct and
secure and that the operating voltage selector
is set correctly for the power supply voltage in
use; 115Vac or 230Vac (+-10%), 50/60Hz.
Open the front panel of the Conductor 4 and check
the location of the link wire(s) connected to the
‘Voltage Selection’ terminals of the power
supply PCB. If necessary, change the link wire
locations to those illustrated for the voltage in
use.
Installation
Features and Functions; Menu Items
S02 - NC
S02 - PM
S02 - CF
Number of Compressors
Maximum Pressure Alarm
Stop Control Function
S01 - Ct
S01 - AR
S01 - RP
Real Time Clock Set
Auto Restart Enable
Rotation Interval
C02 – 01/04
Compressor #1-4
Configuration
C01 - 01/04
Compressor #1-4
Running Hours
T01 - PH
T01 - PL
T01 - Pm
T01 - SQ
T01 – 01/04
High Pressure Set Point
Low Pressure Set Point
Minimum Pressure Alarm
Sequence Algorithm
Compressor #1-4 Priority
Switch on the power supply to the Conductor 4.
5.4 Optional Features and Functions
The control program identification will be
displayed for a short period followed by the
normal operational User display.
Installation requirements may involve the
implementation of additional or optional
functions and features; implement as required.
5.2 Pressure Display
Check the displayed system pressure. If the
pressure is incorrect, or inaccurate, check the
type and range of the sensor and carry out the
pressure sensor commissioning and
calibration procedure.
Menu Navigation
Menus and Menu Items
S03 – 1O
S03 – 1R
Page 20
Sensor Offset Calibration
Sensor Range Calibration
Features and Functions; Menu Items
Net$ync II Conductor 4
6. Menu Navigation
Access Code:
Display Item Structure:
Access to adjustable menu page items is
restricted by access code. To access menu
mode pages press MENU (or UP and DOWN
together); an access code entry display is
shown and the first code character will flash.
All operational system status and values are
accessible from the normal User display. To
view status or values, that are not normally
visible on the default screen, press UP or
DOWN. All standard User display items are
view only and cannot be adjusted. The
standard User display items are regarded as
‘Menu Page 00’ items.
All adjustable value, parameter or option item
displays are grouped into ‘menu mode’ lists.
Items are assigned to a list according to type
and classification. Item lists are identified by
page number (or menu number); All adjustable
parameters and options are assigned to menu
mode pages ‘P01’ or higher.
Normal Operational Display (Menu Page P00):
At controller initialisation, all display elements
and LED indicators are switched on for three
seconds, the display will then show the
software version code for a further 3 seconds
before initialisation is complete and the normal
operating display (Page P00) is shown. In
normal operational display mode the main
display will continuously show the detected
system pressure and the Item display will
show the first item of the ‘Page 00’ menu. User
menu ‘Items’ can be selected using the Up or
Down buttons at any time. Pressing the Enter
button will lock any selected Item display and
inhibit return to the default display. When an
Item display is locked the lock key symbol will
be shown. To unlock an Item display press Up
or Down to view an alternative Item display or
press Reset or Escape. No Item values,
options or parameters can be adjusted in page
‘P00’. If a fault condition occurs the fault code
becomes the first list item and the display will
automatically jump to display the fault code.
More than one active fault code item can exist
at any one time and can be viewed by
pressing UP or DOWN. The most recent
‘active’ fault will be at the top of the list.
0000
Use UP(plus) or DOWN(minus) to adjust the
value of the first code character then press
ENTER. The next code character will flash;
use UP or DOWN to adjust then press
ENTER. Repeat for all four code characters.
If the code number is less than 1000 then the
first code character will be 0(zero). To return
to a previous code character press ESCAPE.
When all four code characters have been set
to an authorized code number press ENTER.
An invalid code will return the display to
normal operational mode; page ‘P00’.
Access Code Accepted
Access Code Rejected
Access Code Timeout:
When in menu mode, if no key activity is
detected for a period of time the access code
is cancelled and the display will automatically
reset to the normal operational display.
Menu Mode Navigation:
In menu mode the menu ‘page’ number will be
highlighted at the top of the display.
P00
To select a menu ‘page’ press UP or DOWN.
To enter the highlighted menu ‘page’ press
ENTER; the first item of the menu ‘page’ will
be highlighted. Press UP or DOWN to scroll
though the selected menu ‘page’ items.
Page 21
Technical Manual
To select an item value or parameter for
modification press ENTER; an adjustment
screen for the item will be displayed.
The value or option can now be modified by
pressing UP(Plus) or DOWN(Minus). To enter
a modified value or option in to memory press
ENTER.
Page 0
Page 1
Page 2
Item 1
Item 2
Item 3
Item 4
Item 5
Item 6
Value
Value
Value
Value
Value
Value
Page 3
Page 4
Page 5
Item 1
Item 2
Item 3
Item 4
Item 5
Value
Value
Value
Value
Value
Item 1
Item 2
Item 3
Item 4
Item 5
Value
Value
Value
Value
Value
Press ESCAPE at any time in menu mode to
step backwards one stage in the navigation
process. Pressing ESCAPE when the page
number is flashing will exit menu mode and
return the display to normal operational mode.
Page 1
Page 0
Page 2
Item 1
Item 2
Item 3
Item 4
Item 5
Item 6
Value
Value
Value
Value
Value
Value
Page 3
Page 4
Page 5
All menu items have a unique reference
consisting of the menu page ID (a) and the
menu page item number (b). Each item in a
menu also has a unique two alphanumeric
character code (c). All three references are
visible at the top of every menu item display.
a
b
P01 01.02
c
AB
Some menu items may consist of several
individual settings. Each setting of the menu
item is also referenced as a sub-item number.
For example: P01-01.02 references sub-item
‘02’ of menu item ‘01’ in menu page ‘P01’.
Sub-item settings, where applicable, are
always displayed together on the same ‘Item’
adjustment display screen. Most menu items
are single value or single option only in which
case the single item is referenced as sub-item
number ‘01’ (for example: P01-01.01).
Page 22
Press and hold RESET for several
seconds at any time to immediately exit menu
mode and return to the normal operational
display. Any value or option adjustment that
has not been confirmed and entered into
memory will be abandoned and the original
setting maintained.
The Conductor 4 will retain an ‘access code’
for a short period after menu exit allowing the menu
structure to be re-entered without the need to
re-enter the access code again. To
immediately clear access code retention press
and hold RESET for several seconds.
A ‘locked’ symbol displayed with any item
indicates the item is locked and cannot be
modified. This will occur if the Item is view only
(not adjustable) or in instances where the item
cannot be adjusted while the Conductor 4 is in an
operational state; stop the Conductor 4 first.
Net$ync II Conductor 4
6.1 Menus:
Pressure Schedule
USER Level Menus (0011)
TABLE #1
T01
PH H
PL L
Pm M
SQ S
01 C
to
04 C
01 S
to
28 S
igh Pressure Set Point
ow Pressure Set Point
inimum Pressure Alarm
equence Rotation Mode
ompressor #1 Priority
ompressor #4 Priority
TABLE #2
T02
PH H
PL L
Pm M
SQ S
01 C
to
04 C
P01
igh Pressure Set Point
ow Pressure Set Point
inimum Pressure Alarm
equence Rotation Mode
ompressor #1 Priority
ompressor #4 Priority
TABLE #3
chedule Setting #1
chedule Setting #28
Prefill
P02
PF P
PT P
PP P
01 C
to
04 C
refill Function
refill Time
refill Pressure
ompressor #1
Conductor 4
Q485
ompressor #4
User Configuration
S01
Ct R
PS P
AR A
RP R
TS D
BL D
eal Time Clock Set
ressure Schedule Enable
uto Restart Enable
otation Interval
efault Table Select
isplay Backlit Adjust
T03
PH H
PL L
Pm M
SQ S
01 C
to
04 C
igh Pressure Set Point
ow Pressure Set Point
inimum Pressure Alarm
equence Rotation Mode
ompressor #1 Priority
Compressor Running Hours
C01
01 C
to
04 C
ompressor #1 Running Hours
ompressor #4 Running Hours
ompressor #4 Priority
Fault Log
E01
01 F
to
15 F
ault Log #1 (most recent)
ault Log #15
Page 23
Technical Manual
SERVICE Level Menus (0021)
Configuration
S02
P> P
NC N
PM M
CF S
TO T
DA D
PC P
AI A
AO A
ER E
ressure Units
umber Of Compressors
aximum Pressure Alarm
top Control Function
olerance
amping
ressure Change Time
uxiliary Input Function
uxiliary Output Function
rror Log Reset
Auxiliary Box Monitoring
S03
01 A
to
12 A
BT R
uxiliary Box #1 Enable
uxiliary Box #12 Enable
S485 Timeout
Sensor Calibration
S04
1O P
1R P
ressure Offset
ressure Range
Compressor Configuration
C02
01 C
to
04 C
Page 24
ompressor #1 Configuration
ompressor #4 Configuration
High Level Menus (0032)
Diagnostics
D01
D1 D
to
D8 D
D9 D
DA D
R1 O
to
R6
A1 A
A2 A
A3 A
Ao
igital Input #1 (Di 1)
igital Input #8 (Di 8)
igital on Analogue Input #2 (Ai2)*
igital on Analogue Input #3 (Ai3)*
utput Relay #1 (R1)
Output Relay #6 (R6)
nalogue Input #1 (Ai1)
nalogue Input #2 (Ai2)*
nalogue Input #3 (Ai3)*
Analogue Output (Ao)
Net$ync II Conductor 4
6.2 Menu Items:
P01
T01
08
01
02
03
04
04
PH
PL
Pm
SQ
1
7.0
6.8
0
TR
04
bar
bar
bar
( )
Tables
T0# – PH
High Pressure Set Point
The ‘upper’ or ‘unload’ pressure set point that
will be used when the ‘Table’ is active.
T0# - PL
Low Pressure Set Point
The ‘lower’ or ‘load’ pressure set point that will
be used when the ‘Table’ is active.
T0# - Pm
Minimum Pressure Alarm
The miniumum pressure ‘Warning’ or ‘Alarm’
level that will be used when the ‘Table’ is
active.
T0# - SQ
Sequence Strategy
The sequence control strategy mode that will
be used when the table is active.
T0# - 01
Compressor #1 Priority
The ‘priority’ setting for compressor number #1
that will be used when the table is active.
T0# - 02
Compressor #2 Priority
The ‘priority’ setting for compressor number #2
that will be used when the table is active.
T0# - 03
Compressor #3 Priority
The ‘priority’ setting for compressor number #3
that will be used when the table is active.
T0# - 04
Compressor #4 Priority
The ‘priority’ setting for compressor number #4
that will be used when the table is active.
# = Table 01, 02 or 03
Priority Settings:
: compressor(s) can be inhibited from use
while a table is active by selecting “X” priority.
The compressor will be held offload and will
not be utilised under any circumstances.
28
01
02
03
04
28
01
02
03
04
- . --:-- . --:-- . --:-- . --:-- . --:--
-----------
Pressure Schedule
P01 – 01 to 28
The ‘Pressure Schedule’ items 01 to 28
P02
07
01
02
03
04
04
PF
PT
PP
01
X
X
- MIN
0 BAR
X
Prefill
P02 - PF
Prefill Function
Determines the ‘Prefill’ strategy or function that
will be used at system startup.
!
= Prefill function OFF
= Prefill, Back-up Mode
X = Prefill, Standard Mode
P02 - PT
Prefill Time
Sets the maximum time allowed for a system
‘Prefill’ at startup.
P02 - PP
Prefill Pressure
If pressure is at, or above, this setting at
system startup the prefill function will be
abandoned immediately and normal pressure
control and sequence strategy will be
implemented. This setting is intended to inhibit
‘Prefill’ operation if pressure is already at an
acceptible level at system startup.
P02 – 01 to 04 Compressor #1 to #4
The function of compressor #1 to #4 during
the ‘Prefill’ period.
!
= do not use
= use for primary prefill
X = use for emergency backup
Page 25
Technical Manual
1
C01
01
02
03
04
01
02
03
04
0
0
0
0
hrs
hrs
hrs
hrs
Control - Equal Hours Run Mode
Record of detected ‘running’ hours for each
compressor. The run hours value can be
manually adjusted, at any time, to match the
running hours meter/display value of each
compressor.
C01 - 01
to
C01 - 04
Run Hours; Compressor 1
Run Hours; Compressor 4
C02
01
02
03
04
01
02
03
04
I-PCB
I-PCB
I-PCB
I-PCB
Installation – Compressor Connections
The type, method of connection, and the
control functionality, of each compressor
connected to the Conductor 4.
C02 - 01
to
C02 - 04
Compressor 1
Compressor 4
C02 01.01
1
01
Q485
10 sec
+V=!
Compressor connectivity and functionality
settings.
Page 26
Compressor Connectivity:
Q485
Fixed speed, load/unload;
connected to Conductor 4 using ‘Q485’
module. (0/100%) 0% or 100% regulation
I-485
Fixed speed, load/unload; connected
to Conductor 4 on Multi485 network.
(0/100%) 0% or 100% regulation
Compressor Start Time:
Set to match the time that the compressor
takes to start it’s main motor and load. This
time will typically be equivalent to the
compressors ‘Star/Delta’ time. If unknown, the
time can be established by experiment;
manually start the compressor, from a stopped
condition, and determine the time from
pressing the start button until the compressor
loads and contributes capacity output to the
system.
This time is used by the Conductor 4 for
‘staggered starting’ of multiple compressors and
other operational calculations. An accurate time is
important for successful Conductor 4 operation.
Q485 Alarm Input:
For ‘Q485’ connectivity applications the
voltage detection function for the ‘Q485’ Alarm
input can be inverted.
+V=!
An Alarm condition is generated if the
‘Q485’ Alarm input detects a voltage
between 12-250Vac/dc (default).
0V=!
An Alarm condition is generated if the
‘Q485’ Alarm input detects no voltage.
Net$ync II Conductor 4
E01
-: --- . -E : ERR . 01
-:--- . --:--- . --:--- . --
15
01
02
03
04
E01 – 01 to 15
06
08
08
08
08
BL
Ct
PS
AR
RP
5
1 . 18:00
X
9 . 00:00
Features and Functions
Error Log; presented in chronological order;
entry 01 = most recent.
Each error log item will show the error code.
To view details for the selected error log item
press ENTER.
E01 01.01
E: ERR.01
16/05/2006
14:25
The first information display shows the:
a) The Error Code
b) Error Code symbols (if applicable)
c) The date the error occurred
d) The time the error occurred
e) The active operational functions of the
P4 at the time the error occurred;
(see: Conductor 4 Status Display)
To return to the main error log menu screen
press ESCAPE.
To view the second information screen press
ENTER.
E01 01.01
2
3
S01 - Ct
Real Time Clock Set
Adjustment for the internal real time clock.
(Hours, Minutes, Date, Month, Year)
The ‘Day of the Week’ (1= Monday to
7=Sunday) is automatically calculated and set
in accordance with the Day, Month and Year.
S01 - PS
Pressure Schedule Enable
= inhibit Pressure Schedule
= enable Pressure Schedule
1
1
S01
4
The operational status of each compressor, at
the time the error occurred, is displayed
symbollically (see: Compressor Status
Displays).
To return to the first information screen press
ENTER or ESCAPE.
S01 - AR
Auto Restart Enable
= inhibit Power Failure Auto Restart
= enable Power Failure Auto Restart
The Conductor 4 will only automatically restart
when power is restored if the Conductor 4 was
in an operational ‘Started’ state when the power
loss or disruption occurred.
S01 - RP
Rotation Interval
Sets the sequence ‘Rotation’ interval or time.
S01 - TS
Default Table Select
Determines the ‘Table’ that will be used by
default when ‘Pressure Schedule’ is not active
and no table is selected remotely on a digital
input.
S01 - BL
Display Backlight Adjust
Adjustable: 1 to 7, default 5
The display will temporarily increase
brightness by 2 levels when a key is pressed
and return to normal setting after a period of
no keypad activity. The default display
backlight level has been set to enable a
‘continuous use service life’ in excess of
90000 hours while providing good readability
in all ambient light conditions. LCD display
‘service life’ is defined as the time period
before the backlight reduces to 50% of initial
brightness.
Page 27
Technical Manual
Typically the display will remain usable for a
much longer period for time. Adjusting the
backlight to high levels will reduce service life.
S02 - AI
S02 08.01
S02
10
01
02
03
04
ER
P>
NC
PM
CF
X
BAR
4
10.0 BAR
X
Pressure Control; Tables
S02 - P>
Pressure Units
Selects the display pressure units:
Bar, psi or kPa.
Auxiliary Input Function
01:T1
AI
NO
The function of the Auxiliary input.
01:T1
02:T2
03:T3
04:TS
05:SS
06:AA
07:AR
Override > Table 1
Override > Table 2
Override > Table 3
Override > Standby
Remote Start/Stop **
Remote Alarm (always active)
Remote Alarm (active when unit
running, inhibited when unit stopped
or in Standby)
Remote Trip (always active)
Remote Trip (active when unit
running, inhibited when unit stopped
or in Standby)
S02 - NC
Number of Compressors
Sets the number of compressors connected
to, and controlled by, the Conductor 4. This value
must be set to match the system at commissioning.
08:TA
09:TR
S02 - PM
Maximum Pressure Alarm
High pressure ‘Fault’ level. This value remains
active at all times and is the same for all
‘Tables’. Set just below system pressure relief
value(s) and below the maximum system
pressure rating of all air system components
NO (Normally Open)
The selected function is activated when the
input is closed circuit (input terminals are
connected together by remote volt-free
contacts)
S02 - CF
Stop Control Function
Determines if the Conductor 4 maintains control
of the compressors when the Conductor 4 is stopped.
= Stop: return pressure control to the
compressors.
= Standby: maintain control and
continouosly hold compressors ‘off load’.
S02 - TO
Tolerance
The pressure control ‘Tolerance’ band setting.
S02 - DA
Damping
The pressure control ‘Damping’ setting.
S02 - PC
Pressure Change Time
The time that the Conductor 4 will implement a
smooth and controlled change from one ‘target’
pressure level to another when a table change
is made.
Page 28
NC (Normally Closed)
The selected function is activated when the
input is open circuit (input terminals are open
circuit)
** Remote Start/Stop
Remote Start and Stop commands are
activated by a ‘change of state’ of the Auxiliary
input (a transition from open circuit to closed
circuit or visa versa). The local panel Start and
Stop functions remain active; both local and
remote Start/Stop functions will function. The
most recent command, from a local or remote
source, will override any previous command,
from a local or remote source.
The Remote Start/Stop function can be
selected for normally open (NO) or normally
closed (NC) operation. For ‘fail safe’ operation
select normally closed (NC); the Conductor 4 will
start if the Auxiliary input changes state from ‘open
circuit’ to ‘closed circuit’ and stop if the input
changes state from ‘closed circuit’ to ‘open
circuit’. Any remote cabling or switch contact
failure that results in an open circuit condition
will stop the Conductor 4.
Net$ync II Conductor 4
S02 - AO
Auxiliary Output Function
S02 09.01
01:AF
AO
NO
The contacts of the Auxiliary output relay
are rated for 115V (UL), 240V (CE), at 5 Amps
maximum.
S02 - ER
Error Log Reset
Clears and resets the ‘Error Log’. Adjust the
item setting to ‘RST’ and press ENTER. The
setting will return to normal and all existing
entries in the error log will be perminantly
deleted.
The function of the Auxiliary output ‘volt-free’
relay contacts.
01:AF
02:AT
03:CF
04:CA
05:CT
06:SF
07:ON
08:SA
09:SP
10:LP
11:HP
12:PO
Any Fault
Any Alarm (Warning), Shutdown (Trip)
or Compressor Not Available.
Any Trip
any Shutdown (Trip) or Compressor
Not Available.
Compressor Fault
Any compressor Alarm (Warning),
Shutdown (Trip) or Not Available
Compressor Alarm
Any compressor Alarm (Warning)
Compressor Trip
Any compressor Shutdown (Trip) or
Not Available
System Fault
Any unit Alarm (Warning) or Shutdown
(Trip)
System On
Unit Started and Active, including PreFill period and Standby (not active
when unit stopped)
System Active
Unit Active, including Pre-Fill period
(not active when unit stopped or in
standby)
System Pressure Control Active
Unit Active excluding Pre-Fill (not
active when unit stopped, or in
standby, or in Pre-Fill mode)
Low Pressure Alarm
High Pressure Alarm
Pressure Control Override
Normal, or Pressure Schedule’
operation is being manually
overridden
S03
13
01
02
03
04
60 sec
X
X
X
X
BT
01
02
03
04
S03 – 01/12
I/O Box Monitoring
= Disabled
= Enabled
The P4 will monitor the selected I/O Gateway and
display any ‘Fault’ detected on the I/O Gateway
inputs; dependant on I/O Gateway set-up.
Examine the I/O Gateway manual for details.
S03 – BT
Communications Timeout
The general operation of the selected I/O Gateway
is also monitored. If the I/O Gateway fails to
communicate on the RS485 network within the
set ‘Communications Broadcast Timeout’ (BT)
the Conductor 4 will display an I/O Gateway RS485
communications Error.
NO (Normally Open)
The auxiliary output relay contacts are
normally open and will close circuit when the
set function is active or true.
NC (Normally Closed)
The auxiliary output relay contacts are
normally closed and will open circuit when the
set function is active or true; or in the event of
a Conductor 4 shutdown or power supply disruption.
Page 29
Technical Manual
2) Calibration Procedure
S04
01 1O
02 1R
S04 - 1O
S04 - 1R
0 BAR
16.0 BAR
Pressure Sensor Offset
Pressure Sensor Range
Pressure Sensor Calibration Procedure:
1) Commissioning
Initially set the ‘Offset’ (minimum) to the
minimum or lowest pressure value for the
sensor. Set the ‘Range’ (maximum) to the
maximum or highest value for the sensor.
For example:
If the pressure sensor is a 0 to 16bar (0 to
232psi) type set the ‘offset’ to 0bar (0psi) and
the ‘Range’ to 16.0bar (232psi).
If the sensor is a –1.0(minus one bar.g) to
15.0bar type, set the ‘offset’ to –1.0bar (minus
one bar) and the range to 15.0bar.
Note: The ‘range’ value equates to the
maximum value not the scope of the sensor.
Execute the calibration procedure.
Page 30
a) Offset: Expose the sensor to atmosphere
and adjust the ‘offset’ setting (if necessary)
until the detected pressure display shows
0.0bar (0psi).
b) Range: Apply an accurately know pressure
to the pressure sensor and adjust the ‘Range’
setting until the detected pressure display
matches the applied pressure. An applied
pressure equal too, or greater than, the
nominal system working pressure is
recommended.
The detected pressure is displayed with the
calibration menu item and will change to
match the new calibration setting as the
setting is adjusted.
There is no need for the applied pressure
to be static; it can be dynamic and changing.
This enables calibration to be carried out on a
fully operational system where changing
system pressure can be accurately verified
from another source.
Correct pressure sensor set-up and
calibration is critical for successful system
operation. It is recommended that pressure
sensor calibration is examined, and adjusted if
necessary, annually or a pre-determined
routine periodic basis.
Net$ync II Conductor 4
D01
Diagnostics
D01
20
01
02
03
04
Ao
D1
D2
D3
D4
4.00 mA
0
0
1
2
The Conductor 4 is equipped with comprehensive
diagnostic functions. Each input can be
examined individually and each output can be
manually activated or manipulated individually.
AirMaster T1 Controller Diagnostics:
D1 D
D2 D
D3 D
D4 D
D5 D
D6 D
D7 D
D8 D
igital Input 1
igital Input 2
igital Input 3
igital Input 4
igital Input 5
igital Input 6
igital Input 7
igital Input 8
ON
OFF
Pulsing
Relay Outputs:
Each relay output can be energised and deenergised
manually by selecting the item. Use
UP(plus) and DOWN(minus) to adjust and
ENTER.
Analogue Inputs:
The item will alternate between the detected
value and the electrical measurement on the
controller input terminals. An independent
measuring device can be used to check the
displayed electrical measurement.
A1:
A2:
A3:
System Pressure, 4-20mA
Digital Input #9, voltage
Auxiliary Digital Input, voltage
Analogue inputs 2 and 3 are equipped with
ACM modules designed to conform to the
standard specification for a controller digital
input. The inputs are utilised as digital inputs
on the Conductor 4.
Analogue Output:
The analogue output can be manually
adjusted. Use UP(plus) and DOWN(Minus) to
adjust and ENTER. The output will return to
normal operational value upon menu exit.
D9 Digital signal detected on A2
DA D igital signal detected on A3
------------------------------------------------------------R1 R elay Output 1
R2 R elay Output 2
OFF
R3 R elay Output 3
R4 R elay Output 4
ON
R5 R elay Output 5
R6 R elay Output 6
------------------------------------------------------------A1 A nalogue Input 1
bar <> mA
A2 A nalogue Input 2
v
A3 A nalogue Input 3
v
------------------------------------------------------------Ao A nalogue Output
0.0 to 20.0mA
Digital Inputs:
OFF (open circuit)
ON (closed circuit)
Pulsing
The pulse signal from an ‘Q485’ is 0V to
24VDC at 50/60Hz. A typical DC voltage
meter, or multimeter, will detect this as 12VDC
+-4V.
Page 31
Technical Manual
7. OPERATION
7.1 User Interface
12:00
#1
a
b
Display:
a
d
f
g
7.0
1
b
BAR
1
2
3
10:35
4
A
B
C
D
System Pressure Value
System pressure Units
Unit Status
Unit Active Functions
Time
Compressor Number
Compressor Sequence Assignment
Compressor Status
Keypad:
d
e
a
e
Press Up or Down to return to the
Sequence/Status display.
7.3 Unit Status:
System Pressure:
Below the active lower, or load, pressure
set point
Between the lower, or load, and upper, or
unload, active pressure set points
Above the upper, or unload, active
pressure set point
Unit Status:
Stopped
Standby
Started and Running
Unit Run Indicator (Green LED)
b
f
g
c
Time of day (24hrs)
Day of the week
#1 = Monday to #7 = Sunday
Increasing to normal operational levels
(Prefill, target pressure change or at
system start)
h
a)
b)
c)
d)
e)
f)
g)
h)
a)
b)
c
a) Start
b) Stop
c) Reset
d) Escape
e) Up (Plus)
f) Down (Minus)
g) Enter
7.2 Sequence Rotation:
To view when the next automated sequence
rotation will occur press Down:
OFF – Not Active, Stopped
Slow Flash: Active, Standby Mode
ON – Active, Running
Unit Fault Indicator (Red LED)
Flash: Shutdown (Trip)
ON – Alarm (Warning)
The P4 fault indicator does not indicate
compressor fault states.
7.4 Compressor Status:
Standby (or Auto Restart)
Running Offload
Running Loaded
Inhibited from use in Table
Service Maintenance Active
Alarm (Warning)
Not Available (Stopped, Shutdown, Trip)
Page 32
Net$ync II Conductor 4
7.5 Unit Functions:
Press Escape to return to the normal
operational display screen.
Operating Mode:
Sequence Rotation:
Equal Hours Run
P00
First In First Out
Timer Rotation
#4
18:00
18 / 05 / 2006
Active Functions:
Power Failure Auto-Restart
ABCD
Standby
1
1 Table #1
2
2 Table #2
3
3 Table #3
Remote Manual Override
Prefill Function
Day of the week (#4: Thursday), the
time of day (18:00) and the date (18/05/2006)
of the next automated sequence rotation
event.
The active ‘mode’ of operation
Pressure Schedule
Function Inhibited (manual override)
“ABCD” The current active rotation sequence
assignment.
7.6 Information Displays
To view detailed information applicable to the
selected User menu display item press Enter:
7.7 Manual Sequence Rotation:
Status Display:
P00
#4
1
18:00
T02
7.0
6.8
6.0
bar
bar
bar
If the ‘Pressure Schedule’ feature is
active; shows the day of the week (#4), the
time of day (18:00) and the table to be used
(T02) of the next scheduled instruction to be
executed.
1
Press Escape to return to the normal
operational display screen.
The sequence assignment can be manually
rotated at any time. When viewing the
‘Sequence Rotation’ information screen press
Enter:
The manual rotation symbols will
appear and flash. Press Enter to execute a
manual rotation or Escape to abandon the
manual rotation.
Automated sequence rotation is not disrupted
by a manual rotation; the next scheduled
automated sequence rotation event will still
occur.
The current active ‘Table’ (T01)
Upper, or unload, pressure set point
Lower, or load, pressure set point
Minimum pressure Alarm (Warning)
Page 33
Technical Manual
7.8 Compressor Identification
Each compressor connected to the Conductor 4
will have a unique assigned compressor
identification number; starting at compressor 1
increasing sequentially to the number of
compressors connected to the Conductor 4.
To manually skip the Prefill function, press
and hold Start for several seconds.
When Prefill is complete, if applicable, the
Conductor 4 will enter normal operating mode.
The Conductor 4 will operate in accordance with the
parameters and options set in the active
‘Table’.
Tables
1
2
3
4
7.9 Stop:
To stop the Conductor 4 press Stop.
The Conductor 4 will respond dependant on
set-up: PC=0) 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).
PC=1) The Conductor 4 will hold each compressor
in an offload state. If the compressor is equipped
with a main motor run-on-time function the
compressor will run offload for a period of time
and then stop in to a ‘standby’ or ‘auto restart’
state.
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 Conductor 4.
7.10 Start:
To start the P4 press Start.
If the Prefill function is enabled, and system
pressure is below the set prefill pressure, the
system will enter Prefill mode for the set Prefill
time.
Prefill
Page 34
Each compressor in the system must be
started (running or in a standby or auto restart
condition) before Conductor 4 control of the compressor
can be established. The Conductor 4 will not start a
compressor that is in a stopped condition.
7.11 Power Failure Auto-Restart
If the power failure auto-restart function is
enabled the Conductor 4 will automatically start,
when power is restored after a disruption or failure, if
the Conductor 4 was in a ‘started’ state when the
power disruption or failure occurred.
The Conductor 4 will not automatically restart if
the Conductor 4 was in a stopped state when the
power disruption or failure occurred.
7.12 Failure Mode
If the Conductor 4 experiences a disruption to
normal control, or a Conductor 4 shutdown fault
occurs, 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).
7.13 Reset
To reset a Conductor 4 Alarm (Warning) or
Shutdown condition press Reset.
Compressor Alarm (Warning) conditions are
automatically reset when the condition has
been resolved and reset on the compressor.
Compressor Not Available (Shutdown, Trip)
conditions are automatically reset when the
condition has been resolved and reset on the
compressor; and the compressor has been
restarted.
Net$ync II Conductor 4
7.14 Fault Codes:
In the event of a unit or system ‘Fault’ the
Conductor 4 will display a fault code. The fault
code becomes an item in the User operational
display menu. If more than one ‘active’ fault
occurs each will be displayed as a separate
item in the operational User menu; press Up
or Down to view all active fault codes or to
view the normal status display.
Alarm (Warning)
Shutdown (Trip)
Fault codes are separated in to unit faults
‘ERR’ and system Alarms (Warning) ‘SYS’.
Each fault type has a unique numeric code.
ERR.01 ERR.04 Pressure Sensor
Compressor fault states are displayed as
part of the normal operational status display
and do not generate fault codes. Examine the
applicable compressor unit to establish the
nature or description of the detected fault
condition.
Special Controller Fault Codes:
E0836 PLL Unlock; Internal failure or
excessively high external
electrical interference
E0866 Controller internal power
supply fault
E5000 Internal memory map error
E5001 Internal memory failure
To Display the Software Version:
Press and hold Reset then press Escape.
The clock time display will change to show the
software version ID (example: “E01”).
Internal 24V Fault
ERR.05 Emergency Stop
ERR.06 Real Time Clock Error
SYS.01 (PM)
Excess Pressure
SYS.02 Min Pressure (Pm)
SYS.04 Insufficient Capacity
SYS.05 Remote Alarm (Warning)
Auxiliary Input Function ‘AA’
SYS.06 Remote Alarm (Warning)
Auxiliary Input Function ‘AR’
SYS.07
Remote Trip (Shutdown)
Auxiliary Input Function ‘TA’
SYS.08 Remote Trip (Shutdown)
Auxiliary Input Function ‘TR’
Page 35
Technical Manual
8.0 Parts List
Item Part No. Description
2014000024
- - 1 2 3 4 Net$ync II Conductor 4 Kit
Net$ync II Conductor 4
Manual, User CD
Unit, Controller
Unit, XPM-TAC24
PCB, Terminal
Gland, Set - Pg13.5
5
2014000029
6
2014000042
Module, Q485
Sensor, Pressure
4-20mA, 232psi (16bar)
2
3
1
20mm
IEC
4
5mm
5
Qty
Part No.
10
10 10 Q485
Description
IEC Fuse T1.0A
IEC Fuse T1.6A
IEC Fuse T3.15A
Mounting Dimensions:
9.0 Technical Data
24mm
Dimensions Weight Mounting Enclosure Supply Power Temperature Humidity 6
291mm x 241mm x 152mm
6.4kg (14lb)
wall, 4 x screw fixings
IP54, NEMA 12
230Vac +/- 10%
115Vac +/- 10%
50VA
0°C to 46°C (32°F to 115°F)
95% RH non-condensing
238mm
24mm
188mm
236mm
8mm Ø
286mm
Page 36
Net$ync II Conductor 4
10.0 Wiring Diagram
C010
C019
X02
C01/3
X07
L2 L1 RS485#1
X03
R2
24Vac
C020
SEQ
C022
C023
R4
10k
C025
C013
C027
C014
C028
C015
R3
X01
2 24Vac
SEQ
150k
C012
C026
R1
C06
C019
C024
C01/4
C034
C018
C021
C012
R6
C023
C027
C018
C029
C030
C016
C033
C017
C034
10k
C022
C026
1
C018
C031
XPM-TAC24
2
X01
L
1
X02
C028
X03
1
2
C016
7
C032
10k
24Vac
0Vac
C029
0VDC
N
E
E
Multi485
C010
C017
C024
150k
24Vac
X02
C011
10k
R-SEQ
C016
C021
C025
C015
X01
C027
C015
8 9 10 11 12
C026
C019
6
C025
C03
C014
2 3 4 5
C024
C04
C013
+
L2 L1
RS485#2
XPM485
C023
C012
-
C022
C011
GND
C021
24Vac
C020
X04
X08
C+
1
2
3
4
5
6
7
8
R5
C09
C09
C010
GND
X09
C09
X07
C08
C08
X05
C07
Ai3
C08
C07
X04
+VDC
SEQ
GND
X03
C07
31 32
C06
C06
27 28 29 30
C05
Ai2
25 26
3
+VDC
19 20 21 22 23 24
4
C05
13 14 15 16 17 18
C04
C04
2
Ao
C03
Ai1
1
X05
X06
A-GND
+VDC
X06
C01
C03
X08
33 34 35 36
Terminal PCB
1
T1-56-321-R6-CB
0Vac - earthed
N E L
230Vac 10%
115Vac 10%
Page 37
Technical Manual
Connection Diagram:
33 34 35 36
Terminal PCB
X08
240V 'CE' / 115V 'UL' @ 5A maximum.
X07
Auxiliary Input #1
- Ai1 System
L1
L2
100m (330ft) max
Pressure
+20VDC
Di5 Ready/Run
+
5
Ai2 Alarm/Serv. 4
3
- GND
2
R5 LOAD
1
R1 SEQ
+
4-20mA
6
Q485 4
X06
L1
L2
Multi485
L1
L2
X05
330ft (100m) max
X04
19 20 21 22 23 24
25 26
27 28 29 30
31 32
Auxiliary Output #1
100m (330ft) max
4
6
Di4 Ready/Run 5
Di8 Alarm/Serv. 4
3
- GND
2
R4 LOAD
1
SEQ
R1
Q485 3
+20VDC
X03
13 14 15 16 17 18
I-PCB 6-core
100m (330ft) max
3
6
Di3 Ready/Run 5
Di7 Alarm/Serv. 4
3
- GND
2
R3 LOAD
1
R1 SEQ
Q485 2
X02
+20VDC
7
8 9 10 11 12
I-PCB 6-core
100m (330ft) max
2
I-PCB 6-core
1
6
Q485 1
X01
2 3 4 5
6
+20VDC
Di2 Ready/Run 5
Di6 Alarm/Serv. 4
3
- GND
2
R2 LOAD
1
R1 SEQ
100m (330ft) max
I-PCB 6-core
Page 38
1
Net$ync II Conductor 4
XPM-TAC24
Power Supply Module
BLACK
BLUE
ORANGE
BROWN
WHITE
RED
GREEN
VIOLET
1
T3.15A T1.6A
T1.6A
T1.0A
FH4
FH3
FH2
FH5
2
3
4
X04
1
VOLTAGE SELECT
230V
2
3
4
230V +-10%
115V
115V +-10%
IEC
5x20mm
T1.0A
X03
2
1
X02
1
2
3
N L
24Vac/2
earthed
4
2
24Vac/1
isolated
E
FH1
X01
E
NL E
Page 39
Technical Manual
Net$ync II
Conductor 4 Commissioning Form
Customer
Contact
Customer Ref:
Phone
Internal Ref:
Installation/Site
Commission Date
Page 40
Commission Engineer
Ser No.
Software
3
#1
bar m /min
kW VA Hz
Comp #1 Manufacturer
Comp #1 Model/Type
Comp #1 Working Pressure
Comp #1 Full Load Capacity
bar/psi
m3/min
#2
bar m3/min
kW VA Hz
Comp #2 Manufacturer
Comp #2 Model/Type
Comp #2 Working Pressure
Comp #2 Full Load Capacity
bar/psi
m3/min
#3
bar m3/min
kW VA Hz
Comp #3 Manufacturer
Comp #3 Model/Type
Comp #3 Working Pressure
Comp #3 Full Load Capacity
bar/psi
m3/min
#4
bar m3/min
kW VA Hz
Comp #4 Manufacturer
Comp #4 Model/Type
Comp #4 Working Pressure
Comp #4 Full Load Capacity
bar/psi
m3/min
T01
T01
T01
T01
T01
T01
T01
T01
PH
PL
Pm
SQ
01
02
03
04
High Pressure Set Point
Low pressure Set Point
Minimum Pressure Alarm
Sequence Rotation Mode
Comp #1 Priority
Comp #2 Priority
Comp #3 Priority
Comp #4 Priority
T02
T02
T02
T02
T02
T02
T02
T02
PH
PL
Pm
SQ
01
02
03
04
High Pressure Set Point
Low pressure Set Point
Minimum Pressure Alarm
Sequence Rotation Mode
Comp #1 Priority
Comp #2 Priority
Comp #3 Priority
Comp #4 Priority
T03
T03
T03
T03
T03
T03
T03
T03
PH
PL
Pm
SQ
01
02
03
04
High Pressure Set Point
Low pressure Set Point
Minimum Pressure Alarm
Sequence Rotation Mode
Comp #1 Priority
Comp #2 Priority
Comp #3 Priority
Comp #4 Priority
EHR
EHR
EHR
FIFO
FIFO
FIFO
TR
TR
TR
bar/psi
bar/psi
bar/psi
bar/psi
bar/psi
bar/psi
bar/psi
bar/psi
bar/psi
Net$ync II Conductor 4
S01
S01
S01
S01
S01
Ct
PS
AR
RP
TS
Real Time Clock Set
Pressure Schedule Enable
Auto Restart Enable
Rotation Interval or Time
Default Table
S02
S02
S02
S02
S02
S02
S02
S02
S02
P>
NC
PM
CF
TO
DA
PC
AI
AO
Pressure Units
Number of Compressors
Maximum Pressure Alarm
Stop Control Function
Tolerance
Damping
Pressure Change Time
Auxiliary Input Function
Auxiliary Output Function
S03
S03
S03
S03
S03
S03
S03
S03
S03
S03
S03
S03
01
02
03
04
05
06
07
08
09
10
11
12
I/O Box #1 Enable
I/O Box #2 Enable
I/O Box #3 Enable
I/O Box #4 Enable
I/O Box #5 Enable
I/O Box #6 Enable
I/O Box #7 Enable
I/O Box #8 Enable
I/O Box #9 Enable
I/O Box #10 Enable
I/O Box #11 Enable
I/O Box #12 Enable
S04
S04
1O
1R
Pressure Offset
Pressure Range
P02
P02
P02
P02
P02
P02
P02
PF
PT
PP
01
02
03
04
Prefill Function
Prefill Time
Prefill Pressure
Compressor #1 Prefill Function
Compressor #2 Prefill Function
Compressor #3 Prefill Function
Compressor #4 Prefill Function
C01
C01
C01
C01
01
02
03
04
Compressor #1 Running Hours
Compressor #2 Running Hours
Compressor #3 Running Hours
Compressor #4 Running Hours
C02
C02
01
Compressor #1 Connection
Compressor #1 Start Time
I-PCB
I-485
V-485
C02
C02
02
Compressor #2 Connection
Compressor #2 Start Time
I-PCB
I-485
V-485
C02
C02
03
Compressor #3 Connection
Compressor #3 Start Time
I-PCB
I-485
V-485
C02
C02
04
Compressor #4 Connection
Compressor #4 Start Time
I-PCB
I-485
V-485
T01
T02
T03
bar
1
psi
2
kPa
3
4
bar/psi
min
!>X
sec
bar/psi
!
!
!
!
hrs
hrs
hrs
hrs
sec
sec
sec
sec
Page 41
Technical Manual
Page 42
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