Quincy Compressor Net$ync II Conductor 24 XC Parts Manual
Quincy Compressor Net$ync II Conductor 24 XC is a specialised supervisory and control product designed to provide energy efficient optimised pressure and sequence management of up to 12 air compressors operating on a common air system. Its general operating mode can be modified by adjustable parameters and priorities to match site requirements.
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MANY0708A.GB – Net$ync II Conductor 24 Technical Manual bar Net$ync II Conductor 24 Net$ync II Conductor 24 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 Detection and Control 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 Start Function 3.9 Pressure Schedule 3.10 Second Pressure Sensor 3.11 Airflow Sensor Monitoring 3.12 Pressure Balance Function 3.13 Zone Control Function 3.14 Insufficient Capacity Alarm 3.15 Restricted Capacity Alarm 3.16 Virtual Relay Technology 4.0 Installation 4.1 Unit Location 4.2 Power Supply 4.3 Pressure Sensor Location 4.4 Pressure Sensor Connection 4.5 Compressor Connection 4.6 ‘Direct Connect Gateway’ Expansion Module (option) 4.7 Remote Inputs 4.8 Remote Virtual Relay Function Inputs 4.9 Remote Outputs 4.10 RS485 Communications 8.7 Information Displays 8.8 Manual Sequence Rotation 8.9 Compressor Identification 8.10 Stop 8.11 Start 8.12 Power Failure Auto-Restart 8.13 Failure Mode 8.14 Reset 8.15 Compressor Fault Indications 8.16 Fault Codes 9.0 Parts List 10.0 Technical Data 11.0 Wiring Connection Diagram Refere to Section Indicated Note Important or Caution, Safety 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 6.3 Diagnostics 7.0 Virtual Relay Automation 7.1 Function Lists 7.2 Virtual Relay Automation Examples 8.0 Operation 8.1 User Interface 8.2 Unit Status 8.3 Compressor Status Indicators 8.4 System Alarms 8.5 Unit Functions 8.6 User Menu Page 1 Technical Manual 1. Safety Precautions ALWAYS EMPLOY SAFE WORKING PRACTESE 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 practise 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. 1.1 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. 1.2 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. Page 2 The product must only be operated at the supply voltage and frequency for which it is designed. 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 24 2. INTRODUCTION 2.2 Pressure Detection and Control The Quincy Net$ync II Conductor 24 is a specialised supervisory and control product designed to provide energy efficient optimised pressure and sequence management of up to 12 air compressors operating on a common air system. The Quincy Net$ync II Conductor 24 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 Quincy Net$ync II Conductor 24 utilises the signal from an electronic pressure sensor that can be mounted remotely from the Quincy Net$ync II Conductor 24 in a suitable location in the compressed air system. 1 2 3 4 5 6 7 8 9 10 11 12 CAP 2.1 Compressor Connections and Control 1 2 3 4 5 6 7 8 9 10 11 12 CAP As default the Quincy Net$ync II Conductor 24 is setup for operation with a 16bar (232psi) pressure sensor but can accept input from any 4-20mA type pressure sensor with a range from 1.0bar (14.5psi) up to 600bar (8700psi). Each air compressor in the system can be integrated with the Quincy Net$ync II Conductor 24 using a Multi485 network connection, for compressor controller’s equipped with Multi485 communications, or using one of a number of networkable EnergAir Net$ync II compressor integration products. Consult the air compressor manual or your air compressor supplier/specialist for details before installing the Quincy Net$ync II Conductor 24. Page 3 Technical Manual 3. Features and Functions 3.1 Pressure Control: The primary function of the Conductor 24’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 XC 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 PH PT b 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 24 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. 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 24 (DA) is adjustable. Net$ync II Conductor 24 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 24, 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 24 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 24 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 24’s dynamic reaction algorithm is preset 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 24 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 24’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 24 3.5 Sequence Control Strategies: The Conductor 24 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 24 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 24 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 24’s compressor running hour’s menu. The Conductor 24 uses these values in EHR mode. The Conductor 24’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 24 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. 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 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. Timer Rotation Mode Energy Control 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. The primary function of Energy Control mode is achieving and maintaining demand matched optimum system efficiency. Energy Control mode can accommodate differential capacity, variable capacity and variable speed air compressor types in any combination or configuration. Control and Rotation: Compressor control and utilisation is dynamically automated and is not based on pre-determined rotation configurations or time intervals. The system management unit is aware of compressor capacity relationships and variable capacity capabilities, where applicable, and is able to dynamically implement and continuously review ‘best fit’ configurations as demand variations occur. 1 2 3 4 #1 A B C D #2 D A B C #3 C D A B 80% #4 B C D A 2 The sequence assignment pattern can be modified by ‘Priority’ settings. The basic principle of the Energy Control strategy is the efficient utilisation of available resources matched to fluctuations in demand. 100% 40% 20% 0% Tables; Priority Settings Control: Compressors are utilised, in response to changing demand, using a ‘FILO’ (First In, Last Out) strategy. Page 8 0% 1 1: Demand 2: Generation Not all potential combinations are shown. 100% Net$ync II Conductor 24 Energy Control mode incorporates adaptive strategies and dynamic responses that continuously modify basic principles. With ‘built-in’ knowledge of individual compressor capabilities the management unit adapts to accommodate system characteristics under varying demand situations. 1 2 Tables: The Conductor 24 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 24. The Conductor 24 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 24 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. 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 24 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. Table Parameters: Sequence Rotation: Each table consists of the following parameters; the parameters can be set differently in each table. 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. 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 to 16) 12: Compressor 12 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 24 will increase, or decrease, the pressure target levels towards the new table settings in a gradual transition over a period of time. 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. 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 week. #- (dash) = deactivate Select the required hour and minutes of the day(s) using the same method. Page 9 Technical Manual A day starts at 00:00hrs and ends at 23:59hrs (24hr clock system). 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 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). The first automated rotation event each day will occur at 00:00hrs and then every set rotation interval time throughout the day. 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 3.6 Priority Settings: 1 2 3 4 Priority settings can be used to modify the ‘Rotation’ sequence assignment. Compressors can be assigned a ‘priority’ of 1 to 12; where 1 is the highest priority. Any compressor can be assigned any priority and any number of compressors can have the same priority. 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 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 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 Page 10 Net$ync II Conductor 24 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 3.7 Prefill: 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 24 will only load compressors that have been pre-determined 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 24 will utilise as many available compressors as required to achieve normal operational pressure as quickly as possible. Normal operational control will then begin. Three prefill modes are available. ‘Backup’ and ‘Standard’ modes require compressor preselection and function in the same way; differing only in response to a failure, or loss, of a prefill compressor. Automatic mode requires no compressor pre-selection. 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, a pre-defined backup compressor replaces it 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. A Automatic Mode: No Prefill compressor selection is necessary; any selection set is ignored. The management unit automatically selects compressor(s) dynamically to achieve pressure in accordance with the set Prefill time. If a compressor is stopped, or shuts down, it is automatically substituted with an alternative compressor. To manually skip Prefill mode, press and hold Start for several seconds. Page 11 Technical Manual 3.8 Start Function: P01 01.0# The ‘Start’ function enables auxiliary equipment to be pre-started prior to utilisation of any compressors. The function also monitors the auxiliary equipment during normal running operation. # - If, at any time during normal operation, the feedback signal disappears the management unit can be set to display an Alarm (Warning) and continue, or Shutdown. This function is intended for automated control and monitoring of auxiliary equipment critical to air compressor system operation; air dryer(s) or cooling water pump(s) for example. 3.9 Pressure Schedule: --:---- 0# = At system start-up (manual start or automated start from standby) any output relay set for the ‘Start’ function will energise. The management system will then wait for the set ’Start’ time before utilising any system compressors. During this time the management system expects to receive a feedback on the ‘Start Function Feedback Input’. The management system response to the feedback is dependant on the selected ‘Start’ function. If feedback is not received by the end for the ‘Start’ time the management unit can be set to display an Alarm (Warning) and continue, or Shutdown. 01 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 T06, 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 24 memory until the last sub-setting is entered. Press Escape to step back one sub-item if required. 3.10 Second Pressure Sensor: The Conductor 24 is equipped with a 4-20mA input dedicated for an optional second pressure sensor. The second pressure sensor (P2) can be utilised for one of two available functions: P1<>P2: P1 P2 The Conductor 24 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. Page 12 If the primary control pressure sensor (P1) fails the management unit will automatically switch to the ‘backup’ pressure sensor (P2). Net$ync II Conductor 24 P2+>DP: P2 DP This function can be used to ‘balance’ pressure control across a system that has multiple remote compressor rooms and/or where pressure differentials across a site system may vary. P1 3.13 Zone Control Function The second pressure sensor can be used to monitor pressure downstream, or upstream, of air treatment equipment. The pressure differential (DP) between the primary control pressure sensor (P1) and the second pressure sensor (P2) can be displayed on the screen. A pressure differential Alarm (Warning) level can also be set to indicate when differential pressure exceeds the set limit. Compressors can be assigned to one of three ‘zones’. The Conductor 24 will always attempt to balance utilisation across the zones to maintain, as near as possible, an equal number of utilised compressors in each zone. 2 1 3 3.11 Airflow Sensor Monitoring The Conductor 24 is equipped with a 4-20mA input dedicated for optional airflow sensor monitoring. Any airflow sensor, that is equipped with a ‘loop powered’ 4-20mA output, can be connected to the Conductor 24. The airflow sensor value can be displayed on the Conductor 24 screen and is available on remote communications. 3.12 Pressure Balance Function rP1 P rP2 The Conductor 24 has the capability to monitor up to two remote pressures from compatible compressor controllers, compressor integration units or other remote system automation units. The remote pressure(s) can be integrated with the primary local pressure to generate a new control pressure value. This function is intended for installations that have multiple collections of compressor(s) distributed across a site. In some instances, large pressure differentials can develop in remote areas of an air network if air generation is concentrated in one area. The aim of the ‘zone’ function is to facilitate a balanced pressure across a site air network by ensuring air generation is distributed. The ‘zone’ function will operate with all available sequence strategy modes and will work in conjunction with the priority and/or pressure balance function. The priority function will override ‘zone’ control where a conflict in compressor selection occurs. This may result in unexpected compressor utilisation; this should not be considered abnormal. The ‘zone’ function can modify compressor selection when using ‘Energy Control’ mode. This may compromise optimum system efficiency in some instances – use ‘zone’ control with caution where system efficiency is important. The Conductor 24 can be instructed to control from the lowest pressure, the highest pressure, or an average of local and remote the pressures. Page 13 Technical Manual 3.14 Insufficient Capacity Alarm CAP The Net$ync II is equipped with a dedicated ‘Insufficient Capacity’ Advisory Alarm (Warning) indication. This indication will illuminate if all available compressors are loaded and system pressure is continuing to decrease. The indication will generally occur prior to any set low pressure Alarm (Warning) and is intended to provide an advanced warning of a potential ‘Low Pressure’ situation. The ‘Insufficient Capacity’ advisory alarm is intended as an advanced warning and is not recorded in the fault history log but is included as a Group Alarm (Warning), or Group Fault item. ‘Insufficient Capacity’ is available as a dedicated data communications item and as a dedicated ‘virtual relay’ function. The ‘Insufficient Capacity’ advisory alarm function can be de-activated. In this instance the unit’s Alarm indicator will still illuminate but no group alarm, group fault, ‘virtual relay’ or remote indication is generated. 3.15 Restricted Capacity Alarm CAP The Net$ync II is equipped with a dedicated ‘Restricted Capacity’ Advisory Alarm (Warning) indication. This indication will flash if all available compressors are loaded and further capacity is required but one, or more, compressors are: a) inhibited from use in a ‘Table’ priority setting b) inhibited from use by the short-term Service/Maintenance function Page 14 c) inhibited from use in the long term maintenance menu. The ‘Restricted Capacity’ advisory alarm is intended to indicate that all available compressors are already loaded and further capacity is required but one, or more, system compressor(s) have been restricted from use. The ‘Restricted Capacity’ advisory alarm is not recorded in the fault history log but is included as a Group Alarm (Warning), or Group Fault item. ‘Restricted Capacity’ is available as a dedicated data communications item and as a dedicated ‘virtual relay’ function. The ‘Restricted Capacity’ advisory alarm function can be de-activated. In this instance the unit’s Alarm indicator will still flash but no group alarm, group fault, ‘virtual relay’ or remote indication is generated. 3.16 Virtual Relay Technology The Net$ync II is equipped with Virtual Relay technology. The ‘Virtual Relay’ concept is a configurable system wide automation system. The concept allows output relay functions to be configured to respond to any ‘virtual relay’ condition, status or signal function available in the unit or from another compatible unit on the system network. Virtual Relays Net$ync II Conductor 24 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 24 is wall mounting using conventional screw fixings. The Conductor 24 can be located remote from the compressors but within 100 m (330ft) cable length from each compressor and within 100 m (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: 4.2 Power Supply 2 A fused switching isolator must be installed to the main incoming power supply, external to the Conductor 24. 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 2 3 P 1 P XPM-TAC24 1 P P 1 2 4 X04 VOLTAGE SELECT 230Vac 1 2 3 4 X04 VOLTAGE SELECT 115Vac Check the input voltage select links on the Conductor 24’s power supply PCB (XPM-TAC24). 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: P 1 2 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 X06 of the Conductor 24 using an earth screened, two-core (0.5mm2 CSA minimum), cable no greater than (100m) 330ft in length. X06 - 22 21 + + 4-20mA P Wire polarity is important. Page 15 Technical Manual 4.5 Compressor Connection To set the ‘Direct Connect Gateway’ module function: Each air compressor in the system can be integrated with the Quincy Net$ync II Conductor 24 using a Multi485 network connection, for compressor controller’s equipped with Multi485 communications, or using one of a number of networkable Quincy Net$ync II compressor integration products. a) Press the Up and Down buttons simultaneously. The display will show an ‘Access Code’ entry screen. b) Enter access code ‘0021’ and press Enter. c) Press Down to select the ‘P01’ menu and press Enter. d) Press Enter to select the first menu item; the setting will flash. e) Press Up or Down to select the required function (C:1-4, C:5-8 or C:9-12) and Enter. X07 25 26 27 28 Multi485 L2 L1 L2 L1 RS485 L2 L1 L1 L2 The Net$ync II Conductor 24 is not equipped with any direct connect, hardwire, ‘Q485’ interface terminals as standard. 4.6 ‘iX’ Expansion Modules (Option) Direct connect, hardwire ‘Q485’ interface modules, can be added with the use of optional ‘Direct Connect Gateway’ Module(s). Each ‘Direct Connect Gateway’ module adds four direct connect ‘Q485’ terminals. Up to three ‘Direct Connect Gateway’ modules can be connected to the Conductor 24 to provide a maximum of 12 direct connect ‘Q485’ terminals. The ‘Direct Connect Gateway’ Module is wall mounting and must be located adjacent to the Net$ync II Conductor 24 unit. The Conductor 24 will register the presence of an ‘Direct Connect Gateway’ Module(s) at power-up. After registration the appropriate compressor(s) can be selected for ‘Q485’ type in the Conductor 24 compressor configuration menu. Failure to continuously detect an ’Direct Connect Gateway’ Module after initial registration and compressor configuration will result in an Error condition. ‘iX’ module connection: 1 2 3 4 5 6 7 8 9 10 11 12 CAP X01 1 1 2 X01 XPM485 L1 L2 XPM-LED C1-4 C5-8 X06 X06 The ’Direct Connect Gateway’ Module can be set to function as ‘Q485’ connections for: a) C:1-4 b) C:5-8 c) C:9-12 Compressors 1 to 4 Compressors 5 to 8 Compressors 9 to 12 27 28 29 30 27 28 29 30 L1 L2 L1 L2 L1 L2 L1 L2 C9-12 10m (33ft) max Use a twisted pair, earth shielded, 0.25mm2-1.0mm2 data communications cable with a total length no greater than 10m (33ft). Conductor 24: Terminal X01 of the ‘XPM-LED’ PCB Expansion Module(s): Terminal X06 Polarity is important. Page 16 Net$ync II Conductor 24 ‘Direct Connect Gateway’ module power supply: Each ‘Direct Connect Gateway’ Module is equipped with the same type of power supply PCB as the Conductor 24 and requires a dedicated 115Vac or 230Vac (+-10%), 50/60Hz @ 50VA power supply connection. XPM-TAC24 1 2 3 1 4 2 3 4 X04 E E L VOLTAGE N SELECT X01 N L E 230Vac 1 2 3 4 X04 VOLTAGE SELECT 115Vac Before applying power to the ‘Direct Connect Gateway’ Module 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. 4.7 Remote Inputs The Conductor 24 is equipped with a number of remote ‘digital’ inputs. Each input has a defined function: 3) Table #1 Activates Table #1 when held closed. 4) Table #2 Activates Table #2 when held closed. If more than one ‘Table’ input is held closed the lowest number Table will have priority. For example; Table #1 has priority over Table #2. Standby has priority over any Table. Remote inputs have priority over Pressure Schedule. 5) Start / Stop Change in state from open to closed will simulate a Start button press. Change in state from closed to open will simulate a Stop button press. Local and Communications Start and Stop remain active. If the Stop button is pressed while this input is held closed, the unit will stop. 6) Sequence Change To force a change in sequence arrangement, close for 1 second minimum then open. 7) Standby Closed: All compressors will be forced to unload and remain offload. Open: normal operation X03 1 XPM-Di8R4 Module 8 9 10 11 12 X03 8 9 6 7 5 5 4 6 3 2 7 13 14 15 16 X04 4 3 10 8) Table #5 Activates Table #5 when held closed. 9) Table #6 Activates Table #6 when held closed. 17 18 19 20 X05 2 1 100m (330ft) max 1) Table #3 Activates Table #3 when held closed. 2) Table #4 Activates Table #4 when held closed. 10) Start Function Feedback Input Closed: Feedback Open: Fault Start Function The inputs are designed to detect a remote ‘volt-free’ switching contact (rated for a minimum 24VDC @ 10mA). Page 17 Technical Manual 4.8 Remote Virtual Relay Function Inputs Virtual Relay Outputs to Function Inputs: The Conductor 24 is equipped with four remote ‘digital’ inputs (D1 to D4) that can be used as ‘input functions’ for any Virtual Relay – local or remote. The design and location of R1, R2 and R3 is ideally suited to enable ‘Virtual Relay’ outputs to directly activate function inputs. D2 For Example: R1 can activate Table #3 by connecting the output terminals of R1 (X01-2) to the ‘Force Table #3’ inputs (X05-17/18). R2 can activate standby mode by connecting the output or R2 (X01-3) to the ‘Force Standby input (X03-12). X03 12 11 10 9 8 7 9 D1 16 15 14 13 12 11 10 D3 D4 X01 The inputs are designed to detect a remote ‘volt-free’ switching contact (rated for a minimum 24VDC @ 10mA). R3 R2 R1 RC Relay Outputs R4 to R10: X02 X12 X11 R5 R4 8 R6 7 X13 1 R1, R2 and R3 remote output relay contacts are rated for 24Vac/dc @ 4A maximum. The maximum current on ‘RC’ must not exceed 8A. R10 6 1 2 3 4 X01 Virtual Relay Automation 5 Relay Outputs R1 to R3: C+ R9 4 The function of each relay output is determined by the set-up of the equivalent ‘Virtual Relay’ (R01 to R10). 3 The Conductor 24 is equipped with 10 remote relay contact output. XPM-Di8R4 Module 4.9 Remote Outputs (Option) X05 Digital input ‘C+’ terminals are all common on the Terminal PCB; only one ‘C+’ connection needs to be made to ‘RC’ (X05-17 to X01-1). 39 40 41 42 43 44 Virtual Relay Automation R3 R2 R1 RC 20 19 18 17 1 2 3 4 100m (330ft) max R8 2 XPM-Di8R4 Module X03 R7 R4 to R10 remote output relay contacts are rated for 240V ‘CE’ / 115V ‘UL’ @ 4A maximum. Virtual Relay Automation Page 18 Net$ync II Conductor 24 Relay Output Defaults: 4.10 RS485 Communications As standard the Conductor 24 is supplied with the following relay output defaults: The Conductor 24 is equipped with an RS485 network communications capability using the Multi485 protocol. This facility can be used for remote connectivity to optional networked units and modules with Multi485 communications capabilities. OFF: R2: ON: Unit RUNNING Standby or Start Time or Pre-Fill or Normal Operation Stopped or Shutdown OFF: Control ON Start Time or Pre-Fill or Normal Operation Standby or Stopped or Shutdown R3: ON: OFF: General Trip (normally closed) OK System Trip or Compressor Trip R4: ON: Unit RUNNING Standby or Start Time or Pre-Fill or Normal Operation Stopped or Shutdown OFF: R5: ON: OFF: Control ON Start Time or Pre-Fill or Normal Operation Standby or Stopped or Shutdown R6: ON: OFF: General Trip System Trip or Compressor Trip OK R7: ON: General Fault System Alarm/Trip or Compressor Alarm/Trip OK OFF: R8: ON: OFF: Auxiliary Start Time Output Start Time or Pre-Fill or Normal Operation Stopped or Standby or Shutdown R9: ON: OFF: Low Pressure Alarm Low Pressure Alarm OK R10: ON: OFF: Differential Pressure Alarm High Differential Pressure Alarm OK X07 Multi485 L2 L1 25 26 27 28 R1: ON: L2 L1 L2 L1 RS485 L1 L2 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 24 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 5.0 COMMISSIONING 5.3 Unit Configuration Commissioning Procedure Before successful basic operation can be established the following items must be set (in the order show) to suit installation requirements. When commissioning the Conductor 24, 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 24 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 24 and check the location of the link(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 Switch on the power supply to the Conductor 24. The control program identification will be displayed for a short period followed by the normal operational User display. 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 S04 – 1O S04 – 1R Page 20 Sensor Offset Calibration Sensor Range Calibration 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 C03 – 01/12 Compressor #1-12 Configuration C01 - 01/12 Compressor #1-12 Running Hours T01 - PH T01 - PL T01 - Pm T01 - SQ T01 – 01/12 High Pressure Set Point Low Pressure Set Point Minimum Pressure Alarm Sequence Algorithm Compressor #1-12 Priority 5.4 Optional Features and Functions Installation requirements may involve the implementation of additional or optional functions and features; implement as required. Features and Functions; Menu Items Net$ync II Conductor 24 6.0 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 LED indicators are switched on for several 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 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 Item 1 Item 2 Item 3 Item 4 Item 5 Value Value Value Value Value 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 24 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 24 is in an operational state; stop the Conductor 24 first. Net$ync II Conductor 24 6.1 Menus USER Level Menus (0011) 1 TABLE #1 T01 PH H igh Pressure Set Point PL Low Pressure Set Point Pm M inimum Pressure Alarm SQ Sequence Algorithm 01 C ompressor #1 Priority to 12 C ompressor #12 Priority 2 TABLE #2 Pressure Schedule P01 01 S to 28 S chedule Setting #1 chedule Setting #28 Prefill P02 PF P PT P PP P 01 to 12 refill Function refill Time refill Pressure Compressor #1 Compressor #12 T02 PH H igh Pressure Set Point PL Low Pressure Set Point Pm M inimum Pressure Alarm SQ Sequence Algorithm 01 C ompressor #1 Priority to 12 C ompressor #12 Priority 3 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 TABLE #3 T03 Compressor Running Hours PH H igh Pressure Set Point PL Low Pressure Set Point Pm M inimum Pressure Alarm SQ Sequence Algorithm 01 C ompressor #1 Priority to 12 C ompressor #12 Priority C01 01 to 12 Compressor #1 Running Hours Compressor #12 Running Hours Compressor Maintenance to: C02 6 TABLE #6 T06 PH H igh Pressure Set Point PL Low Pressure Set Point Pm M inimum Pressure Alarm SQ Sequence Algorithm 01 C ompressor #1 Priority to 12 C ompressor #12 Priority 01 C to 12 C ompressor #1 Maintenance ompressor #12 Maintenance Fault Log E01 01 to 15 Fault Log #1 (most recent) Fault Log #15 Page 23 Technical Manual SERVICE Level Menus (0021) Pressure Balance S05 Configuration S02 P> P ressure Units F> F low Units NC N umber Of Compressors PM M aximum Pressure Alarm CF S top Control Function TO T olerance DA D amping ST S tart Delay Time SF S tart Function PC P ressure Change Time P2 Second Pressure Function DP D P Setting DD D P Delay Time CA C AP Alarm Inhibit MA M ax Cap Restricted Alarm Inhibit ER E rror Log Reset AF P1 P2 D1 D2 D+ M D- M 1O 1R 2O 2R Aux Pressure Function Select Aux Pressure #1 Source Aux Pressure #2 Source Aux Pressure #1 Deviation Limit Aux Pressure #2 Deviation Limit ax + Aux Pressure Deviation in - Aux Pressure Deviation Aux Pressure #1 Offset Aux Pressure #1 Range Aux Pressure #2 Offset Aux Pressure #2 Range Compressor Configuration C03 01 C to 12 C ompressor #1 Configuration ompressor #12 Configuration Auxiliary Box Monitoring S03 01 to 12 BT R Compressor Zone Auxiliary Box #1 Enable Auxiliary Box #12 Enable S485 Timeout Sensor Calibration S04 1O P 1R P 2O P 2R P FO F FR F Page 24 C04 ressure Offset ressure Range ressure 2 Offset ressure 2 Range low Offset low Range 01 C to 12 C ompressor #1 Zone Select ompressor #12 Zone Select Net$ync II Conductor 24 High Level Menus (0032) Diagnostic Menu 1 D01 Relay Functions R01 01 R to 10 R 11 V to 16 V elay #1 Function elay #10 Function irtual Relay #11 Function irtual Relay #16 Function D1 D to D8 D R1 O to R6 A1 A2 A3 Ao igital Input #1 (Di 1) igital Input #8 (Di 8) utput Relay #1 (R1) Output Relay #6 (R6) Analogue Input #1 (Ai1) Analogue Input #2 (Ai2) Analogue Input #3 (Ai3) Analogue Output (Ao) Timer Relay Functions R02 T1 T T2 T P1 P2 P3 P4 AF C RF LF C imer Relay #1 imer Relay #2 Pulse Relay #1 Pulse Relay #2 Pulse Relay #3 Pulse Relay #4 ompressor Available Relay Compressor Run Relay ompressor Load Relay Diagnostic Menu 2 D02 SI LT Screen Invert LED Panel Test Diagnostic Menu 3 D03 D1 X to D8 X R1 X to R4 X PM#1 - Digital Input #1 (Di9) PM#1 - Digital Input #8 (Di16) PM#1 - Output Relay #1 (R7) PM#1 - Output Relay #4 (R10) Page 25 Technical Manual 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 ( ) 28 01 02 03 04 28 01 02 03 04 - . --:-- . --:-- . --:-- . --:-- . --:-- ----------- Pressure Schedule 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# - ‘n’ Compressor #’n’ Priority The ‘priority’ setting for compressor number ’n’ that will be used when the table is active. ‘n’ = number of compressors in the system. # = Table T01 to T06 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. Page 26 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 A = Prefill, Automatic 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. Net$ync II Conductor 24 P02 – 01 to 04 Compressor 1 to ‘n’ The function of compressor 1 to ‘n’ during the ‘Prefill’ period. ‘n’ = number of compressors in the system. = do not use = use for primary prefill ! = use for emergency backup These settings are applicable to Prefill – Standard and Prefill - Back-up modes only. In Automatic mode the system management unit dynamically utilises compressors as required. Press and hold ‘Start’ for 5 seconds to manually skip Prefill mode at startup. S01 BL Ct PS AR RP 06 08 08 08 08 5 1 . 18:00 X 9 . 00:00 Features and Functions 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 S01 - AR Auto Restart Enable = inhibit Power Failure Auto Restart 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. Typically the display will remain usable for a much longer period for time. Adjusting the backlight to high levels will reduce service life. 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 – ‘n’ Run Hours; Compressor 1 Run Hours; Compressor ‘n’ ‘n’ = number of compressors in the system. = enable Power Failure Auto Restart The Conductor 24 will only automatically restart when power is restored if the Conductor 24 was in an operational ‘Started’ state when the power loss or disruption occurred. S01 - RP Rotation Interval Sets the sequence ‘Rotation’ interval or time. Page 27 Technical Manual To return to the main error log menu screen press Escape. C02 01 02 03 04 To view the second information screen press Enter. 01 02 03 04 E01 01.01 1 = Remove compressor from operation = Compressor can be utilised For a compressor(s) that is unavailable for use for a prelonged period for time due to maintenance or repair. The compressor will not be utilised under any circumtances; any Alarm (Warning) or Trip (shutdown) fault will be ignored. E01 -: --- . -E : ERR . 01 -:--- . --:--- . --:--- . -- 15 01 02 03 04 E01 – 01 to 15 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 1 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 Conductor 24 at the time the error occurred; (see: Conductor 24 Status Display) Page 28 2 3 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. 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. S02 – F> Air Flow Meter Units Selects the display units for the optional 420mA air flow sensor monitoring feature: m3/min: cubic meters per minute cfm: cubic feet per minute S02 - NC Number of Compressors Sets the number of compressors connected to, and controlled by, the Conductor 24. This value must be set to match the system at commissioning. 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 Net$ync II Conductor 24 S02 - CF Stop Control Function Determines if the Conductor 24 maintains control of the compressors when the Conductor 24 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 – ST Start Time Sets the period of time, at system start, that the management unit will wait for ancillery equipment to start/respond before loading any compressor. S02 – SF Start Function Start Time Determines the function of the Start Time feature and the reaction of the management unit to a failure of ancillery equipment to respond within the Start Time. No Start Time Function Management unit will wait for the full Start Time regardless of feedback. If feedback does not occur before Start Time expires the management unit will Trip (shutdown). If the feedback disappears at any time during operation the management unit will Trip (shutdown). Management unit will wait for the full Start Time. The management unit will begine to utilise compressor(s) as soon as feedback is received. If feedback does not occur before Start Time expires the management unit will Trip (shutdown). If the feedback disappears at any time during operation the management unit will Trip (shutdown). If feedback does not occur before Start Time expires the management unit will show an Alarm (Warning) and begine to utilise compressor(s) as required. If the feedback disappears at any time during operation the management unit will show an Alarm (Warning). Management unit will wait for the full Start Time. The management unit will begine to utilise compressor(s) as soon as feedback is received. If feedback does not occur before Start Time expires the management unit will show an Alarm (Warning) and begine to utilise compressor(s) as required. If the feedback disappears at any time during operation the management unit will show an Alarm (Warning). S02 - PC Pressure Change Time The time that the XC will implement a smooth and controlled change from one ‘target’ pressure level to another when a table change is made. S02 – P2 Second P.Sensor Function P2=X: Second pressure sensor function inhibit; no sensor connected. P1<>P2 : The system management unit will automatically utilise the second pressure sensor (P2) in the event of a primary pressure sensor (P1) failure. The primary and secondary pressure sensors must be installed to monitor the same pressure at the same location. P2=>DP: The management unit will monitor and display the differential pressure (DP) between the primary (P1) and secondary (P2) pressure sensors. The differential is displayed as a positive value regardless of positive or negative relationship between the sensors. The system management unit will use the primary pressure sensor (P1) for control. Management unit will wait for the full Start Time regardless of feedback. Page 29 Technical Manual S02 – DP DP Alarm Level Differential pressure Alarm level when P2 set for ‘P”=>DP’ mode. Set to 0(zero) to inhibit DP Alarm function. S02 – DD DP Alarm Delay Differential pressure Alarm delay time (seconds) when P2 set for ‘P”=>DP’ mode. The set differential pressure must exceed, and remain above, the differential pressure Alarm level for the delay time. S02 – CA Capacity Alarm Enable = inhibit Capacity Alarm The Conductor 24 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 24 will display an I/O Gateway RS485 communications Error. S04 = enable Capacity Alarm When inhibited the Capacity Alarm panel indication will still function; alarm code generation and remote alarm indications are inhibited. S02 – MA Restricted Cap. Alarm Enable = inhibit Restricted Capacity Alarm = enable Restricted Capacity Alarm When inhibited the Restricted Capacity Alarm panel indication will still function; alarm code generation and remote alarm indications are inhibited. S02 - ER Error Log Reset Clears and resets the ‘Error Log’. Adjust the item setting to ‘ ’ and press ENTER. The display will return to the main menu and all existing entries in the error log will be perminantly deleted. S03 13 01 02 03 04 BT 01 02 03 04 S03 – 01/12 = Disabled = Enabled Page 30 60 sec X X X X I/O Gateway Monitoring 01 02 03 04 1O 1R 2O 2R S04 - 1O S04 - 1R S04 - 2O S04 - 2R S04 - FO S04 - FR 0 16.0 0 16.0 BAR BAR BAR BAR Pressure Sensor Offset Pressure Sensor Range Pressure Sensor #2 Offset Pressure Sensor #2 Range Air Flow Sensor Offset Air Flow 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. Net$ync II Conductor 24 2) Calibration Procedure 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. The detected flow rate is displayed with the calibration menu item and will change to match the new calibration setting as the setting is adjusted. S05 11 01 02 03 04 2R AF P1 P2 D1 16.0 BAR ------0.0 BAR Remote Presure Balance The pressure balance feature enables upto two additional remote pressures to be integrated with the primary detected pressure, using one of three available functions, to produce a calculated ‘balanced’ pressure that is used for pressure control. 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. rP1 P rP2 Air Flow Sensor Calibration Procedure: 1) Commissioning Initially set the ‘Offset’ (minimum) to 0(zero) and the ‘Range’(maximum) to the flow value for the sensor at full scale (20mA). Execute the calibration procedure. 2) Calibration Procedure a) Offset: Ensure no air flow is being detected by the sensor and adjust the ‘offset’ setting (if necessary) until the detected flow display shows 0(zero) flow. b) Range: Subject the sensor to an accurately know flow rate and adjust the ‘Range’ setting until the detected flow display matches the knwn flow rate. Remote pressure references are transmitted on the RS485 network at maximum intervals of ten seconds. If RS485 communications is disrupted the management unit will automatically default to using the primary pressure for control. AF Aux Pressure Function Select The highest pressure The average of all pressures The lowest pressure P1 Aux Pressure #1 Source Determines the source of the first remote pressure: C01 to C12: B01 to B12: “-“ Compressor 1 to 12 I/O Gateway 1 to 12 no first remote pressure Page 31 Technical Manual P2 Aux Pressure #2 Source pressure is restricted from exceeding this limit. Determines the source of the second remote pressure: For example: If ‘D-’ is set for 0.5bar, the resulting calculated ‘balanced’ pressure (in accordance with the set function) is prevented from exceeding more than 0.5bar below the detected primary pressure. C01 to C12: B01 to B12: “-“ D1 Compressor 1 to 12 I/O Gateway 1 to 12 no second remote pressure Aux Pressure #1 Deviation Limit Sets a ‘+/-‘ pressure tolerance limit that the first remote pressure can deviate from the detected local primary pressure. If the first remote pressure exceeds this limit it is ignored and not included in the final control pressure calcuation. For example: If D1 is set for 1.0bar, and the first remote pressure is 1.1bar above or below the primary pressure, the first remote pressure is ignored and not used in ‘balanced’ control pressure calculations. D2 Aux Pressure #2 Deviation Limit Sets a ‘+/’- pressure tolerance limit that the second remote pressure can deviate from the detected local primary pressure. If the first remote pressure exceeds this limit it is ignored and not included in the final control pressure calcuation. For example: If D2 is set for 1.0bar, and the second remote pressure is 1.1bar above or below the primary pressure, the second remote pressure is ignored and not used in ‘balanced’ control pressure calculations. D+ Max +(plus) Aux Pressure Deviation Sets a limit that the calculated ‘balanced’ pressure can deviate above the primary detected pressure. The calculated ‘balanced’ pressure is restricted from exceeding this limit. For example: If ‘D+’ is set for 0.5bar, the resulting calculated ‘balanced’ pressure (in accordance with the set function) is prevented from exceeding more than 0.5bar above the detected primary pressure. D- Max –(minus) Aux Pressure Deviation Sets a limit that the calculated ‘balanced’ pressure can deviate below the primary detected pressure. The calculated ‘balanced’ Page 32 1O Aux Pressure #1 Offset Offset calibration setting for the first remote pressure. Set to match the ‘offset’ calibration of the selected remote pressure source. 1R Aux Pressure #1 Range Range calibration setting for the first remote pressure. Set to match the ‘range’ calibration of the selected remote pressure source. 2O Aux Pressure #2 Offset Offset calibration setting for the second remote pressure. Set to match the ‘offset’ calibration of the selected remote pressure source. 2R Aux Pressure #2 Range Range calibration setting for the second remote pressure. Set to match the ‘range’ calibration of the selected remote pressure source. C03 01 02 03 04 01 02 03 04 I-485 I-485 I-485 I-485 Installation – Compressor Connections The type, method of connection, and the control functionality, of each compressor connected to the XC. C02 - 01 to C02 – ‘n’ Compressor 1 Compressor ‘n’ ‘n’ = number of compressors in the system. Net$ync II Conductor 24 C03 01.01 01 1 100 % V-485 50 % 10 sec 60 % For example: Compressor 1 Compressor 2 Compressor 3 Compressor 4 Compressor 5 Compressor 6 5 m³/min 10 m³/min 12 m³/min 12 m³/min 20 m³/min 20 m³/min 25% 50% 60% 60 % 100% 100% % Minimum Output Capacity Compressor connectivity and functionality settings. Only applicable for a variable output compressor (V-485). 1 The minimum output capacity of a variable output compressor must be set as a percentage of the compressor’s maximum output scaled in accordance with the % maximum capacity output value. Minimum output capacity is regarded as the output capacity at the lowest possible speed (variable speed compressor) or the minimal output achievable (stepping or other variable regulation control compressor). Compressor Connectivity: I-485 Fixed speed, load/unload; connected to XC on Multi485 network. (0/100%) 0% or 100% regulation V-485 Variable Capacity/Speed; connected to XC on Multi485 network. (0 . . 100%) variable %Load regulation Q485 Fixed speed, load/unload; connected to ‘iX’ Expansion Module (option) (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 24 for ‘staggered starting’ of multiple compressors and other operational calculations. An accurate time is important for successful Conductor 24 operation. % Maximum Output Capacity The maximum output capacity of each compressor must be set as a percentage with reference to the highest output capacity (the largest) compressor in the system. The heist output capacity compressor must be assigned with 100% capacity. Equal capacity (equal sized) compressors should be assigned the same % capacity value. For example 1: For a variable speed compressor that has been assigned a maximum capacity output percentage of 100%, and is able to reduce speed to 50% of maximum speed: Minimum Output Capacity = 50% For example 2: For a variable speed compressor that has been assigned a maximum capacity output percentage of 50%, and is able to reduce speed to 50% of maximum speed: Minimum Output Capacity = 25% For example 3: For a 3-step (0/50/100) reciprocating compressor that has been assigned a maximum capacity output percentage of 60%, the minimum output capacity is the half-output regulation step: Minimum Output Capacity = 30% % Minimum Efficiency Only applicable for a variable output compressor (V-485). The minimum efficiency point is regarded as the speed, or step, below which another smaller capacity compressor in the system could achieve the equivalent output at a higher efficiency. Page 33 Technical Manual The percentage value is directly related, and scaled, to the maximum and minimum output percentage values. For example: For a variable speed compressor that is able to reduce speed to 50% of full speed, which has been assigned a maximum output capacity of 50% and a minimum output capacity of 25%. If another compressor in the system is able to provide 60% of the compressor’s full speed output more efficiently, set the % Minimum Efficiency value to 30%. This percentage value represents 60% of the full speed output of the compressor. When the compressor is detected as operating below the % Minimum Efficiency value the system management unit will re-evaluate utilisation and re-configure, if possible, to utilise a smaller capacity compressor, or combination of compressors. This process is automatic and executed dynamically in accordance with prevailing operational conditions at the time. The intent of this feature is to prevent a variable output capacity compressor operating at minimal speed, or minimal output, for prolonged periods of time. Generally a variable output compressor operating at minimal capacity is less efficient than a smaller capacity compressor that is able to achieve the same output at higher, or maximum, output capacity. Q485 Alarm Input (Direct Connect Gateway Option only) 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. Page 34 C04 01 02 03 04 01 02 03 04 1 1 1 1 Zone Control C04 - 01 to C04 – ‘n’ Zone; Compressor 1 Zone; Compressor ‘n’ ‘n’ = number of compressors in the system. Each compressor in a system can be assigned to one of three zones. To inhibit zone control, set all compressors to zone ‘1’. Net$ync II Conductor 24 6.3 Diagnostics 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. D01 Diagnostics - Controller D01 20 01 02 03 04 Ao D1 D2 D3 D4 4.00 mA 0 0 1 2 The unit 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 igital Input 1 D2 D igital Input 2 ON D3 D igital Input 3 D4 D igital Input 4 OFF D5 D igital Input 5 Pulsing D6 D igital Input 6 D7 D igital Input 7 D8 D igital Input 8 ------------------------------------------------------------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 Analogue Input 1 bar <> mA A2 Analogue Input 2 flow <> mA A3 Analogue Input 3 bar <> mA ------------------------------------------------------------Ao Analogue Output 0.0 to 20.0mA Digital Inputs: 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 Air Flow Sensor, 4-20mA 2nd Pressure, 4-20mA 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. D02 Diagnostics – LED Panel SI LT D03 Screen Invert LED Panel Test 0 = on test 1 = all on 2 = control test Diagnostics – XPM-Di8R4 Module D1 D igital Input 1 D2 D igital Input 2 ON D3 D igital Input 3 D4 D igital Input 4 OFF D5 D igital Input 5 Pulsing D6 D igital Input 6 D7 D igital Input 7 D8 D igital Input 8 ------------------------------------------------------------R1 R elay Output 1 R2 R elay Output 2 OFF R3 R elay Output 3 R4 R elay Output 4 ON 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. 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. To Display the Software Version: Press and hold Reset then press Escape. Page 35 Technical Manual 7.0 Virtual Relay Automation The ‘Virtual Relay’ concept is a configurable system wide automation system. The ‘Virtual Relay’ concept allows output relay functions to be configured to respond to any ‘virtual relay’ condition, status or signal function available in the unit or from another compatible unit on the system network. Virtual Relay Input Functions: All compatible units have a comprehensive selection of fixed condition, status or signal virtual relay ‘input functions’ appropriate to the product application. All ‘input functions’ are available for local use on the unit, and an appropriate selection are made available to other remote system units on the network. Each virtual relay input function within a unit is defined to a specific condition. For example: input function ‘Rn’ = the unit is running. If the unit ‘is’ running the condition of input function ‘Rn’ will be ‘True’; usually expressed as ‘1’ in logical notation. If the unit ‘is not’ running the condition of input function ‘Rn’ will be ‘False’; usually expressed as ‘0’ in logical notation. Virtual Relays: Virtual relays are software equivalents (virtual representations) of real relays. These ‘relays’ function in software only and do not physically exist on the unit. Any virtual relay ‘input function’ can be selected as an input that will energise a virtual relay. The output state of the virtual relay is represented in software as ON (True or ‘1’) or OFF (False or ‘0’). The virtual relay output state can be selected as input for any other ‘virtual relay’ and/or operate a ‘real’ physical relay. Compatible units are equipped with 16 configurable ‘virtual relays’. Each relay can be separately configured. The unit will also be equipped with one, or more, ‘real’ physical relay outputs; the volt-free contacts of which are available on the unit’s wire connection terminals. The real physical relay(s) will respond to the operation of the equivalent ‘virtual relay’. Page 36 For example: Relay output #1 will operate in exact accordance with ‘virtual relay’ #1. To define the function and operation of relay output #1, configure the function and operation of ‘Virtual’ Relay #1. In this respect, the existence of a physical relay #1 on the unit makes virtual relay #1 ‘REAL’. Example: Virtual relay #1 can be assigned with the ‘Rn’ virtual relay function as input. This can be envisaged as the ‘Rn’ function providing the ‘virtual’ power to the coil of the ‘Virtual Relay’. Rn Rn Rn = 0 0 Rn = 1 1 If the unit is not running and the ‘Rn’ function is false the output of virtual relay #1 will be false or ‘0’; when the unit is running the output will be true or ‘1’. If the ‘virtual relay’ has an equivalent ‘real’ physical output relay on the unit (for example: auxiliary output relay #1 or output relay R1), the relay coil of R1 will actually energise and de-energise in unison with the output statue of ‘virtual relay’ #1. If ‘virtual relay’ #1 is configured to respond to the ‘Rn’ function, R1 will energise when ‘Rn’ is true or ‘1’, and deenergise when ‘Rn’ is false or ‘0’. Rn R1 Rn = 0 Rn R1 Rn = 1 Some units are equipped with several ‘real’ physical relay outputs; relays R1, R2, R3 and R4 for example. In this instance these relays will respond to the configuration of ‘virtual relays’ 1, 2, 3 and 4 respectively; virtual relays 5 to 16 remaining totally virtual. Virtual relays that do not have associated ‘real’ physical relays can be used to perform function ‘logic’ on standard input functions and act as customised ‘input functions’ for other ‘virtual relays’; local or remote. Net$ync II Conductor 24 Logic Function: Virtual relays have the capability to accept two input functions and apply ‘logic’ to determine the appropriate output response: 1) 2) 3) AND: If the state of function #1 is true ‘and’ the state of function #2 is true then switch on. In all other conditions remain off. Fn = A --- - -- The local or remote setting cannot be adjusted manually; it will automatically change as the ‘system unit’ is defined. The local ‘L’ or remote ‘R’ character indicates if the function information is being generated locally within the unit or remotely from another unit on the network. Fn #1 Fn #2 L Local 0 1 0 1 0 0 1 1 R Remote OR: If the state of function #1 ‘or’ the state of function #2 is true, or the state of both functions are true, then switch on. If both functions are false, switch off. Fn #1 Fn #2 0 1 0 1 0 0 1 1 XOR: If the state of function #1 ‘or’ function #2 is true then switch on. If the states of both functions are true, or the states of both functions are false, then switch off. Fn #1 Fn #2 0 1 0 1 0 0 1 1 Defining a Function: The input function for a ‘virtual relay’ is defined by a 7 alphanumeric character selection that consists of four parts: Local or Remote It is important to be aware if the function information is being generated and transmitted on the network from a remote unit. 1) There may be a delay of several seconds for function information from a remote unit to be transmitted and received by the local unit. A ‘virtual relay’ acting on remotely generated function information will not respond instantaneously to a change in actual function state. 2) If the remote unit becomes unavailable, or network communications is disrupted, the function information will no longer be available. Each ‘virtual relay’ has a setting to take this event in to consideration. Virtual Relay Configuration - BBB - - Fn = System Unit: The unit form where the required function status information is available. This can be the local unit or another compatible remote unit on the system network. SYS C01-C12 B01-B12 Management System Unit Compressor 1 to 12 Gateway 1 to 12 For compressor units directly connected to a system management unit using an ‘Q485’ module the function information will automatically be derived from the system management unit. Fn = A BBB C DD A) Local or Remote B) System Unit C) Function Type D) Function Definition Page 37 Technical Manual - --- C -Fn = Function Type: Dependant on the selected unit, a number of input function types or categories will be available. Each category contains a number of relevant input functions. A single alpha character indicates function type or category: A T Alarm or Warning Condition Not Available, High Level Alarm, Trip or Shutdown Condition Signal State Relay State Status Function S R F - - - - - DD Fn = Function Definition: Defines a specific input function. Function Lists Virtual Relay Menu Access: The ‘High Level’ menu access code is required to access virtual relay configuration menus. Unit Emergency Stop: The ‘Emergency Stop’ function of a unit (non-standard option) will de-energise all ‘real’ physical output relays, regardless of configuration or function. Special Function Virtual Relays: In addition to the standard virtual relays there are other special function virtual relays available; dependent on unit type. These include timer relays, pulse relays and specialised compressor status monitoring relays. All special function virtual relays have no direct association with any real physical output on a unit but can act as ‘input functions’ for any other local virtual relay. Virtual Relay Configuration Virtual Relay Automation Examples Page 38 Net$ync II Conductor 24 Virtual Relay Configuration: ST: Virtual Relays 01 to 16 R01 01.01 F1: F2: CF: 0 ST: 0 01 --- --- Fu: - On: Of : The normal state of the output when the input function logic is False: 0 1 --- Normally off ‘0’ – output will switch on ‘1’ when the input logic is True. Normally on ‘1’ – output will switch off ‘0’ when the input logic is True. 1 0 0s 0s NO NC F1: Input Function #1 This setting simulates the normally open (NO) or normally closed (NC) contacts of a relay device. The input function logic simulates the power to a relay device coil where ‘True’ equates to the relay coil being energised. F2: Input Function #2 On: On Delay If a second input function is not required adjust the ‘system unit’ setting of ‘F2’ to “- - -“ (dashes). The ‘Fu:’ setting will automatically change to “_F1” when only one function is set. Fu: Logic Function _F1 AND OR XOR CF: only one input function (F1) logical ‘AND’ function logical ‘OR’ function logical ‘Exclusive OR’ function If one or both of the set input functions is from a remote unit (R) this setting determines what happens in the event that the remote unit becomes unavailable or a communications disruption is experienced. 0 1 On: The output will switch off ‘0’ The output will switch on ‘1’ In the event of a remote unit communications disruption the input function state will remain as last updated until the communications timeout expires. When the input logic changes to True the output will not change state until the input has remained ‘True’ for the set ‘on delay’ time (seconds). Of: Off Delay Of: When the input logic changes to False the output will not change state until the input has remained ‘False’ for the set ‘off delay’ time (seconds). The ‘CF’ setting applies after the communications timeout and determines the output state of the virtual relay. This applies even if one input function is local (L). The ‘CF’ setting does not apply, and is ignored, if both input functions are local (L). Page 39 Technical Manual Virtual Timer Relay Configuration: In the event of a remote unit communications disruption the input function state will remain as last updated until the communications timeout expires. Virtual Relays T1, T2 Virtual timer relays have no association with any real physical relay outputs. The output state of a virtual timer relay can be used as an input function for any other virtual relay. When the input function logic is ‘True’ the timer relay will constantly cycle between the set ‘on’ and ‘off times. R02 01.01 F1: F2: CF: 0 SS: 0 --- --- Fu: - On: Of : Input Function #1 F2: Input Function #2 0s 0s Logic Function CF: only one input function (F1) logical ‘AND’ function logical ‘OR’ function logical ‘Exclusive OR’ function If one or both of the set input functions is from a remote unit (R) this setting determines what happens in the event that the remote unit becomes unavailable or a communications disruption is experienced. 0 1 Page 40 The timer relay stops The timer relay continues The start state of the output when the input function logic changes from False to True: 0 1 --- If a second input function is not required adjust the ‘system unit’ setting of ‘F2’ to “- - -“ (dashes). The ‘Fu:’ setting will automatically change to “_F1” when only one function is set. _F1 AND OR XOR SS: T1 F1: Fu: The ‘CF’ setting applies after communications timeout and determines the operation of the virtual timer relay. This applies even if one input function is local (L). The ‘CF’ setting does not apply, and is ignored, if both input functions are local (L). On: Off time ‘Of:’ is applied first On time ‘On:’ is applied first SS: 0 SS: 1 Of: On: Of: On: On: Of: On: Of: On Time Determines the ‘ON’ time of the cycling timer relay (seconds). Of: Off Time Determines the ‘OFF’ time of the cycling timer relay (seconds). The maximum adjustable time is 3600 seconds (1 hour). Net$ync II Conductor 24 Virtual Pulse Relay Configuration: Virtual Relays P1, P2, P3, P4 Virtual pulse relays have no association with any real physical relay outputs. The output state of a virtual pulse relay can be used as an input function for any other virtual relay. When the input function logic changes to a ‘True’ state the pulse relay will provide a single pulse output of the set duration. R02 01.01 F1: F2: CF: 0 FS: 0 P1 --- --- Fu: - On: F1: Input Function #1 F2: Input Function #2 --0m If a second input function is not required adjust the ‘system unit’ setting of ‘F2’ to “- - -“ (dashes). The ‘Fu:’ setting will automatically change to “_F1” when only one function is set. Fu: Logic Function _F1 AND OR XOR CF: only one input function (F1) logical ‘AND’ function logical ‘OR’ function logical ‘Exclusive OR’ function If one or both of the set input functions is from a remote unit (R) this setting determines what happens in the event that the remote unit becomes unavailable or a communications disruption is experienced. 0 1 No pulse output; disable pulse timer. Pulse. In the event of a remote unit communications disruption the input function state will remain as last updated until the communications timeout expires. The ‘CF’ setting applies after communications timeout and determines the operation of the virtual pulse relay. This applies even if one input function is local (L). The ‘CF’ setting does not apply, and is ignored, if both input functions are local (L). FS: Function Selection: ‘0’ OFF, no pulse. ‘1’ Pulse when input logic changes state from False to True. Ignore input status change if already pulsing. Continue with pulse if input logic status changes to False during pulse duration. ‘2’ Pulse when input logic changes state from False to True. If already pulsing, reset pulse duration time and continue pulse from beginning. Continue with pulse if input logic status changes to False during pulse duration. ‘3’ Pulse when input logic changes state from False to True. End pulse immediately if input logic changes to False during pulse duration time. On: Pulse Duration Time On: Determines the ‘pulse’ duration. Pulse relays P1 and P2 have adjustable pulse times in minutes. The maximum adjustable time is 3600 minutes (60 hours). P3 and P4 are set in seconds. The maximum adjustable time is 3600 seconds (1 hour). Page 41 Technical Manual Virtual Running Relay Configuration: Virtual Load Relay Configuration: Function ‘RF’ The virtual ‘Running’ relay is a specialised function that monitors for running conditions from selected compressor(s). The virtual running relay has no association with any real physical output. The output state of the virtual running relay can be used as an input function for any virtual relay. R02 08.01 C01: 1 C02: 1 C03: 1 RF C04: 1 2 AND C05: 0 C06: 0 1 RF C07: 0 C08: 0 C09: C10: C11: C12: - Function ‘LF’ The virtual ‘Load’ relay is a specialised function that monitors for loaded conditions from selected compressor(s). The virtual load relay has no association with any real physical output. The output state of the virtual load relay can be used as an input function for any virtual relay. R02 09.01 C01: 1 C02: 1 C03: 1 LF C04: 1 2 C05: 0 OR C06: 0 1 LF C07: 0 C08: 0 C09: C10: C11: C12: - The ‘Inputs’ for the virtual running relay are the selected compressors. The ‘Inputs’ for the virtual load relay are the selected compressors. 1) Compressors 1) Compressors 0 1 Not selected; compressor status is ignored Selected 0 1 Not selected; compressor status is ignored Selected 2) Logic Function 2) Logic Function AND logical ‘AND’ function If all selected compressor(s) are running switch on, otherwise switch off. AND logical ‘AND’ function If all selected compressor(s) are loaded switch on, otherwise switch off. OR logical ‘OR’ function If any one, or more, of the selected compressor(s) are running switch on. Only switch off if none of the selected compressor(s) are running. OR logical ‘OR’ function If any one, or more, of the selected compressor(s) are loaded switch on. Only switch off if none of the selected compressor(s) are loaded. The above example configuration set-up shows an eight compressor system with compressors 1 to 4 selected for monitor. The function logic (AND) means the output will only be True if ‘all’ the selected compressors are detected as running. Page 42 The above example configuration set-up shows an eight compressor system with compressors 1 to 4 selected for monitor. The function logic (OR) means the output will be True if ‘any’ of the selected compressors are detected as being loaded. Net$ync II Conductor 24 Virtual Availability Relay Configuration: Function ‘AF’ The virtual ‘Availability’ relay is a specialised function that monitors for availability of compressor(s) to the system management unit. A compressor becomes unavailable in the event of a trip (shutdown) condition or if the compressor is stopped. The virtual available relay has no association with any real physical output. The output state of the virtual available relay can be used as an input function for any other virtual relay. R02 07.01 C01: 1 C02: 1 1 C03: 1 AF C04: 1 2 C05: 0 AND C06: 0 AF C07: 0 C08: 0 C09: C10: C11: C12: - The ‘Inputs’ for the virtual availability relay are the selected compressors. 1) Compressors 0 1 Not selected; compressor status is ignored Selected. 2) Logic Function AND logical ‘AND’ function If all selected compressor(s) are OK and available switch off. Switch on if ‘any’ compressor becomes unavailable. OR logical ‘OR’ function If any selected compressor(s) are OK and available switch off. If ‘all’ selected compressor(s) become unavailable switch on. The above example configuration set-up shows an eight compressor system with compressors 1 to 4 selected for monitor. The function logic (AND) means the output will be False if ‘all’ of the selected compressors are detected as being available; the output will be True if ‘any’ of the selected compressors becomes unavailable. Page 43 Technical Manual 7.1 Function Lists: T1: Table #1 Active Net$ync II Management Unit - Functions T2: Table #2 Active L SYS F - - T3: Table #3 Active T4: Table #4 Active T5: Table #5 Active T6: Table #6 Active PF: Prefill Active AX: Start Time Function Active ZO: Zone Function Active EC: Energy Control Mode Active TM: Timer Rotation Mode Active EH: Equal Hours Mode Active PB: Pressure Balancing Function Active ON: System Management Unit Pressure Regulation Control Active ON: Prefill and normal operation OFF: Start Time Function, Standby, Stopped or Shutdown fault PS: Pressure Schedule Active RU: System Management Unit Running ON: Start Time Function, Prefill, normal operation and Standby modes OFF: Stopped or Shutdown fault AE: Start Time Function Input Fault AO: Capacity Alarm Override Active SR: Sequence Rotation Pulse The output will switch on for 5 seconds each time a Rotation Sequence change is made (automated or manual) TC: Table Change Pulse The output will switch on for 5 seconds each time a Table change is made (automated or manual) _1: Always ON (always True or ‘1’) SQ: ‘Q485’ Sequence Control Active SA: System Alarm (Warning): Any alarm condition associated with the system management unit. ST: System Trip (Shutdown): Any trip condition associated with the system management unit. SF: System Alarm (Warning) or Trip (Shutdown): Any alarm or trip condition associated with the system management unit. CA: Compressor Alarm (Warning): Any compressor alarm condition. CT: Compressor Trip (Shutdown): Any compressor trip condition. CF: Compressor Alarm (Warning) or Trip (Shutdown): Any compressor alarm or trip condition. BA: I/O Gateway Alarm (Warning): Any I/O Gateway input alarm condition (A). BT: I/O Gateway High Level Alarm (Warning): Any I/O Gateway input high level alarm condition (T). BF: I/O Gateway Alarm or High Level Alarm (Warning): Any I/O Gateway input alarm or high level alarm condition (A or T). BS: I/O Gateway Signal: Any I/O Gateway input signal (S). LP: Low Pressure Alarm (Warning) HP: High Pressure Alarm (Warning) IC: Insufficient Capacity Alarm (Warning) RC: Restricted Capacity Alarm (Warning) Page 44 Net$ync II Conductor 24 Net$ync II Management Unit - Signals T1: Virtual Timer Relay #1 L SYS S - - T2: Virtual Timer Relay #2 D1: Virtual Relay digital input #1 P1: Virtual Pulse Relay #1 D2: Virtual Relay digital input #2 P2: Virtual Pulse Relay #2 D3: Virtual Relay digital input #3 P3: Virtual Pulse Relay #3 D4: Virtual Relay digital input #4 P4: Virtual Pulse Relay #4 Net$ync II Management Unit - Relays RF: Comp Running Relay Relay Outputs R1 to R10 will respond to the setup of Virtual Relay R1 to 10 respectively. LF: Comp Loaded Relay AF: Comp Not Available Relay L SYS R - R1: Output Status of Virtual Relay #1 R2: Output Status of Virtual Relay #2 R3: Output Status of Virtual Relay #3 R4: Output Status of Virtual Relay #4 R5: Output Status of Virtual Relay #5 R6: Output Status of Virtual Relay #6 R7: Output Status of Virtual Relay #7 R8: Output Status of Virtual Relay #8 R9: Output Status of Virtual Relay #9 10: Output Status of Virtual Relay #10 11: Output Status of Virtual Relay #11 12: Output Status of Virtual Relay #12 13: Output Status of Virtual Relay #13 14: Output Status of Virtual Relay #14 15: Output Status of Virtual Relay #15 16: Output Status of Virtual Relay #16 Page 45 Technical Manual Compressor - Functions I/O Gateway – Input Alarm (A) R C01 F - - Monitors analogue and/or digital I/O Gateway inputs that has been set for Alarm (A) function. C01: Compressor #1 to C12: Compressor #12 RA: Available: started, running or standby mode (auto restart mode). Rn: Running Ld: Loaded AL: Any Alarm (Warning) Tr: Any Trip (Shutdown) Se: Service Maintenance Condition The ‘Q485’ Service Maintenance function has been activated; compressor is out-of-service for a short period. GF: Group Fault Any Alarm (Warning) or Trip (Shutdown) fault Ma: Maintenance The compressor has been selected as out-of-service for long term maintenance in the management unit ‘maintenance menu’. NW: Page 46 Network: RS485 data communications On = OK; Off when communications disrupted; only applicable to compressors connected to system management unit using RS485 data communications. R B01 A - B01 = I/O Gateway #1 to B12 = I/O Gateway #12 A1: A2: A3: A4: Alarm (A): Analogue Input#1 Alarm (A): Analogue Input#2 Alarm (A): Analogue Input#3 Alarm (A): Analogue Input#4 D1: D2: D3: D4: D5: D6: D7: D8: Alarm (A): Digital Input#1 Alarm (A): Digital Input#2 Alarm (A): Digital Input#3 Alarm (A): Digital Input#4 Alarm (A): Digital Input#5 Alarm (A): Digital Input#6 Alarm (A): Digital Input#7 Alarm (A): Digital Input#8 I/O Gateway – Input High Level Alarm (T) Monitors analogue and/or digital I/O Gateway inputs that has been set for High Level Alarm (T) function. R B01 T - B01 = I/O Gateway #1 to B12 = I/O Gateway #12 A1: A2: A3: A4: High Level Alarm (T): Analogue #1 High Level Alarm (T): Analogue #2 High Level Alarm (T): Analogue #3 High Level Alarm (T): Analogue #4 D1: D2: D3: D4: D5: D6: D7: D8: High Level Alarm (T): Digital Input#1 High Level Alarm (T): Digital Input#2 High Level Alarm (T): Digital Input#3 High Level Alarm (T): Digital Input#4 High Level Alarm (T): Digital Input#5 High Level Alarm (T): Digital Input#6 High Level Alarm (T): Digital Input#7 High Level Alarm (T): Digital Input#8 Net$ync II Conductor 24 I/O Gateway – Input Signal (S) I/O Gateway – Functions Monitors analogue and/or digital I/O Gateway inputs that has been set for signal (S) function. R B01 F - - The ‘Signal’ function is intended for automation purposes only and does not generate a fault condition or display message. B01 = I/O Gateway #1 to B12 = I/O Gateway #12 R B01 S - B01 = I/O Gateway #1 to B12 = I/O Gateway #12 A1: A2: A3: A4: Signal (S): Analogue Input#1 Signal (S): Analogue Input#2 Signal (S): Analogue Input#3 Signal (S): Analogue Input#4 D1: D2: D3: D4: D5: D6: D7: D8: Signal (S): Digital Input#1 Signal (S): Digital Input#2 Signal (S): Digital Input#3 Signal (S): Digital Input#4 Signal (S): Digital Input#5 Signal (S): Digital Input#6 Signal (S): Digital Input#7 Signal (S): Digital Input#8 AA: Analogue Input Alarm Any analogue input Alarm function (A) AT: Analogue Input High Level Alarm Any analogue input High Level Alarm function (T) AS: Analogue Input Signal Any analogue input Signal function (S) AF: Analogue Input Fault Any analogue input Alarm function (A) or High Level Alarm function (T). DA: Digital Input Alarm Any digital input Alarm function (A) DT: Analogue High Level Alarm Any digital input High Level Alarm function (T) DS: Digital Input Signal Any digital input Signal function (S) DF: Digital Input Fault Any digital input Alarm function (A) or High Level Alarm function (T). GA: General Input Alarm Any analogue or digital input Alarm function (A) GT: General High Level Alarm Any analogue or digital input High Level Alarm function (T) GS: General Input Signal Any analogue or digital input Signal function (S) GF: General Input Fault Any analogue or digital input Alarm function (A) or High Level Alarm function (T). NW: Network: RS485 data communications On = OK; Off when communications disrupted. Page 47 Technical Manual 7.3 Virtual Relay Automation Examples Example 1: Virtual relay #1 of the system management unit is configured to respond to the local ‘Ru’ (unit running) function. Virtual relay #1 is associated with output relay R1 of the unit. The contacts of R1 are used to operate an air dryer unit. R01 01.01 01 F1: L SYS F Ru F2: - - - - - - Fu: _F1 CF: 0 On: 0s ST: 0 Of : 0s When the system management unit is running and utilising compressors the air dryer unit is activated. When the system management unit is stopped, or enters standby mode using the real time clock pressure schedule facility, the air dryer unit will stop. Example 2: Virtual Relay #1 of the system management unit is configured to respond to the local ‘LP’ (low pressure alarm) function. Virtual relay #1 is associated with output relay R1 of the unit. The contacts of R1 are used to operate a zone value to isolate a non-critical part of the air system. Virtual Relay #1 is also configured to monitor digital input #2 of I/O Gateway #1, located remotely. The digital input is connected to a manual zone isolation switch in a remote control room. R01 01.01 F1: L SYS F LP F2: R B01 S D2 Fu: OR CF: 0 On: 0s ST: 0 Of : 0s If a low-pressure alarm occurs, or the remote manual zone isolation switch is activated, the zone valve is energised and the air system zone isolated. R1 I/O Gateway 1 R1 Page 48 01 D2 Net$ync II Conductor 24 Example 3: Virtual Relay #1 of the system management unit is configured to respond to the local virtual timer relay ‘T1’. Virtual relay #1 is associated with output relay R1 of the unit. The contacts of R1 are used to operate a number of condensate drain valves in the air system. Example 4: An installation consists to four compressors. Compressors 1 and 2 are located in an area adjacent to the system management unit. Compressors 3 and 4 are located in a remote area and connected to the management unit using RS485 communications. R01 01.01 Compressors 1 and 2 are water cooled; if one or both of the compressors are utilised a water cooling pump must be operated. 01 F1: L SYS R T1 F2: - - - - - - Fu: _F1 CF: 0 On: 0s ST: 0 Of : 0s Virtual Timer Relay T1 is configured to respond to the local ‘Ru’ (unit running) function and will switch ‘on’ for 5 seconds, every 2 minutes, when the ‘Ru’ input function is ‘True’. R02 01.01 T1 F1: L SYS F Ru F2: - - - - - - Fu: _F1 CF: 0 On: 5s SS: 0 Of : 115 s When the system management unit is running the condensate drains will open periodically in accordance with the ‘on time’ and ‘interval time’ (off time) configured for virtual timer relay T1. When the system management unit is stopped, or enters standby mode using the real time clock pressure schedule facility, the condensate drains will not operate. R1 Virtual Relay #1 of the system management unit is set-up to respond to the ‘RF’ (selected compressor(s) running virtual relay). R01 01.01 01 F1: L SYS R RF F2: - - - - - - Fu: _F1 CF: 0 On: 0s 30 s ST: 0 Of : Virtual relay #1 is also set-up to run the water cooling pump for a further 30 seconds cooling down period after compressor 1 and/or 2 stop running. The ‘RF’ virtual relay is set-up to detect when compressor 1 and/or 2 is running. Compressor(s) 3 and 4 are ignored. R02 08.01 C01: 1 C02: 1 C03: 0 RF C04: 0 C05: OR C06: - RF C07: C08: C09: C10: C11: C12: - Virtual relay #1 is associated with output relay R1 that is used to start and run the water cooling pump. When the system management unit utilises compressor 1 and/or compressor 2 the water cooling pump is automatically run. The pump is not run if only compressor 3 and/or compressor 4 is utilised. Page 49 Technical Manual 8.0 OPERATION Unit Status: Stopped 8.1 User Interface Standby Graphic Display: d 1 7.0 Started and Running b BAR Alarm (Warning) c 17:30 #1 e a) b) c) d) e) a a b On Slow Flash: 1sec Fast Flash: f g Off 1sec Keypad: e Indicators Intermittant: System Pressure Value System Pressure Units Unit Status Unit Active Functions User Menu Item d Shutdown (Trip) c 1sec a) b) c) d) e) f) g) Start Stop Reset Escape (Cancel) Up (Plus) Down (Minus) Enter 8.2 Unit Status: System Pressure: Increasing to normal operational levels (Prefill, target pressure change or at system start) 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 Page 50 Unit Indicators Unit Run Indicator (Green LED) OFF – Not Active, Stopped Slow Flash: Active, Standby Mode ON – Active, Running Unit Fault Indicator (Red LED) Fast Flash: Shutdown (Trip) Slow Flash: Alarm (Warning) The Conductor 24 fault indicator does not indicate compressor fault states; see Compressor Status Indicators. Net$ync II Conductor 24 8.3 Compressor Status Indicators: Fast Flash – One or more compressors Not Available, Shutdown Fault or Stopped a b c 1 Each compressor in the system has a set of dedicated status indicators. The indicators will continuously show the status of each compressor at all times. a) Load Status OFF – Not Loaded, Offload Slow Flash – The compressor has been requested to load but is not loaded (load or re-load delay period) ON – Loaded Slow Flash – One or more compressors Alarm (Warning) b) Insufficient Capacity Alarm (Warning) On – Insufficient Capacity c) Restricted Capacity Alarm (Warning) Slow Flash – Restricted Capacity 8.5 Unit Functions: Operating Mode: Equal Hours Run Timer Rotation b) Run Status OFF – Not Running Slow Flash – The compressor has been requested to load but is not running (blowdown delay or other start delay) ON – Running c) Available (Started) OFF – No Commpressor Connected Fast Flash – Not Available, Shutdown Fault or Stopped Slow Flash – Alarm (Warning) Intermittent Flash – The compressor has been intentionally removed from service. Available, OK 8.4 System Alarms (Warnings): Active Functions: Power Failure Auto-Restart 1 1 Table #1 Active 2 2 Table #2 Active 3 3 Table #3 Active 4 4 Table #4 Active 5 5 Table #5 Active 6 6 Table #6 Active Standby Mode Active Prefill Function Zone Function Pressure Schedule a b Energy Control Function Inhibited (manual override) CAP Remote Manual Override c a) Group Compressor Fault OFF – All Compressors OK Page 51 Technical Manual 8.6 User Menu Primary Detected Pressure: A number of User menu information displays are available that can be accessed directly from the front panel using the Up and Down navigation buttons. Real Time Clock: 17:30 #1 Compressor Detailed Status: A: 100% Compressor 1 ‘A’ (Duty) sequence assignment ‘100%’ percentage load Status Symbol: Standby Running, Offload Running, Loaded # Removed From Service in Table Priority Selection (# = Table Number) Removed From Service in Long Term Maintenance Menu Removed From Service by Short Term Q485 Maintenance Switch Function Alarm (Warning) Not Available, Shutdown (Trip), Stopped Network Communications Error (RS485 connectivity only) The detailed status of each compressor in the system is shown separately. Page 52 bar The pressure detected on the unit’s primary pressure sensor. 17:30 (24hr system) #1 = Monday to #7 = Sunday 1 7.0 When using remote pressure balancing functions the main display ‘control’ pressure may differ from the primary detected pressure. Pressure Balance Function 2nd Pressure Input: 6.9 bar The second local pressure value. 2nd Pressure Sensor Input Differential Pressure: 510 mBar The differential pressure between the Primary and 2nd Pressure sensor inputs. Only displayed if the 2nd Pressure sensor function is selected for air treatment pressure differential monitoring. 2nd Pressure Sensor Input Remote Pressure #1: 7.2 bar The first remote pressure value from a remote source. Used for the Pressure Balance Function. Only displayed if the Pressure Balance Function is activated and the first remote pressure has been selected. Net$ync II Conductor 24 8.7 Information Displays Pressure Balance Function Remote Pressure #2: 7.1 bar The second remote pressure value from a remote source. Used for the Pressure Balance Function. Only displayed if the Pressure Balance Function is activated and the second remote pressure has been selected. Pressure Balance Function To view detailed information applicable to the selected User menu display item press Enter. Press Escape to return to the normal user menu display items. Real Time Clock: P00 2 #1 18:30 3 T2 4 1 1 Next Scheduled Sequence Rotation: 00:00 #1 Shows the next Pressure Schedule event. 1: 2: 3: 4: The next scheduled sequence rotation: 00:00 Time (24hr system) #1 Monday A setting of zero hundred hours (00:00hrs) on Monday (#1) equates to a sequence rotation at one second past midnight on Sunday. The Current Active Table Day (#1=Monday, #7=Sunday) Time (24hr system) Table Items 2 and 3 show the day and time that the unit will change to use the ‘Table’ shown in item 4. Compressor Status: P00 V-485 4 1 100 % 5 1 20 % 30 % 6 3 1 1 2 1: 2: 3: 4: 5: 6: 7: 7 Compressor Number Priority Setting Zone Allocation Setting Compressor/Connection Type Maximum Capacity % Setting Minimum Capacity % Setting Minimum Efficiency % Setting Item values 6 and 7 are only shown if compressor type is V-485 (variable capacity/speed). Page 53 Technical Manual Primary Detected Pressure: 2nd Remote Pressure: P00 P00 1 1 7.2 bar 2 6.8 bar 3 6.0 bar 4 B02 1: Active Table 2: Upper (Unload) Pressure Set Point 3: Lower (Load) Pressure Set Point 4: Minimum Pressure Alarm (Warning) 1: Source of 2nd Remote Pressure Differential Pressure: Sequence Rotation: P00 P00 Only show if pressure balancing function active and 2nd remote pressure in use. 1.0 bar 1 #4 30 sec 2 18 / 05 / 2006 P2(SYS) 3 1: Alarm (Warning) Level 2: Alarm (Warning) Delay Time 3: Source of 2nd Pressure 18:00 ABCD 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. Only show if the 2nd pressure sensor is activated in air treatment pressure differential mode. The active ‘mode’ of operation 1st Remote Pressure: “ABCD” The current active rotation sequence assignment. P00 8.8 Manual Sequence Rotation: B01 1: Source of 1st Remote Pressure Only show if pressure balancing function active. Pressure Balance Function Page 54 1 1 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 again 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. Net$ync II Conductor 24 8.9 Compressor Identification Each compressor connected to the Conductor 24 will have a unique assigned compressor identification number; starting at compressor 1 increasing sequentially to the number of compressors connected to the Conductor 24. 1 2 3 4 5 6 7 8 9 10 11 12 To manually skip the Start function, press and hold Start for several seconds. 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 CAP To manually skip the Prefill function, press and hold Start for several seconds. When Prefill is complete, if applicable, the Conductor 24 will enter normal operating mode. 1 2 3 4 8.10 Stop: The Conductor 24 will operate in accordance with the parameters and options set in the active ‘Table’. Tables To stop the Conductor 24 press Stop. The Conductor 24 will respond dependant on the setup of item ‘CF’ in menu S02: 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 Conductor 24 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 24. 8.11 Start: Each compressor in the system must be started (running or in a standby or auto restart condition) before Conductor 24 control of the compressor can be established. The Conductor 24 will not start a compressor that is in a stopped condition. 8.12 Power Failure Auto-Restart If the power failure auto-restart function is enabled the Conductor 24 will automatically start, when power is restored after a disruption or failure, if the Conductor 24 was in a ‘started’ state when the power disruption or failure occurred. The Conductor 24 will not automatically restart if the Conductor 24 was in a stopped state when the power disruption or failure occurred. 8.13 Failure Mode If the Conductor 24 experiences a disruption to normal control, or an Conductor 24 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). To start the Conductor 24 press Start. If the ‘Start Function’ is enabled there will be a period of time before any compressor is requested to load. Start Function Page 55 Technical Manual 8.14 Reset Trip (Shutdown): To reset an Conductor 24 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. 8.15 Compressor Fault Indications Compressor fault conditions are displayed by the compressor indicators and in the user user menu status screen. Compressor fault conditions are not regarded as Conductor 24 unit fault conditions. Compressor Status Sysmbols and Comressor Status Indicators 8.16 Fault Codes Fault codes are separated in to unit faults ‘ERR’ and system Alarms (Warning) ‘SYS’. ERR: Unit faults are errors with the Conductor 24 controller itself and are all conditions that prevent normal operation from continuing. SYS: System faults are items that arise from conditions external to the Conductor 24 controller; the Conductor 24 itself continues to function correctly. There are two types of Fault condition: Alarm (Warning): 1sec The Fault LED will ‘slow flash’ to indicate an Alarm (Warning) condition. An Alarm (Warning) indicates that the Conductor 24 is continuing with normal operation but user attention is required. All Alarm (Warning) conditions are registered in the Conductor 24 Error Log. All Alarm (Warning) conditions must be manually reset. Page 56 1sec The Fault LED will ‘fast flash’ to indicate a Trip (Shutdown) condition. A Trip (Shutdown) condition will stop normal operation of the Conductor 24. Pressure regulation control will automatically revert to the individual compressors that will continue to operate using the pressure settings for their own control systems. All Trip (Shutdown) conditions are registered in the Conductor 24 Error Log. All Trip (Shutdown) conditions must be manually reset. Fault Codes: Each individual fault has a unique numeric code. ERR.01 Pressure Sensor Fault The signal from the control pressure sensor is out-of-range (<3.5mA or >21.8mA). ERR.02 Flow Sensor Fault The signal from the airflow sensor is out-ofrange (<3.5mA or >21.8mA). ERR.03 2nd Pressure Sensor Fault The signal from the 2nd pressure sensor is outofrange (<3.5mA or >21.8mA). ERR.04 Internal 24V Fault The 24VDC power supply, internal to the unit’s controller, is below 19.2V (internal controller fault) ERR.05 Emergency Stop The wire link between terminals ‘+C’ and ‘C1’ of the unit’s controller is open circuit. These terminals are permanently connected together on the XC Terminal PCB: this error will never occur in normal operational circumstances. ERR.06 Real Time Clock Error The Real Time Clock device, internal to the unit’s controller, has failed. Net$ync II Conductor 24 ERR.07 XPM-LED Module Error Data communications with the internal XPMLED (Status LED Display) module have been disrupted or lost. ERR.08 XPM-Di8R4 Module Data communications with the internal XPMDi8R4 module have been disrupted or lost. ERR.09 XPM-Di8R4 Module Short Circuit condition detected on internal XPM-Di8R4 module. ERR.10 Q485 Gateway Expansion Module C1-4 Data communications with the external Q485 Expansion module ‘C:1-4’ have been disrupted or lost. SYS.03 Start Function Feedback Start Function Feedback signal did not occur or has been lost during operation. SYS.04 Capacity Alarm (Warning) Insufficient Capacity; all available compressors are loaded and pressure is still decreasing. SYS.05 Remote Alarm (Warning) Auxiliary Input Function ‘AA’ The auxiliary Input is set for ‘Alarm (always active)’ function and is in a Fault condition. SYS.06 Remote Alarm (Warning) Auxiliary Input Function ‘AR’ ERR.11 Q485 Gateway Expansion Module C1-4 Short Circuit condition detected on external IPCB Expansion module ‘C:1-4’. The auxiliary Input is set for ‘Alarm (active when unit running)’ function and is in a Fault condition. ERR.12 Q485 Gateway Expansion Module C5-8 Data communications with the external Q485 Gateway Expansion module ‘C:5-8’ have been disrupted or lost. SYS.07 Remote Trip (Shutdown) Auxiliary Input Function ‘TA’ ERR.13 Q485 Gateway Expansion Module C5-8 Short Circuit condition detected on external IPCB Expansion module ‘C:5-8’. ERR.14 Q485 Gateway Expansion Module C9-12 Data communications with the external Q485 Gateway Expansion module ‘C:9-12’ have been disrupted or lost. The auxiliary Input is set for ‘Trip/Shutdown (always active)’ function and is in a Fault condition. SYS.08 Remote Trip (Shutdown) Auxiliary Input Function ‘TR’ The auxiliary Input is set for ‘Trip/Shutdown (active when unit is running)’ function and is in a Fault condition. ERR.15 Q485 Gateway Expansion Module C9-12 Short Circuit condition detected on external IPCB Expansion module ‘C:9-12’. SYS.01 Excess Pressure (PM) Pressure has exceeded the set Maximum Pressure Limit. SYS.02 Min Pressure (Pm) Pressure has fallen below the set Minimum Pressure Limit (see ‘Tables’) Page 57 Technical Manual Internal Controller Fault ‘E’ Codes: ‘E’ code errors are specific to the unit’s ‘internal to controller’ digital logic circuits and will only occur in the most exceptional of circumstances. All ‘E’ code conditions are Trip (Shutdown) type faults. The ‘Fault’ (red) LED will ‘fast flash’ and the condition is registered in the Error Log. If an ‘E’ code fault condition persists, consult your product supplier for advise or renew the unit’s controller. E0836: PLL Unlock; Internal failure or excessively high external electrical interference detected. The main timing circuit (processor clock) has been disrupted and the processor is running on an ‘internal to chip’ back-up clock. The back-up clock is intended to keep the processor running, at a much slower processing speed, to enable emergency actions to be taken. The controller is unable to continue running the main software application in this condition. The unit will Shutdown; compressors will continue to operate using local pressure regulation. The controller’s main power supply must be removed and re-applied to reset this condition. E0866: Controller internal power supply fault The low voltage logic processing power supply, internal to the unit’s controller, is below minimum operational levels; internal to controller fault. Renew the controller if this fault condition persists. The Trip must be manually reset from the keypad. E5000: Internal memory map error The unit’s controller has detected disruption to the internal operational memory storage (RAM). The integrity of the RAM memory contents are suspect; the controller must be reset to clear and re-map the memory. Renew the controller if this fault condition persists. The controller’s main power supply must be removed and re-applied to reset this condition. E5001: Internal memory failure The unit’s controller has detected disruption to the internal permanent application memory storage (FLASH). The integrity of the FLASH memory contents is suspect. Re-load the main application software in the first instance; renew the controller if the condition persists. The controller’s main power supply must be removed and re-applied to reset this condition. To Display the Software Version: Press and hold Reset then press Escape. The user menu display item will show the software version ID (example: “E01”). Page 58 Net$ync II Conductor 24 9.0 Parts List Item Part No. Description 2014000027 - 1 2 3 4 5 6 7 Net$ync II Conductor 24 Manual, User CD Unit, Controller Unit, XPM-PSU24 Unit, XPM-Di8R4 Unit, XPM-TAC24 PCB, Terminal Unit, XPM-LED Gland, Set - Pg13.5 8 2014000042 Sensor, Pressure 4-20mA, 232psi (16bar) 4 5 6 3 2 1 7 Engineering 8 20mm IEC Qty 5mm Part No. 10 10 10 Description IEC Fuse T1.0A IEC Fuse T1.6A IEC Fuse T3.15A 10.0 Technical Data Dimensions Weight Mounting wall, Enclosure Supply Power Temperature Humidity 340mm x 241mm x 152mm 13.40” x 9.45” x 6.0” 7.5kg (16.5lb) 4 x screw fixings IP54, NEMA 12 230Vac +/- 10% 115Vac +/- 10% 100VA 0°C to 46°C (32°F to 115°F) 95% RH, non-condensing Mounting Dimensions: 27mm 286mm 27mm 188mm 8mm Ø Page 59 Technical Manual C09 C030 4 Ai2 C030 C010 3 +VDC C010 C031 Ai3 C031 C012 A-GND C012 Ao C033 C06 C012 1 L1 2 L2 3 Page 60 XPM-PSU24 X01 3 C032 C034/5 C011 C034/6 1 2 X03 X02 XPM-LED L2 Multi485 Network L1 C023 C010 C029 C015 - P2 2nd Pressure X06 C08 C031 21 22 23 24 C028 X05 C022 17 18 19 20 C021 4-20mA - P1 Control Pressure 4-20mA C014 X03 C021 C022 24Vac 1 X02 24VDC 2 1 1 (2/2) XPM-Di8R4 C030 C09 X02 C023 1 7 24Vac X03 C026 5 6 C027 X04 C034/2 8 9 10 11 12 C034/1 X01 2 L2 L1 C020 2 1 X07 25 26 27 28 C034/4 C025 24VDC 0VDC Ao 4-20mA Output ‘active’ X01 X01 XPM-TAC24 X02 1 2 N E E L XPM485 1 L1 2 L2 C033 0Vac - earthed X03 X10 C028 C06 C034/3 R4 2 X09 C08 C020 3 C03 C028 X02 X03 X01 24Vac 1 C027 R3 2 1 C03 C07 (2/2) C017 C016 C016 R2 230Vac 10% 115Vac 10% C04 C017 C08 R1 N E L C018 C027 C07 R6 RS485#1 C032 C07 C04 C05 X08 C026 C014 C026 C018 C019 35 36 37 38 X04 C014 C025 C05 C023 31 32 33 34 C025 C013 C019 29 30 X09 C013 R4 Relay Output 4 250V ‘CE’ 115V ‘UL’ 4A max C022 13 14 15 16 X06 X08 X07 L2 L1 Multi485 C024 R5 Relay Output 5 C021 C024 R5 C011 C020 C032 C+ 1 2 3 4 5 6 7 8 RS485#2 (2/2) C033 C011 X13 5 +VDC R6 Relay Output 6 X12 C09 X11 6 Ai1 39 40 41 42 43 44 C029 C029 2 C015 L2 L1 XPM485 2 C034 C015 +VDC X05 Conductor 24 T1-46-333-R6-CB 1 2 3 4 1 of 2 11.0 Wiring Connection Diagram Di4 +C Di3 +C Di2 +C Standby Sequence Change Remote Start/Stop - F1 Flow Meter 4-20mA Terminal PCB X01 4 3 2 1 R3 Relay Output 3 R2 Relay Output 2 R1 Relay Output 1 RC Common R3 R2 R1 RC 24V max RC=8A max X05 20 19 18 17 Di8 Table #4 +C Di7 Table #3 +C X04 16 15 14 13 Di6 Table #2 +C Di5 Table #1 +C 250V ‘CE’ 115V ‘UL’ 4A max XPM-Di8R4 8 R10 Relay Output 10 R9 Relay Output 9 R8 Relay Output 8 R7 Relay Output 7 7 R4 2 L1 L2 6 3 XPM485 L1 L2 2 XPM485 (1/2) R3 4 R2 2 3 X05 X02 1 5 Conductor 24 2 of 2 Net$ync II Conductor 24 1 Di1 Di7 3 5 +C Di9 Table #5 +C Di10 Table #6 +C Di11 Start Function +C Feedback Input Di12 not used +C Di13 VR Input #1 +C Di14 VR Input #2 +C Di15 VR Input #3 +C Di16 VR Input #4 L2 L1 Di8 16 15 14 13 12 11 10 Di6 2 XPM485 1 L2 L1 X03 X04 Di5 9 8 Di4 6 XPM-PSU24 Di3 7 Di2 (1/2) 4 3 1 2 1 X01 0VDC +24VDC 1 2 - + R1 3 (1/2) XPM-TAC24 XPM-Di8R4 XPM-PSU24 Terminal PCB XPM-LED T1-46-333 Page 61 Technical Manual XPM-TAC24 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 Page 62 4 2 24Vac/1 isolated NL E E FH1 X01 E Net$ync II Conductor 24 Net$ync II Conductor 24 Commissioning Form Customer Contact Customer Ref: Phone Internal Ref: Installation/Site Commission Date Ser No. Software Commission Engineer 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 3 #5 bar m /min kW VA Hz Comp #5 Manufacturer Comp #5 Model/Type Comp #5 Working Pressure Comp #5 Full Load Capacity bar/psi m3/min #6 bar m3/min kW VA Hz Comp #6 Manufacturer Comp #6 Model/Type Comp #6 Working Pressure Comp #6 Full Load Capacity bar/psi m3/min #7 bar m3/min kW VA Hz Comp #7 Manufacturer Comp #7 Model/Type Comp #7 Working Pressure Comp #7 Full Load Capacity bar/psi m3/min #8 bar m3/min kW VA Hz Comp #8 Manufacturer Comp #8 Model/Type Comp #8 Working Pressure Comp #8 Full Load Capacity bar/psi m3/min Page 63 Technical Manual Page 64 3 #9 bar m /min kW VA Hz Comp #9 Manufacturer Comp #9 Model/Type Comp #9 Working Pressure Comp #9 Full Load Capacity bar/psi m3/min #10 bar m3/min kW VA Hz Comp #10 Manufacturer Comp #10 Model/Type Comp #10 Working Pressure Comp #10 Full Load Capacity bar/psi m3/min #11 bar m3/min kW VA Hz Comp #11 Manufacturer Comp #11 Model/Type Comp #11 Working Pressure Comp #11 Full Load Capacity bar/psi m3/min #12 bar m3/min kW VA Hz Comp #12 Manufacturer Comp #12 Model/Type Comp #12 Working Pressure Comp #12 Full Load Capacity bar/psi m3/min T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 T01 PH PL Pm SQ 01 02 03 04 05 06 07 08 09 10 11 12 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 Comp #5 Priority Comp #6 Priority Comp #7 Priority Comp #8 Priority Comp #9 Priority Comp #10 Priority Comp #11 Priority Comp #12 Priority T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 T02 PH PL Pm SQ 01 02 03 04 05 06 07 08 09 10 11 12 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 Comp #5 Priority Comp #6 Priority Comp #7 Priority Comp #8 Priority Comp #9 Priority Comp #10 Priority Comp #11 Priority Comp #12 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 TR TR TR ENERGY ENERGY ENERGY bar/psi bar/psi bar/psi bar/psi bar/psi bar/psi bar/psi bar/psi bar/psi Net$ync II Conductor 24 T03 T03 T03 T03 T03 T03 T03 T03 05 06 07 08 09 10 11 12 Comp #5 Priority Comp #6 Priority Comp #7 Priority Comp #8 Priority Comp #9 Priority Comp #10 Priority Comp #11 Priority Comp #12 Priority T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 T04 PH PL Pm SQ 01 02 03 04 05 06 07 08 09 10 11 12 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 Comp #5 Priority Comp #6 Priority Comp #7 Priority Comp #8 Priority Comp #9 Priority Comp #10 Priority Comp #11 Priority Comp #12 Priority P02 P02 P02 P02 P02 PF PT PP - Prefill Function Prefill Time Prefill Pressure Primary Compressors Backup Compressors S01 S01 S01 S01 PS AR RP TS Pressure Schedule Auto Restart Rotation Interval Default Table Select S02 S02 S02 S02 S02 S02 S02 S02 S02 S02 S02 S02 S02 NC PM CF TO DA ST SF PC P2 DP DD CA MA S03 S03 S04 S04 S04 S04 S04 S04 EHR TR bar/psi bar/psi bar/psi ENERGY !>X A^^ 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 Number of Compressors Max Pressure Alarm Stop Control Function Tolerance Damping Start Delay Time Start Function Pressure Change Time 2nd Pressure Sensor DP Alarm Level DP Delay Time Capacity Alarm Capacity Restricted Alarm 1 2 3 4 5 6 7 8 9 10 BT Aux I/O Box Monitoring RS485 Timeout 1 1o 1r 2o 2r 3o 3r Pressure Offset Pressure Range 2nd Pressure Offset 2nd Pressure Range Airflow Sensor Offset Airflow Sensor Range sec bar/psi 11 11 12 12 11 12 bar/psi sec min P1<>P2 2 3 4 P2+=DP 5 6 7 mBar sec 8 9 10 11 sec 12 bar/psi bar/psi bar/psi bar/psi m3/min m3/min Page 65 Technical Manual Page 66 C03 C03 C03 C03 C03 07 - Compressor #7 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 08 - Compressor #8 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 09 - Compressor #9 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 10 - Compressor #10 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 11 - Compressor #11 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 12 - Compressor #12 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C04 C04 C04 C04 C04 C04 C04 C04 C04 C04 C04 C04 01 02 03 04 05 06 07 08 09 10 11 12 Compressor #1 Zone Compressor #2 Zone Compressor #3 Zone Compressor #4 Zone Compressor #5 Zone Compressor #6 Zone Compressor #7 Zone Compressor #8 Zone Compressor #9 Zone Compressor #10 Zone Compressor #11 Zone Compressor #12 Zone 1 1 1 1 1 1 1 1 1 1 1 1 sec % % % sec % % % sec % % % sec % % % sec % % % sec % % % 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 Net$ync II Conductor 24 C03 C03 C03 C03 C03 07 - Compressor #7 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 08 - Compressor #8 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 09 - Compressor #9 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 10 - Compressor #10 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 11 - Compressor #11 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C03 C03 C03 C03 C03 12 - Compressor #12 Type Start Time Max Capacity Min Capacity Min Efficiency I-485 V-485 I-PCB C04 C04 C04 C04 C04 C04 C04 C04 C04 C04 C04 C04 01 02 03 04 05 06 07 08 09 10 11 12 Compressor #1 Zone Compressor #2 Zone Compressor #3 Zone Compressor #4 Zone Compressor #5 Zone Compressor #6 Zone Compressor #7 Zone Compressor #8 Zone Compressor #9 Zone Compressor #10 Zone Compressor #11 Zone Compressor #12 Zone 1 1 1 1 1 1 1 1 1 1 1 1 sec % % % sec % % % sec % % % sec % % % sec % % % sec % % % 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 Page 67 Technical Manual Net$ync II Virtual Relay Automation R01 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R02 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R03 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R04 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R05 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R06 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R07 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R08 F1: F1 / AND / OR / XOR F2: Page 68 On: t Of: t ST=0 ST=1 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec Net$ync II Conductor 24 Net$ync II Virtual Relay Automation R09 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R10 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R11 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R12 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R13 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R14 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R15 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 R16 F1: F1 / AND / OR / XOR F2: On: t Of: t ST=0 ST=1 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 F1 F2 Fu CF ST On Of F1 0 0 AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec AND 1 1 OR XOR sec sec Page 69 Technical Manual Net$ync II Virtual Relay Automation T01 F1: F1 / AND / OR / XOR F2: t On: SS: 0 SS: 1 t t Of: T02 F1: F1 / AND / OR / XOR F2: t On: SS: 0 SS: 1 t t Of: T03 F1: F1 / AND / OR / XOR F2: t On: SS: 1 t t Of: P01 F1: F1 / AND / OR / XOR F2: On: t t P01 F1: F1 / AND / OR / XOR F2: On: t t P03 F1: F1 / AND / OR / XOR F2: On: t t P04 F1: F1 / AND / OR / XOR F2: On: Page 70 t t SS: 0 F1 F2 Fu CF SS On Of F1 0 0 F1 F2 Fu CF SS On Of F1 0 0 F1 F2 Fu CF SS On Of F1 0 0 F1 F2 Fu CF FS On F1 F2 Fu CF FS On F1 F2 Fu CF FS On F1 F2 Fu CF FS On AND 1 1 OR XOR sec sec AND 1 1 OR XOR min min AND 1 1 OR XOR hr hr F1 0 0 AND 1 1 OR XOR 2 3 min F1 0 0 AND 1 1 OR XOR 2 3 min F1 0 0 AND 1 1 OR XOR 2 3 sec F1 0 0 AND 1 1 OR XOR 2 3 sec Net$ync II Conductor 24 Net$ync II Virtual Relay Automation Fu RF f Fu LF f Fu AF f AND OR C01 C07 C02 C08 AND OR C01 C07 C02 C08 AND OR C01 C07 C02 C08 C03 C09 C04 C10 C05 C11 C06 C12 C03 C09 C04 C10 C05 C11 C06 C12 C03 C09 C04 C10 C05 C11 C06 C12 Page 71 Technical Manual Page 72 ">

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Key features
- Pressure control
- Tolerance
- Damping
- Sequence Control
- Prefill
- Priority settings
- Compressor Status Monitoring
- Alarm system
- Compressor Fault Indications
- RS485 communication
Frequently asked questions
The Conductor 24 maintains system pressure between the 'High Pressure' and 'Low Pressure' set points, while aiming for optimal energy efficiency. It dynamically calculates a 'Target' pressure level and adjusts compressor loading and unloading based on pressure changes and demand fluctuations.
'Tolerance' defines a pressure band above and below the set pressure control levels. It allows for exceptional instances of abrupt or significant increase/decrease in demand without compromising optimal energy efficient control by providing a buffer zone for pressure fluctuations.
The Conductor 24 offers three sequence control strategies: 'Equal Hours Run', 'Timer Rotation', and 'Energy Control'. Each strategy defines how compressors are arranged and utilized in response to system pressure variations, optimizing efficiency and compressor life.