MANY0706A.GB – Net$ync II Direct Connect Gateway Technical Manual
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Net$ync II
Direct Connect Gateway
Net$ync II Direct Connect Gateway
1. Safety Precautions
ALWAYS EMPLOY SAFE WORKING
PRACTISE 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.
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
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.
Service, maintenance, repairs or modifications must
only be carried out by competent personnel under
qualified supervision.
1.2 Installation
•
Installation work must only be carried out by a
competent person under qualified supervision.
A fused isolation switch must be fitted between the
main power supply and the product.
The product should be mounted in such a location
as to allow operational and maintenance access
without obstruction or hazard and to allow clear
visibility of indicators at all times.
If raised platforms are required to provide access to
the product they must not interfere with normal
operation or obstruct access. Platforms and stairs
should be of grid or plate construction with safety
rails on all open sides.
1.3 Operation
The product must only be operated by competent
personnel under qualified supervision.
Never remove or tamper with safety devices, guards
or insulation materials fitted to the unit.
The product must only be operated at the supply
voltage and frequency for which it is designed.
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.
Page 1
Technical Manual
Net$ync II Direct Connect Gateway (Option)
A Net$ync II Direct Connect Gateway will add, or
extend, the number of available direct connect ‘Q485’
terminals to a standard Net$ync II Conductor 12 or
Conductor 24 system management unit.
Net$ync II Conductor 24:
As standard a Net$ync II Conductor 24 system
management unit has no direct connect ‘iPCB’ terminals; all connectivity is by RS485
data communications. Up to three ‘Net$ync II
Direct Connect Gateway’ units can be connected
to a Net$ync II Conductor 24 to provide a maximum
of 12 direct connect ‘Q485’ terminals.
Net$ync II Conductor 12:
A Net$ync II Conductor 12 has four direct connect ‘iPCB’ terminals as standard. Up to two ‘Net$ync II
Direct Connect Gateway’ units can be connected to
a Net$ync II Conductor 12 to provide a maximum of
12 direct connect ‘Q485’ terminals.
The Net$ync II Direct Connect Gateway unit is
wall mounting and must be located adjacent to the
Net$ync II system management unit.
e) Press Up or Down to select the required
function (C:1-4, C:5-8 or C:9-12) and Enter.
A Net$ync II Conductor 12 or Conductor 24 system
management unit will register the presence of a
Net$ync II Direct Connect Gateway unit at power-up.
After registration the appropriate compressor(s) can be
selected for ‘Q485’ type in the management system
compressor configuration menu.
Failure to continuously detect a Net$ync II Direct
Connect Gateway after initial registration and
compressor configuration will result in an Error condition.
Net$ync II Direct Connect Gateway Unit Connection:
Net$ync
II Conductor
24
Metacentre
XC:
1
2
3
4
5
6
7
8
9
10
11
12
CAP
XC
1
X01
2
1
X01
XPM485
L1 L2
XPM-LED
C1-4
C5-8
X06
X06
27 28 29 30
27 28 29 30
L1 L2 L1 L2
L1 L2 L1 L2
C9-12
10m (33ft) max
The Net$ync II Direct Connect Gateway unit can
be set to function as ‘Q485’ connections for:
a) C:1-4**
b) C:5-8
c) C:9-12
Net$ync
II Conductor
12
Metacentre
SX:
Compressors 1 to 4
Compressors 5 to 8
Compressors 9 to 12
**
A Net$ync II Conductor 12 system management
unit is already equipped with ‘Q485’ terminals
dedicated for compressors 1 to 4; do not set
the Net$ync II Direct Connect Gateway for ‘C:1-4’
mode in this instance.
1
2
3
4
5
6
7
8
9
10
11
12
CAP
SX
1
1
X01
XPM485
L1 L2
Page 2
XPM-LED
C5-8
To Set Net$ync II Direct Connect Gateway Function:
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.
X01
2
X06
C9-12
X06
27 28 29 30
27 28 29 30
L1 L2 L1 L2
L1 L2
10m (33ft) max
Net$ync II Direct Connect Gateway
Use a twisted pair, earth shielded,
0.25mm2-1.0mm2 data communications cable
with a total length no greater than 33ft (10m).
Net$ync II Conductor 12/Conductor 24:
Terminal X01 of the
‘XPM-LED’ PCB
Net$ync II Direct Connect Gateway:
Terminal X06
Net$ync II Direct Connect Gateway Power Supply:
Each Net$ync II Direct Connect Gateway is equipped
with the same type of power supply PCB as the
Net$ync II Conductor 12 or Conductor 24 system
management unit and requires a dedicated 115Vac
or 230Vac (+-10%), 50/60Hz @ 50VA power
supply connection.
Compressor Interface PCB
The ‘Q485’ is designed to interface a
compressor with the Direct Connect Gateway using
a 6-core, earth shielded, cable no greater than 100m
(330ft) in length.
Each compressor in the system must be
assigned a unique identification number from 1
up to the number of compressors in the
system. The identification number should be
clearly indicated on each compressor for
operational reference.
For each compressor connected to the Direct
Connect Gateway using an ‘Q485,’ the signal wires
must be connected to the Direct Connect Gateway
terminals dedicated for the assigned compressor
reference number.
XPM-TAC24
1
2
3
4
X04
VOLTAGE SELECT
230Vac
1
2
3
C01
4
C02
Q485
X04
VOLTAGE SELECT
115Vac
C04
#1
C03
1
2 3
4
5
C05
6
LED 1
Before applying power to the Net$ync II Direct
Connect Gateway ensure that the power supply
connections are correct and secure and that the
operating voltage selector is set correctly for the
power supply voltage in use; 115Vac or 230Vac (+10%), 50/60Hz.
Compressor Identification:
The system identification number for each
compressor connected to the Direct Connect
Gateway unit is dependant of the Direct
Connect Gateway unit mode.
C:1-4
Compressor ‘Q485’ terminal #1 is dedicated
for compressor ‘1’ through to ‘Q485’ terminal
#4 for compressor ‘4’.
C:5-8
Compressor ‘Q485’ terminal #1 is dedicated
for compressor ‘5’ through to ‘Q485’ terminal
#4 for compressor ‘8’.
C:9-12
Compressor ‘Q485’ terminal #1 is dedicated
for compressor ‘9’ through to ‘Q485’ terminal
#4 for compressor ‘12’.
LED 2
X01
1 2
3
4
5
6
The ‘Q485’ is a DIN rail mountable module
designed to be installed within the compressor
control or switchgear area.
Each air compressor must be equipped with a
load/unload regulation system and, if not
regulated with a single electro-mechanical
pressure switch, have a facility for a remote
load/unload control with the ability to accept a
volt-free switching contact input for remote
load/unload.
Consult the air compressor manual or your
air compressor supplier/specialist for details
before installing the Net$ync II management
system.
Page 3
Technical Manual
The ‘Q485’ uses a 12V to 250V input voltage
detection system and universal relay contact
control outputs (250V ‘CE’ / 115V ‘UL’ @ 5A
maximum). Integrated directly into the circuits
of an air compressor, the ‘Q485’ avoids the
need for additional relays or remote inputs.
The ‘Q485’ also acts as an electrical barrier
between the compressor and the Direct Connect
Gateway providing protection and voltage isolation.
4.5.1 Input Functions
The ‘Q485’ is fitted with a six-pin terminal C04
for compressor monitoring. The ‘Q485’ uses
two inputs (Ready and Run) to determine
compressor status. An Alarm input can be
used if compressor alarm indication is
available and required. The Alarm input is
optional and is not necessary for system
operation.
Ready Input:
The ‘Ready’ connection is intended to indicate
that the compressor is in a ‘started’ state, has
no operational inhibiting fault condition and is
ready to respond to management system
regulation without manual intervention.
READY LAMP
0V
+V
When the compressor ready lamp, or other
control circuit, is energised the ‘Q485’ will
detect the voltage and signal the ‘Direct Connect
Gateway’ that the compressor is ready and available
to load and produce air when a load request signal is
given.
The ‘Q485’ input common terminal must
always be connected to the neutral, common
or 0V line of the applied input voltage.
Ready Input, Alternative Connection Method:
In instances where a convenient voltage signal
for a compressor ready condition is not
available the ‘Ready’ input can be connected
directly to a constant compressor control
system power supply voltage (12V to 250Vac
or dc). This will signal the management system
that the compressor is ready and available at
all times when power is applied to the
compressor. The management system has a
built-in function to determine when a
compressor is not responding, or is in a
shutdown condition, regardless of a constant
ready signal. If the management system
requests a compressor to run/load, but fails to
detect a RUN signal within 60 seconds, the
management system will regard the
compressor as ‘not ready’ and indicate the
compressor as not available. If a RUN signal is
detected at any time, the management system
will automatically reset the compressor ‘not
ready’ condition and re-establish control.
+Vac
F1
ALARM
RUN
C04
READY
The READY input will accept 12V to 250V ac
(50/60Hz) or dc.
Do not connect a voltage greater than
250Vac/dc to this input.
This input must be connected to the terminals
of a ‘ready’ or ‘operational’ lamp, or other
circuit of the compressor control system, that
will be energised when the compressor is in a
started (standby or running) condition.
The voltage to this input must de-energise
when the compressor is stopped and
unavailable to produce air upon a load signal,
or the Emergency Stop button is pressed, or
when the compressor experiences a fault that
prevents the compressor from running.
Page 4
0Vac
READY
Never connect the READY input positive
connection directly to the output of a control
system transformer, always connect after a
fuse or circuit breaker.
If a normally closed contact of an Emergency
Stop button is included in the compressor
power supply circuit, connect after the
Emergency Stop button contacts. This will
instantly indicate a compressor ‘not ready’
condition if the Emergency Stop button is
activated.
Net$ync II Direct Connect Gateway
Run Input:
MAIN (LINE) CONTACTOR
0V
The ‘Q485’ input common terminal must
always be connected to the neutral, common
or 0V line of the applied input voltage.
Alarm Input (optional):
+V
The ‘Q485’ is equipped with an alarm (or
warning) input that can be used to detect
alarm or warning conditions.
ALARM
RUN
A fault, that stops the compressor, and/or
prevents the compressor from running, is
determined from the ‘Run’ and ‘Ready’ inputs;
Alarm detection is optional and is not a
requirement.
READY
C04
Alarm Lamp
The RUN input will accept 12V to 250V ac
(50/60Hz) only (DC cannot be used).
0V
+V
Do not connect a voltage greater than
250V to this input.
12V to 250Vac must be applied to the ‘Run’
terminals when the compressor motor is
running.
This input can be connected to the control
terminals A1 and A2 (coil) of the main starter
contactor of the compressor. When the
compressor control system energises the main
contactor, the ‘Q485’ will detect the voltage
across the contactor coil terminals and signal
the Direct Connect Gateway that the compressor is running.
Alternatively, if the main contactor coil voltage
is greater than 250Vac, a contactor auxiliary
switch can be used to apply a suitable voltage
to the ‘Run’ input terminals.
MAIN (LINE) CONTACTOR
+V
0V
+V
0V
AUXILIARY SWITCH
ALARM
RUN
READY
C04
Alarm
Run
Ready
C04
The Alarm input will accept 12V to 250V ac
(50/60Hz) or dc.
Do not connect a voltage greater than
250Vac/dc to this input.
This input can be connected to the terminals of
an alarm lamp or other accessible part of the
control circuit that is energised when the
compressor is in an alarm condition.
If an alarm condition is experienced the
compressor alarm lamp, or alarm circuit, will
energise. The ‘Q485’ will detect the voltage
and signal the Direct Connect Gateway that an
alarm has occurred. If the compressor has no
accessible alarm circuit, or this function is not
required, the ‘Q485’ alarm terminals can be ignored.
The ‘Q485’ input common terminal must
always be connected to the neutral, common
or 0V line of the applied input voltage.
In instances where a motor starter contactor is
not available or accessible, any part of a
compressor control circuit that is energised
when the compressor is running can be
monitored. For example: fan contactor or
voltage signal to a remote starter.
Page 5
Technical Manual
4.5.2 Output Functions
The Direct Connect Gateway will control the ‘ ’
load/unload relay outputs in accordance with the
active system load and unload pressure set points.
The ‘Q485’ load/unload relay contacts can be
used for compressor controllers that have
‘pressure switch’ load/unload regulation.
‘Q485’ Internal Output Circuits
C
OUT
NO
1
Load
The NC (normally closed) and NO
(normally open) terminal references of the
‘Q485’ are related to internal connection
functions and should not be referenced to the
connections of a compressor pressure switch;
which will generally be in reverse order.
Lethal voltages may be present on the
terminals of the air compressor pressure
switch. Isolate the air compressor power
supply before starting any work.
Two Wire Pressure Switch Connections:
C
Seq
IN
NO
OUT
C
2
SEQ
Relay
1&2
LOAD
SOLENOID
IN
C
3
OUT
NC
0V
+V
IN
NC
LOAD
Relay
3
Contacts :250Vac/dc @ 5A
maximum
GND
DI1
DI2
+20V
24Vac
C02
C
NC
NO
C
OUT
SEQ LOAD
CONT UNL
NC
NO
C03
IN
Three Wire Pressure Switch Connections:
The C01 and C02 terminal functions of the ‘Q485’
are intended to control load and unload
regulation of the compressor.
Pressure Switch Regulation:
LOAD
SOLENOID
0V
+V
For air compressors fitted with an electromechanical
pressure switch a six-pin terminal
C02 has been provided to enable connection
to a pressure switch that has a two wire or
three-wire connection.
The local pressure settings of all
compressors in the system should be set in a
cascaded manner such that the system will
operate normally in the event of management
system inoperability.
Page 6
OUT
C02
IN
NC
C
NO
NC
C
NO
When connected the pressure switch can be
switched in and out of circuit automatically. If
the management system is stopped or
experiences a failure or loss of power,
pressure control will automatically revert back
to the pressure switch and the compressor will
continue to operate in ‘Local’ mode.
RUN-ON
TIMER
Net$ync II Direct Connect Gateway
Remote Load/Unload Regulation:
For air compressors controllers fitted with
‘Remote/Local Pressure Regulation’ digital
inputs, a 4-pin connector C01 has been
provided.
This terminal provides volt free contact closure
for load control and also provides volt free
contact closure for remote pressure control
enable.
A remote load enable input provides the facility
to change the compressor load regulation from
internal control to a remote switching source.
Note: Compressors that use electronic
pressure detection but are not equipped with a
remote pressure control enable feature will not
automatically revert to local control if the
management system is stopped or
experiences a fault or loss of power.
Load and Sequence Connection:
The local/remote pressure regulation input
and/or remote load input logic of some
electronic pressure sensor type controllers are
reversed, in this instance the ‘pressure switch’
outputs (terminal C02) can be used to
establish alternative logic control connections.
For Example:
If the compressor controller ‘Local/Remote
Pressure Control’ input is a normally open
type; remote when closed, but the ‘Remote
Load’ input is a normally closed type; load
when open, the ‘Q485’ pressure switch
terminal contacts can be used to achieve the
correct switching logic.
C02
NO
OUT
C
NC
NO
IN
C
Local/Remote
common
Remote Load
common
NC
COMPRESSOR CONTROLLER
INPUTS
Local/Remote
or
Remote Load Enable
Remote Load
Inputs Common
C
SEQ
C
LOAD
C01
Compressors that use electronic pressure
detection but are not equipped with a remote
pressure control enable feature will not
automatically revert to local control if the
management system is stopped or
experiences a fault or loss of power.
Examine the ‘Q485’ internal output circuit
diagram to establish any desired switching
logic that may differ from normal practise.
Do not attempt to utilise ‘Digital Pressure
Regulation Control’ (terminal C01) and the
‘Pressure Switch Control’ (terminal C02)
output connections at the same time for
different products. These two output functions
are internally connected and a short circuit
condition and/or malfunction may result.
The ‘Q485’ connection examples shown in
this manual are intended to provide a guide
for the majority of compressor control
systems in use. Some compressors have
variations in operation and/or function;
consult your compressor
supplier/specialist for advice.
Compressor controller inputs common
voltage may be 0V or +V.
Page 7
Technical Manual
Service Maintenance Switch:
The ‘Q485’ is equipped with a volt-free input
(terminal C05) that can be used to remove the
compressor from system management control,
without generating a fault condition, during
short-term maintenance or servicing periods.
C05
1
2
When the ‘Service Maintenance Switch’ input
terminal pins are connected together, using a
volt-free switching contact, the system
management unit will indicate that the
compressor is not available but will not
generate an Alarm, Trip or Shutdown
condition. The system management unit will
also remove the compressor from the
sequence strategy and substitute with an
alternative available compressor if necessary.
When the ‘Service Maintenance Switch’ inputs
are open circuit again the compressor will
automatically be accepted back in to the
sequence strategy and will be utilised as and
when next required.
The use of a ‘key switch’ is recommended for
this purpose in order to prevent the switch
contacts being inadvertently left in the closed
circuit condition after service maintenance is
complete.
DO NOT connect any external voltage
source to the pins of terminal C05.
Page 8
Net$ync II Direct Connect Gateway
Parts List
Item
Part No.
2014000030
-
1
2
3
4
Description
2
Direct Connect Gateway
Manual, User CD
Unit, Controller iX
Unit, XPM-TAC24
PCB, Terminal
Gland, Set - Pg13.5
3
Required For Each Compressor:
1
Item
Part No.
Description
5
2014000028
Unit, Q485
Qty
Part No.
Description
10
10
10
IEC Fuse T1.0A
IEC Fuse T1.6A
IEC Fuse T3.15A
Technical Data
Dimensions
Weight Mounting
Enclosure
Supply Power Temperature
Humidity
4
340mm x 241mm x 152mm
13.40” x 9.45” x 6.0”
7.5kg (16.5lb)
wall, 4 x screw fixings
IP54, NEMA 12
230Vac +/- 10%
115Vac +/- 10%
100VA
0°C to 46°C (32°F to 115°F)
95% RH, non-condensing
Mounting Dimensions:
27mm
286mm
27mm
188mm
8mm Ø
Page 9
Technical Manual
C08
C08
C010
C027
C011
C023
R1
C013
C027
C014
C028
C015
R3
GND
C027
C018
C029
C030
C022
C026
2
C018
C025
C015
1
24Vac
V1
0Vac - earthed
Terminal PCB
X01
10k
C021
6
C034
24Vac
2
7
V2
C028
C029
0Vac
XPM-TAC24
X02
X01
L N E
230Vac 10%
115Vac 10%
C033
X03
1
C016
C032
X02
10k
C017
8 9 10 11 12
C016
R4
2
1
C023
2 3 4 5
X03
R2
10k
C025
C026
24Vac
V4
C022
C024
C035/4
X07
L2 L1 RS485#1
C020
75k
C012
V3
X02
C035/3
0VDC
L
C06
C021
C012
R6
N
E
E
Net$ync II Direct Connect Gateway
10k
C024
C018
C031
Page 10
25 26
SEQ
C017
C019
R5
1 X01
C016
X03
C026
C015
13 14 15 16 17 18
C025
C03
C019
C014
R-SEQ
C024
C04
C013
SEQ
C023
C012
24Vac
C022
C011
+
C021
-
C020
24Vac
RS485#2
XPM485
C010
C019
X04
X08
C09
C09
C010
C+
1
2
3
4
5
6
7
8
L2 L1
XPM485
C09
X08
C07
Ai3
C08
C07
X07
+VDC
SEQ
GND
X06
C07
X05
C06
C06
X04
C05
Ai2
31 32
+VDC
33 34
4
C05
27 28 29 30
C04
C04
19 20 21 22 23 24
C03
Ai1
3
Ao
+VDC
2
A-GND
C035
C03
1
X05
X06
S1-40-321-DiC-R6
Net$ync II Direct Connect Gateway
L2
Net$ync II Conductor 12/24
3
SEQ
1
+20VDC
6
Ready/Run
5
Alarm/Serv.
GND
LOAD
3
SEQ
1
+20VDC
6
Ready/Run
5
Alarm/Serv.
GND
LOAD
3
SEQ
1
+20VDC
Ready/Run
6
4
2
4
2
4
2
5
Alarm/Serv.
GND
LOAD
3
SEQ
1
4
2
100m (330ft) max
4
i-PCB 3
5
Alarm/Serv.
GND
LOAD
i-PCB 4
6
100m (330ft) max
3
i-PCB 2
X04
X03
X02
X01
L1 XPM-LED: X01
100m (330ft) max
2
i-PCB 1
X06
X05
X07
27 28 29 30
6
5
2 3 4
1
10m (33ft) max
L1
XPM485
L2
+20VDC
Ready/Run
7
8 9 10 11 12
13 14 15 16 17 18
19 20 21 22 23 24
25 26
31 32
X08
33 34 35 36
Terminal PCB
100m (330ft) max
1
Page 11
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
24Vac/2
earthed
Page 12
1
X02
1
2
3
4
N L
E
E
2
24Vac/1
isolated
NL E
X01
FH1
">
