INGERSOLL-RAND CENTAC CMC TECHNICAL REFERENCE MANUAL (Part No. 22204796) INGERSOLL-RAND AIR COMPRESSORS CMC TECHNICAL REFERENCE MANUAL Copyright Notice Copyright 1996-2003 Ingersoll-Rand Company THIS MANUAL IS SOLD "AS IS" AND WITHOUT ANY EXPRESSED OR IMPLIED WARRANTIES WHATSOEVER. Printing Date: 24 March 2003 Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Table of Contents What’s New About the 3.10 Release ______________________________________1 References ___________________________________________________________2 General - CMC Panel ___________________________________________________3 Control Methodology___________________________________________________4 Performance Control _______________________________________________________ 4 PID Control _______________________________________________________________ 7 Surge Control ____________________________________________________________ 12 Prelube Pump ____________________________________________________________ 18 Oil Heater _______________________________________________________________ 18 Protection and Monitoring _____________________________________________19 Analog Functions _________________________________________________________ 19 Digital Functions _________________________________________________________ 19 Compressor Operating Methodology ____________________________________21 Stopped _________________________________________________________________ 21 Rotating_________________________________________________________________ 21 Compressor Operating States ______________________________________________ 23 OUI (Operator User Interface) _______________________________________________ 24 General Sequence of Operation _____________________________________________ 41 Indicator, Switch and Light Layout___________________________________________ 42 CMC Tuning Procedures _______________________________________________42 Setting MaxLoad__________________________________________________________ 42 Setting MinLoad __________________________________________________________ 43 Setting MinLoad Surge Index Increment ______________________________________ 44 Setting Surge Sensitivity ___________________________________________________ 44 Tuning Stability __________________________________________________________ 45 Calibrating the Control Valves ______________________________________________ 46 Autodual Control Settings __________________________________________________ 47 Setting the Start Time _____________________________________________________ 48 Setting the CT Ratio _______________________________________________________ 48 Inlet Unload Position ______________________________________________________ 48 Setting Set Point Ramp Rate ________________________________________________ 48 Alarm and Trip Settings____________________________________________________ 49 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Troubleshooting _____________________________________________________50 Troubleshooting Example __________________________________________________ 51 Input/Output (I/O) System __________________________________________________ 52 Control Power System (CPS) _______________________________________________ 72 Controller Problems_______________________________________________________ 76 Options _____________________________________________________________78 Enclosures ______________________________________________________________ 78 Control Electrical Package _________________________________________________ 80 Stage Data Package _______________________________________________________ 80 Alarm Horn ______________________________________________________________ 80 Running Unloaded Shutdown Timer _________________________________________ 80 Water Solenoid Post Run Timer _____________________________________________ 80 Panel Mounted Wye-Delta Starter ____________________________________________ 80 N.O. Contact for Remote Indication of Common Alarm and Trip __________________ 80 Power Regulating Constant Voltage Transformer ______________________________ 80 Automatic Starting ________________________________________________________ 81 Remote 4-20 mA Pressure Setpoint __________________________________________ 82 Ambient Control plus Parallel Valve Control Logic _____________________________ 82 Mass Flow Control ________________________________________________________ 84 Steam and Gas Turbine Driven Compressors __________________________________ 85 Diesel Driven Compressors ________________________________________________ 92 Communication ______________________________________________________93 Human Machine Interface (HMI) Systems _____________________________________ 93 Direct CMC Communications with RS422/485__________________________________ 93 The CMC-MODBUS Interface________________________________________________ 94 The CMC-DF1 Interface ___________________________________________________ 115 Documentation______________________________________________________143 System Information __________________________________________________143 Status Codes ___________________________________________________________ 143 Base Control Module (BCM) _______________________________________________ 145 Operator User Interface Module (OUI) _______________________________________ 148 Universal Communication Module (UCM) Optional ____________________________ 152 Technical Specification_______________________________________________160 Glossary _____________________________________________________________1 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Table of Figures Figure 1: Compressed Air System ................................................................................................................ 4 Figure 2: Modulate Control .......................................................................................................................... 5 Figure 3: Autodual Control ........................................................................................................................... 5 Figure 4: Performance Control..................................................................................................................... 6 Figure 5: Prpportional Band, Pb................................................................................................................... 7 Figure 6: Proportional Plus Integral Control................................................................................................. 8 Figure 9: MinLoad and MaxLoad ............................................................................................................... 10 Figure 14: Rise to Surge ............................................................................................................................ 14 Figure 15: Changes in Discharge Pressure............................................................................................... 14 Figure 16: Surge Detection System ............................................................................................................ 16 Figure 18: Plant Air System ........................................................................................................................ 42 Figure 19: Troubleshooting Tree................................................................................................................. 50 Figure 21: Measuring Flow ......................................................................................................................... 85 Figure 22: MODBUS Messages................................................................................................................. 95 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL What’s New About the 3.10 Release This is the initial release of the CMC Manual for version 3.10. This version was created to support new features incorporated into the CMC Product, and provide additional information compared with previous versions. Specifically, new features are as follows: 1. PID Scaling, p.9 2. Valve Characterization, p.15 3. Ambient Control plus Parallel Valve Control Logic, p.82 4. Mass Flow Control, p.84 5. Support for new, high speed IR-Bus at 38.4 kbps 6. Processor upgraded from 16 MHz to 25 MHz on Base Control Module (BCM) 7. Replaceable fuse (F2) for display, p.149 8. Operator instructions on display, p.35 9. “Pop-up” window to provide useful customer information, p.28 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 1 2 CMC TECHNICAL REFERENCE MANUAL References The following references were used in creating this document. All of this documentation is recommended for a more detailed understanding of specific control modes and control panel functions. NEMA STANDARDS PUBLICATION NO. 250, Enclosures for Electrical Equipment (1000 Volts Maximum), Revision 2, May 1988 NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment, 1986 Edition Nisenfeld, A. Eli, Centrifugal Compressors: Principles of Operation and Control, Instrument Society of America, 1982 Moore, Ralph L., Control of Centrifugal Compressors, Instrument Society of America, 1989 Doebelin, Ernest O., Control System Principles and Design, John Wiley & Sons, 1985 Rowland, James R., Linear Control Systems Modeling, Analysis, and Design, John Wiley & Sons, 1986 Deshpande, Pradeep B. and Ash, Raymond H., Computer Process Control With Advanced Control Applications, 2nd Edition, Instrument Society of America, 1988 CENTAC ENERGY MASTER, Version CEM230, Ingersoll-Rand Company, March 1992 White, M.H., Surge Control for Centrifugal Compressors, Chemical Engineering, December 25, 1972 Hall, James W., THERMODYNAMICS OF COMPRESSION: A Review of Fundamentals, Instrument Society of America, 1976 Gaston, John R., Centrifugal Compressor Operation & Control: Part II "Compressor Operation", Instrument Society of America, 1976 Gaston, John R., Antisurge Control Schemes For Turbocompressors, Chemical Engineering, April 1982 Warnock, J. D., Methods for Control of Centrifugal and Reciprocating Compressors, Moore Products, 1984 Harrison, Howard L. and Bollinger, John G., Introduction to Automatic Controls, Second Edition, Harper & Row, 1969 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL General - CMC Panel The CMC panel is the microprocessor-based control and monitoring system for Centac. The CMC handles compressor control and monitoring functions; as well as, control of auxiliary equipment such as the main motor starter, oil heater, and prelube pump. The CMC panel has a custom computer board called the Base Control Module (BCM). This board has a microcontroller and memory chips that tell the rest of the panel what to do for the various input pressures, temperatures and vibrations. All hardware for data analysis, number of input and output (I/O) points and system memory are optimally selected for accurately controlling and protecting Centac compressors. Features of the CMC system are: • Ease of use ... only twelve buttons to push on the operator OUI! • Multiple function, 240 x 128 pixel graphic LCD to display data, operating status and basic operator instructions. • Unload, Modulate and Auto-Dual operating modes. • Advanced surge detection and control. • High current limit for main drive electric motor protection. • First-out indication and event log to help determine the root cause of a compressor trip. • Pinion vibration alarm and trip for each compression stage. • Base Control Module CPU running at 25Mhz. • Base Control Module, Operator User Interface and Universal Communication Modules capable of serial communication at 38,400 baud • Optional port for communicating to the Air System Controller (ASC), Air System Manager (ASM) or other Distributed Control Systems (DCS) via MODBUS protocol. • Optional reduced voltage motor starter included in panel for some sizes. NOTE For the purpose of consistency and clarity, all of the descriptions and examples that follow refer to "air" for the more generic "gas". Any gas compressed by a Centac compressor would also apply. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 3 4 CMC TECHNICAL REFERENCE MANUAL Control Methodology The CMC utilizes performance and surge control methodologies to meet varying compressed air system needs. The term "performance control" is used for grouping the control modes that affect compressor power consumption through movement of the intake and discharge valves. Performance Control The CMC has three standard performance control modes or methods of operation. These modes are Unload, Modulate and Autodual for typical plant air compressors operating in constant pressure applications. For the discussions that follow, Figure 1 depicts a compressed air system and the relationship between the compressor and the plant air system. Atmosphere Silencer Inlet Valve Inlet Filter Bypass Valve Check Valve Plant Air System Compressor Figure 1: Compressed Air System Unload The compressor is unloaded, when no air is being supplied to the Plant Air System, and all of the air produced by the compressor is being vented to the atmosphere. In this mode, the inlet valve is slightly open to allow enough air to pass through the compressor for internal cooling, prevention of rotor instability and surge avoidance. This air is then discharged through the open bypass valve to the atmosphere. Typically, the compressor is set to make a positive pressure across the first compression stage, which produces a discharge pressure something greater than the atmospheric pressure. The inlet valve opening required to create this positive pressure is directly related to the horsepower consumed; therefore, careful consideration should be given to this inlet valve position for minimizing overall power consumption. Modulate Constant pressure control is a frequently required performance control method for Centac air compressors. If left uncontrolled, the compressor's discharge pressure would rise and fall along the natural performance curve as system demand changed. Modulate control satisfies the constant pressure requirement. The performance map in Figure 2 shows Modulate control. Modulate maintains the system discharge pressure at the system pressure set point as entered into the CMC by the user. Once loaded, the compressor will operate along the constant pressure line until the user switches to Unload or presses the stop button. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 5 CMC TECHNICAL REFERENCE MANUAL Control is accomplished by modulating the inlet valve within the compressor's throttle range. When system demand is less than the minimum throttled capacity, the discharge pressure is maintained by modulating the bypass valve and venting some or all of the air to atmosphere. This valve is opened just prior to reaching the surge line. Whenever the bypass valve is open, the inlet valve maintains its position at the minimum throttled capacity setting. Modulate provides a constant discharge pressure with variable capacity from design to zero. Natural Pressure Curve Constant Pressure Line Surge Line Design Point Maximum Throttle Point (MinLoad) Discharge Pressure Unloaded Inlet Valve Throttle Range Bypass Valve Throttle Range Natural Power Curve Surge Line Constant Power Line Power at Coupling This control method is used when stable control of the discharge pressure is required. Modulate is the most commonly used control method for Centac compressors. Unloaded Capacity Figure 3: Modulate Control Energy Saving Control - Autodual Autodual automatically loads the machine when demand is high and unloads the machine when demand is low. When the compressor is controlling to pressure setpoint and demand is within the inlet valve throttle range, constant pressure is maintained in the same manner as Modulate. When the machine is controlling to the pressure setpoint and system demand is low, the compressor is operated in the bypass valve throttle range. Autodual automatically unloads the machine when the bypass valve is opened beyond the Unload Point for a programmed time period called the Unload Delay Time. The Bypass Valve Unload Point is selected to correspond with the check valve 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Natural Curve Surge Line Unload Point Design Point Reload Point (Reload Percent) Discharge Pressure Unloaded Bypass Valve Throttle Range Power at Coupling Inlet Valve Throttle Range Unload Point Unloaded Capacity Figure 2: Autodual Control Natural Curve 6 CMC TECHNICAL REFERENCE MANUAL closing since at this point the machine is not supplying the system (Figure 3). The Unload Delay Timer should be set to prevent unloading during short excursions through the Unload Point. The Reload Percent determines the System Pressure at which the machine will automatically load into the system. How does Constant Pressure Modulation Work? The goal of constant pressure modulation is to maintain a specified discharge pressure in the compressed air system while the capacity requirements change. Modulate control provides constant pressure from 100 percent of the compressor's capacity to zero capacity. Autodual control provides constant pressure from the 100 percent of the compressor's capacity to the Unload Point. If all plant air systems were identical in capacity usage requirements, the CMC could be preprogrammed to respond to those changes; however, all plant air systems are not alike. The frequency and variability of the capacity changes means that the control logic must be flexible, so the CMC utilizes proportional, integral and derivative control algorithms to determine the magnitude of the signal that is sent to the inlet and bypass valves. These algorithms, or programming logic, allow the CMC control system to be "tuned" to a specific plant air system. Measuring the Discharge Pressure In order to maintain constant pressure, the system discharge air pressure must be measured. A pressure transducer is mounted in the control panel and tubed to the compressor discharge downstream of the check valve as shown in Figure 4. CMC Pneumatic Tubing PT 4-20 mA Bypass Valve Base Control Module 4-20 mA CT Check Valve Starter Motor 4-20 mA PTx Compressor Inlet Valve Figure 4: Performance Control This transducer sends a 4-20 mA signal to the CMC board. The CMC compares the measured discharge pressure to the system pressure set point entered into the CMC by the user through the Operator User Interface (OUI). Depending upon the difference between these two values the CMC will send a 4-20 mA signal to "Modulate", open or close, the inlet and/or bypass valve to maintain the specified system pressure set point. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 7 CMC TECHNICAL REFERENCE MANUAL PID Control Proportional Band Proportional control varies the signal sent to the valves as a linear response to the difference between the actual system pressure and the system pressure set point. Valve responsiveness can be adjusted through the CMC with the proportional band, Pb, set point. This set point is the controller gain. Gain is a scaling factor. This scaling factor, graphically depicted in Figure 5, is the amount of change in the input variable (actual minus set point pressures) to cause a full scale change in the output variable (valve position). In other words, if the pressure in the air system fluctuates frequently, it would be prudent to set Pb to a low value to keep up with those system changes. Otherwise, if the system is very stable, a larger value can be used. Pb is directly related to valve life and indirectly related to valve cycling; so, as Pb decreases, valve life decreases and cycling increases. As stated earlier, the CMC uses a proportional, integral and derivative control algorithm. The result of proportional only control is offset from the controlled variable, discharge pressure. This means that if the set point pressure is 100, the actual pressure may only be 95. The value of this offset depends upon the proportional band value. What is the valve response when the difference between actual and set point pressures is zero? There is no response. Proportional control only functions when a difference or error exists. Design discharge pressure could not be attained in a proportional only control system. Therefore, an integral control algorithm is added to achieve the desired discharge pressure. Integral Time The offset produced by the proportional control algorithm could be eliminated by manually readjusting the system pressure set point. Using the example above, the set point could be reset to 105 to obtain the 100 desired. Manually resetting the set point would be required as the system demand fluctuated. Integral control, also known as reset control, automatically resets the desired system pressure set point. For the CMC, the rate at which the controller resets the system pressure setting is known as Integral Time, It, and is expressed in units of repeats per second. Output Variable (Valve Position) Full Scale Slow Response Pb 0 Large Change Full Scale Fast Pb low Response Output Variable (Valve Position) 0 Small Change If precise control of the specified discharge Input Variable pressure is required, the It set point should be set (Actual - Set Point Pressures) for a fast value. It is inversely related to valve life Figure 5: Proportional Band, Pb and directly related to valve cycling, therefore, as It decreases, valve life increases and cycling decreases. For the CMC controlling Centac compressors, It values are typically less than 1.00. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 high 8 CMC TECHNICAL REFERENCE MANUAL Figure 6 shows the relative valve response over time for two combinations of Pb and It. As shown, when Pb is low and It is fast, valve activity is significant in both magnitude and frequency to obtain the desired set point. The other scenario, Pb is high and It is slow, has relatively little valve activity, and may never reach the set point position. Opened Proportional Band - Low Integral Time - Fast Set Point Valve Activity Proportional Band - High Integral Time - Slow Proportional Band and Closed Integral Time are Time variables used internally by the control system to determine valve response Figure 6: Proportional Plus Integral Control and direction for a given compressed air system. Each has an optimum value based upon the system's characteristics. Determining these optimum values is a trial and error exercise. These set points should be re-evaluated any time there is a major change in the compressed air system. Derivative action depends on the slope of the error, unlike P and I. If the error is constant derivative action has no effect. The derivative term looks at the rate of change of the input and adjusts the output based on the rate of change. Controller Output Derivative Component Proportional Component Error Derivative Action Derivative action (also called rate or preact) anticipates where the process is heading by looking at the time rate of change of the controlled variable (its derivative). TD is the ‘rate time’ and this characterizes the derivative action (with units of seconds). Time Figure 7; PD Controller Proportional-Integral-Derivative When an error is introduced to a PID controller, the controller’s response is a combination of the proportional, integral, and derivative actions, as shown in Figure 8. Assume the error is due to a slowly increasing process variable. As the error increases, the proportional action of the PID controller produces an output that is proportional to the error signal. The reset action of the controller produces an output whose rate of change is determined by the magnitude of the error. In this case, as the error continues to increase at a steady rate, the reset output continues to increase its rate of change. The rate action of 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 9 CMC TECHNICAL REFERENCE MANUAL the controller produces an output whose magnitude is determined by the rate of change. When combined, these actions produce an output as shown in Figure 8. On the combined action curve, the output is simply the sum of the individual Proportional, Integral and Derivative corrections. Note: The response curves in Figure 8 are drawn assuming no corrective action is taken by the control system. With previous CMC versions, PID settings could vary considerably depending upon the variable regulated. A PID Scaling feature has been added to the CMC. This feature will provide for more uniform PID settings for different process control. Up to this point, constant pressure control has been accomplished with an analog input (system pressure) and two analog outputs (inlet valve and bypass valve position). In the following paragraphs it will be discussed how motor current, the other analog input, is used for constant pressure control. Also covered in the following paragraphs is the discussion as to at what time the bypass valve is modulated as opposed to inlet valve. Error Proportional Only Action Reset Only Action Rate Only Action Combined Output 10% 5% 0% 20% 10% 0% 5% 0% 10% 0% 55% 40% 30% T1 T0 1 Sec T2 2 Sec Figure 8: Proportional-Integral-Derivative Motor Current, MinLoad and MaxLoad Motor current, in units of power (normally amps), has two functions in the CMC. The first is over current protection for the main motor, and is referred to as MaxLoad or High Load Limit (HLL). The second function determines the point at which the bypass valve begins to modulate for controlling pressure. This point is called MinLoad or Throttle Limit (TL). The location of these two points is graphically depicted on the pressure and power versus capacity curves as shown in Figure 11. MaxLoad or High Load Limit (HLL) setpoint, in units of amps, is a parameter entered into the CMC that prevents the main drive motor from overloading. Once this value is reached, the CMC logic limits the inlet valve from opening any further. This action constrains the motor by limiting the amp draw to the maximum allowable service factor amps by using the inlet valve MaxLoad PID loop to maintain the MaxLoad current setpoint as shown in Figure 9. When the motor is sized for cold conditions, there are circumstances when MaxLoad will never be reached. For example, the value of MaxLoad as shown in Figure 9, cannot be attained for the T=hot curve because it is beyond the maximum compressor capability; that is, the inlet valve is fully open. This scenario never limits the inlet valve. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 10 CMC TECHNICAL REFERENCE MANUAL When ambient conditions produce the T=cold curve, the compressor will not be able to achieve the maximum capacity because it is beyond the MaxLoad value. Since MaxLoad is less than or equal to the motor nameplate FLA times the adjusted service factor, the maximum compressor capacity at T=cold could only be reached if the motor were sized for the T=cold condition. MinLoad Control Setpoint in units of amps (sometimes referred to as throttle limit TL) is the power value at which the CMC transfers modulation control from the inlet to the bypass valve (Figure 10). The reason for this transfer is to prevent the compressor from entering into a surge condition. The bypass valve vents air to the atmosphere and maintains the pressure setpoint by using the bypass valve pressure PID loop. At the same time, the inlet valve maintains the MinLoad setpoint by using the inlet valve MinLoad PID loop; therefore, once the MinLoad Figure 9: MinLoad and MaxLoad Inlet Valve Pressure PID Control Zone HLL TL Inlet Valve MaxLoad PID Control Zone Power at Coupling Amps Inlet Valve MinLoad PID Control Zone MaxLoad Capacity - Mass Flow Bypass Valve Pressure PID Control Zone Discharge Pressure MinLoad Power at Coupling Discharge Pressure Tcold Thot setpoint is reached, the compressor continues to produce a constant amount of air. Part of this air goes to the Plant Air System, and the remainder is blown off. Even though the Plant Air System receives only a portion of the air produced, the amount of power remains constant. The following table presents seven capacity requirements for a plant air system. At each of the capacities, the table shows the compressor output, valve position, discharge pressure and power. Each of these values represents a percentage and is only an example. P2 is the specified discharge pressure and P0 is the barometric pressure. Capacity - Mass Flow Figure 10: MinLoad 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 11 CMC TECHNICAL REFERENCE MANUAL System Required Capacity 0 0 Compressor Operating State Off Unloaded Compressor Output Capacity 0 10 Open Position Inlet Bypass Valve Valve 0 100 10 100 100 Full Load 100 100 0 P2 100 75 MinLoad 75 70 0 P2 80 50 MinLoad 75 70 25 P2 80 25 MinLoad 75 70 50 P2 80 0 MinLoad 75 70 100 P2 80 Discharge Pressure 0 >P0 Power 0 20 From the table above, once the system required capacity moves below 75 percent, the compressor still produces 75 percent capacity with 80 percent of the power. If the system needs only 25 percent capacity, it will still have to pay for 80 percent of the power. This is why it is important to open the bypass valve at the last possible moment; therefore, setting MinLoad properly is critical for efficient energy management. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 12 CMC TECHNICAL REFERENCE MANUAL Surge Control As stated earlier, setting MinLoad properly is critical for efficient energy management. Also, a well thought-out design method of transferring into and out of the MinLoad state contributes to good Surge Control. The discussion thus far has only considered motor current as the point at which the transition from the Loaded state to the MinLoad state occurs. The following sections will consider methods other than motor current as to when to transition to the MinLoad state. ‘Surge’ - Definition Surge is the reversal of flow within one or more stages of a dynamic compressor. This reversal takes place when the capacity being handled is reduced to a point where insufficient pressure is being generated to maintain positive capacity. This condition can potentially damage the compressor if it is severe and is allowed to remain in that state for a prolonged period; therefore, control and prevention is required. Control Methodology Surge prevention is accomplished opening the bypass valve prior to reaching the surge point. The point at which the bypass valve opens is MinLoad. By blowing a portion of the air to the atmosphere, the compressed air system gets the air that it demands. The compressor avoids surge because it is still producing the minimum air capacity. The following methods of MinLoad control are available on the CMC. Motor Current Motor Current, amps Amps vary with voltage Natural Surge Points MinLoad Setpoint Curve "marginally" affected by changes in inlet temperature at a constant inlet pressure The most common method determining when to transition to the MinLoad status is by using motor current. Motor current may be correlated to flow through the compressor. As flow increases through the compressor motor current increases as well. The most significant factor affecting motor current is voltage. If voltage dropped it would cause current to rise even though no change in flow occurred. Therefore motor current can vary as illustrated in Figure 11. Capacity, scfm Figure 11: Motor Current Method 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 13 CMC TECHNICAL REFERENCE MANUAL Motor Power, kW Optional Motor Power (kW) Another method of determining when to transition to MinLoad control on motor driven units is by using motor power or kilowatts (kW). This method takes into account any changes in motor current due to the influence of voltage. If voltage drops and current rises, kW would remain constant. This allows for better correlation in flow through the compressor, therefore, allowing for more accurate control and potentially blowing less air to atmosphere. Natural Surge Points MinLoad Setpoint Curve "marginally" affected by changes in T1 at a constant P2 This method virtually eliminated inefficiencies due to changes in voltage. Capacity, scfm Figure 12: Optional Motor Power, kW Optional Ambient Control (Polytropic Head) Head, ft-lb/lb Another method of determining when to transition to MinLoad control is by using Polytropic Head calculation. For purposes of the CMC we refer to this method as Ambient Control. Natural Surge Point MinLoad Setpoint For a given set of hardware (impellers and diffusers) running at a constant speed, this curve is fixed Curve unaffected by changes in T1, P1 or P2 Capacity, icfm Figure 13: Optional Head Control Ambient Control calculates the work performed by the compressor and is expressed in foot-pounds per pound of gas (ft-lb/lb). For a given set of hardware, the amount of work the compressor is capable of is fixed. If the compressor is called upon to exceed that amount of work, it will surge. By knowing the amount of work the compressor will do before surging a more conservative MinLoad point expressed in ft-lb/lb may be set. The ability to set the MinLoad point closer to the surge line allows the compressor to throttle more (deeper) before blowing air to the atmosphere and thus conserving energy. Surge Detection Even though the CMC controls to prevent surge, it can still occur. Insufficient rise to surge, rapid changes in system discharge pressure, and various other reasons exist for a compressor to surge. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 14 CMC TECHNICAL REFERENCE MANUAL Insufficient Rise To Surge Rise to surge is the percentage of the compressor's surge pressure to discharge pressure (see Figure 14). When an insufficient rise to surge situation exists, small fluctuations in the air system demand and ambient temperature can cause the compressor to surge. From Figure 14, when T=cold, there is sufficient rise to surge. As the ambient temperature increases to T=hot, the amount of rise to surge decreases because the discharge pressure is remaining constant and the natural curve is changing with temperature. T=cold Discharge Pressure Rise To Surge T=hot Typically sufficient rise to surge exists when a ten- percent rise to surge can be achieved for the hottest ambient that is expected Capacity for the site. If this design criterion Figure 14: Rise to Surge is followed, the control system should be able to prevent surge for variations in air demand and inlet temperature. The same design methodology applies for changes in cooling water temperature for multi-stage compressors. Changes in System Discharge Pressure MinLoad corresponds to a specific constant discharge pressure; therefore, if the discharge pressure changes, MinLoad must be reset to properly control surge. As shown in Figure 15, when the discharge pressure is changed from point 1 to 2, a surge can occur at point 2 if MinLoad is not reset. Changes in system discharge pressure also apply, but more subtly, when the compressor begins to age. Dirty inlet filter elements and fouled coolers can change the compressor's natural curve; so MinLoad should be checked periodically to prevent surge from an incorrect setting. Rapid System Demand Changes Discharge Pressure TL2 TL1 Capacity - Mass Flow Figure 15: Changes in Discharge Pressure When the system demand varies rapidly over a wide range of capacity, the controller may not react fast enough to open the bypass valve to prevent surge. The CMC reads discharge pressure, motor amps, and approximately twenty other pressure and temperature inputs; plus controls the inlet and bypass valve position. The time required to do all of this approximately 100 milliseconds. When the controller is too slow to react, it is referred to as "driving through MinLoad". The only prevention for a 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 15 CMC TECHNICAL REFERENCE MANUAL situation like this is to set MinLoad at a more conservative value. The only negative implication to this is reduced energy savings, because the bypass valve is opened early. Incorrect Instrumentation Output If the instrumentation, defined in Figure 4, is improperly calibrated or gives inaccurate readings, the compressor could surge even though the CMC thinks it should not. Areas of concern are insufficient power air, incorrect valve transducer calibration, and repeatability of both inlet and bypass valves. If the valves are being sent signals for specific movements and they do not respond by moving to the new positions, then the CMC has very little chance of correctly controlling surge, or even the discharge pressure. As discussed earlier, the CMC uses motor current as the standard method for determining when to open the bypass valve. The time to begin opening the bypass valve is near MinLoad amps. The equation, GHP= I× V× η × PF× 3 motor 746 indicates that horsepower is directly related to current; it is, but it is also related to voltage. This is not normally a concern because voltage is primarily constant. However, there are some locations where extreme voltage variations do exist. In these circumstances, the CMC cannot correctly determine when it reaches MinLoad and a surge can occur. For these applications, an optional watt transducer can be used to avoid this situation. Incorrect Valve Response Valve Characterization is available on the CMC. Valve characterization allows a more linear use of the valve throttling characteristics. Linear flow is a flow characteristic in which the valve relative opening directly correlates to the percentage flow, e.g. a 50 % open valve gives 50% of maximum flow, with a constant pressure drop across the valve. The CMC modifies the controller output to allow a more linear response to valve throttling. This feature requires configuration by an Ingersoll-Rand service technician. How is Surge Detected? Note that it has been shown that even though the CMC has surge prevention logic, a surge can still occur. The CMC has a surge detection system comprised of a surge pressure transducer and motor current transformer (see Figure 16). The CMC senses surge when the rate of change in last stage discharge pressure and the rate of change in motor current are greater than the surge sensitivity setpoint value. When this occurs, the CMC will alarm and unload the compressor. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 16 CMC TECHNICAL REFERENCE MANUAL Pneumatic Tubing CMC PT 4-20 mA Bypass Valve Base Control Module 4-20 mA CT Check Valve Starter Motor 4-20 mA PTx Compressor Inlet Valve Figure 16: Surge Detection System Surge AbsorberTM When the controller recognizes that a surge occurred, the compressor will unload. With the Surge AbsorberTM feature enabled, the controller will increment the bypass valve position by a fixed percentage, send the inlet valve to the MinLoad point (if it is not already there) and then let normal system demand reload the compressor to the operating pressure. This process will repeat up to three times within a ten-minute period. If the compressor surges four times in ten minutes, the compressor will remain unloaded until an operator presses the reset button. Each detected surge drives a Surge Event to the Event Log. If the compressor unloads due to repeated surges, a Surge Unload Alarm Event is driven to the Event Log. Surge Indexing MinLoad Surge Index Increment Discharge Pressure MinLoad User Setpoint MinLoad Control Setpoint (reset returns control here) Power at Coupling Amps MinLoad Control Setpoint #3 (currently active) MinLoad Control Setpoint #1 MinLoad Control Setpoint #1 Capacity - Mass Flow Since the setting of MinLoad Control Setpoint is sensitive to many variables in a compressed gas system, there is potential for the setting to require adjustment throughout the operation of the compressor. When MinLoad is set incorrectly, one of two things can happen. When MinLoad is set too high, the compressor will consume excessive power at MinLoad. When MinLoad is set too low, the compressor is allowed to go past the surge line and surge occurs. Figure 17: Surge Indexing 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL When Surge Indexing is enabled, it corrects the situation when MinLoad is set too low by automatically adjusting MinLoad to a higher value upon a surge. The indexed setting, MinLoad Control Setpoint will remain in effect until MinLoad User Setpoint is Operator User Interface, or the Reset button is held for more than five seconds. When MinLoad User Setpoint is manually changed, the MinLoad Control Setpoint is automatically changed to match the new setting, and when reset, the MinLoad Control Setpoint is reset to the new MinLoad. Entering a zero into the MinLoad Surge Index Increment variable disables surge Indexing. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 17 18 CMC TECHNICAL REFERENCE MANUAL Oil System Control The CMC panel provides control of the prelube pump and lube oil heater in the starting sequence, during normal operation and after compressor stops or trips. Prelube Pump The prelube pump is started when the panel power is on and seal air is present. The prelube pump stops after the compressor start button is pushed and the programmable timer “Start Time” has expired. The pump does not come on again until the Stop key is pressed, and will remain on until the panel power is turned off or Seal Air is lost. Oil Heater The oil heater is thermostatically controlled. When the oil temperature is below the set point temperature, the oil heater is energized, above the set point temperature it is de-energized. The oil heater control does not have any interaction with the microprocessor board and is designed to operate with the control panel de-energized as long as three-phase power is available. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 19 Protection and Monitoring Each CMC base module has twenty-three analog inputs, sixteen digital inputs, four analog outputs and sixteen digital outputs for control, protection and monitoring. These input functions provide the CMC with information about the compressor. The CMC board uses the output functions to communicate to the user and perform actions like starting the compressor and turning on the prelube pump. All of these inputs and outputs are required to interface physical actions to and from the electronics. Analog Functions An analog function is one in which an electrical signal represents a specific pressure, temperature, vibration and current input; or valve position output. As these inputs and outputs fluctuate, the electrical signal to and from the microprocessor board also fluctuates proportionally to the amount of change. Analog Inputs Twenty-one grounded and two floating analog inputs are used for protection, monitoring and control. Each input used for protecting the compressor can be programmed for alarm and trip indication. Each of these functions is pre-programmed with the function title, engineering units, range, alarm and trip values, so no configuration is required upon receipt by the customer. The CMC uses pressure transmitters to measure pressure, resistance temperature detectors (RTD) and transmitters to measure temperature, eddy current based vibration transmitters to measure shaft vibration and a current transformer to measure the motor current. The CMC logic used for the protective alarm and trip functions is as follows: if the actual value of the input is greater than or equal to the alarm or trip value, indicate the condition. This logic is used for all inputs except, low oil pressure and low oil temperature where the logic is reversed. To prevent nuisance alarms and trips, all standard analog inputs use an alternate alarm and trip value during the stopped, starting, and coasting states. The alternate setpoints cannot be edited through the Operator User Interface. Analog Outputs Two of the available four analog output functions are for inlet and bypass valve positioning. These are only output functions. The standard configuration for a CMC has no input information as to the valve location. The CMC calculates the position based upon where the valves are supposed to be and sends those signals to the valves. Digital Functions A digital function is one in which the presence of an electrical signal indicates ON or YES, and the lack of that signal represents OFF or NO. This is analogous to a light switch that has only two states, ON or OFF. The term "discrete" is also used instead of digital in many instances. The term that will be used throughout this documentation shall be digital. Digital Inputs The sixteen digital inputs provide status of field switches. Emergency Stop and Low Seal Air Pressure trip are standard. Any of these inputs can be configured as an alarm or trip. All inputs operate on 24 VDC power. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 20 CMC TECHNICAL REFERENCE MANUAL Digital Outputs The sixteen digital outputs are used by the CMC to start the prelube pump, energize the main starter contacts, indicate that an alarm or trip condition exists, indicate that the compressor is unloaded, activate the running unloaded shutdown timer and to sound the horn. Outputs can operate on 120 VAC, 60 Hz, single-phase power or 24 VDC power. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 21 Compressor Operating Methodology In the following description of compressor operation, the term “state” is used to indicate what the compressor is doing, or mode of operation, at any given time. These operating states exist in a hierarchy. For example, the two highest level states are “Stopped” and “Rotating”. All other states exist at a level below these two states. Compressor Operating States Waiting This state implies that the compressor is NOT rotating. It is important to note that this is an implication only. If the instrumentation is not working properly or the system is setup improperly, the compressor could be rotating. Not Ready Waiting Ready After the panel power is energized, the controller starts the Waiting Timer and does not allow further User operation until after the timer expires. This timer is set at the factory for two minutes (120 seconds) and is not adjustable. This period allows the compressor prelube pump to circulate oil throughout the casing and prevents restarting while the compressor is coasting down after an electrical interruption. Motor Driven Packages + Compressor + + Stopped Stopped Rotating Starting Unloaded A-D Unloaded Surge Unload Loading MinLoad Loaded Full Load Not Ready When in this state, the compressor is “Not Ready To Start”. This state is entered when Unloading the Waiting Timer has expired and any time Coasting that a compressor trip has been identified. A very common and quite often overlooked reason for the compressor being “Not Ready” is when the Emergency Stop push button has been engaged. This state can exist indefinitely. MaxLoad Ready Similar to the previous state, this state could be redefined as “Ready to Start”. This state is entered when all compressor permissive functions have been satisfied. This state can exist indefinitely. Rotating This mode does not necessarily mean that the compressor is actually rotating. It means that it is possibly rotating or rotation is pending and expected. Starting Any time after the compressor is ready and a start command is given, this state is entered. The goal for this period is to get the compressor to rated speed and running unloaded. “Starting” is allowed for only the Start Timer period and is adjustable. This time period is limited to a maximum of one minute, or 60 seconds. The reason for the limit is to prevent 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 22 CMC TECHNICAL REFERENCE MANUAL the compressor from operating in the critical speed for an extended period. Stage vibration alarm and trip setpoints are increased during this period to get the compressor through the critical speed region. After the compressor has “Started”, the alarm and trip setpoints are adjusted back to their original values. The same procedure occurs for stage air temperature also. This state exits only after the Starting Timer has expired. THE COMPRESSOR IS ALWAYS STARTED UNLOADED. On exit of “Starting”, the compressor will return to the mode that it was in the last time it ran. For example, typical operation implies that prior to stopping the compressor, the Unload key is pressed. If this occurred, then the compressor will remain in “Unload” after starting. If the compressor was running and tripped, the compressor will automatically return to the “Loaded” mode on exit of the Starting state. The User may also press the Load or Unload key prior to pressing the Start key to force the compressor to into either post-Starting state. Unloaded The compressor is in this state after a start (and Load Selected is not in effect) or when the User issues an unload command. A-D Unloaded and Surge Unload are also considered states. However, these two states are really just reasons for being in the Unloaded state. AD Unloaded means “AutoDual Unloaded” which occurs when AutoDual is enabled and the system pressure has been high enough for a long enough time to drive an unload command. “Surge Unload” is similar in that a surge event drives the unload command instead of AutoDual. These states can exist indefinitely. Loading When a valid load command is issued, the compressor will enter this state. This state exists until the MinLoad state is satisfied. The duration of this state depends upon PID settings for the inlet valve at the MinLoad state and the demand for air. MinLoad, Loaded, Full Load and MaxLoad These states transition among themselves as demand for air changes. “MinLoad” means that the bypass valve is controlling pressure and the inlet valve is maintaining the MinLoad Control Setpoint. “Loaded” means that the inlet valve is controlling pressure and the bypass valve is closed. “Full Load” occurs when the inlet valve has reached the full open or 100% position. “MaxLoad” means that the inlet valve is maintaining the MaxLoad Setpoint to prevent motor damage. In both the “Full Load” and “MaxLoad” states, system pressure may be lower than setpoint pressure. Unloading This state occurs when a valid Unload command is issued and will persist until the compressor reaches the Unloaded state. Coasting When a trip or any stop command is issued and the compressor is running, the motor will be de-energized and the compressor will begin to coast to a Stopped state. This state will remain as long as the adjustable Coast Timer is in effect. At the end of the timer, the compressor will enter either the Ready or Not Ready state. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 23 CMC TECHNICAL REFERENCE MANUAL WARNING Failure to set the Coast Timer for a period greater than or equal to the actual coasting time can result in compressor damage. Compressor Operating States The following diagrams graphically depict the states relative to valve position. This diagram is provided to assist in the understanding of overall compressor operation. Compressor Operating States Coasting Unloaded Unloading MaxLoad Loaded Full Load Loaded MinLoad Loading Starting Unloaded Ready Not Ready Waiting with Valve Position System Pressure Setpoint Inlet Valve Bypass Valve System Pressure milli amps % 100 20 4 100 75 16 8 75 12 50 16 25 20 0 % milli amps Unload 50 12 Stop or Trip Tight Closure 25 8 0 4 Load Start Inlet Valve Unload Position Power On Stopped 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Rotating 24 CMC TECHNICAL REFERENCE MANUAL User Interface OUI (Operator User Interface) User interface is defined as the means by which people interact with the compressor control system. The standard configuration of the CMC has two components of the user interface. They are the OUI and the device plate. The key component of "easy to use" is that there are only twelve buttons to press on the OUI and four buttons, lights, and switches on the device plate. The CMC OUI consists of six command buttons (Start, Stop, Load, Unload, Acknowledge and Reset), four navigation keys (Up, Right, Left and Down), an Edit mode selection key (Enter) and a Contrast key. These keys in conjunction with the 240x128-pixel graphics display make up the user interface to the compressor. The bezel that surrounds the OUI ensures that the NEMA 4 rating is maintained for the OUI. CENTAC Microcontroller SYSTEM System Pressure Pressure Setpoint INFO SETTINGS 105.3 105.0 173.4 Motor Current Running Hours 11445 Loaded Inlet Valve Bypass Valve 22JUL96 95 0 12:00:00 Load Selected Remote 1/2 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 25 Command Keys These keys “command” the compressor to perform actions as specified in the following table. When any of these keys are pressed the action will be logged in the event log. Key Name Acknowledge Reset Function Silences the optional horn or acknowledges an alarm. Clears all trip latches. Required to be pressed after a trip condition to restart the compressor. Starts the compressor. Start Stop Load Stops the compressor. This button should be pressed instead of the E-Stop for normal operation. Engages Modulate or Autodual control mode. Unloads the compressor. Unload Enter Key - Display Operating Mode The Enter key toggles the display between the NAVIGATION mode and the EDIT mode. Navigation Keys The arrow keys for Up, Right, Left and Down perform differently depending upon the current display-operating mode. FOLDER NAVIGATION To move among the tabbed folders, press the RIGHT or LEFT key. The folder list is circular; that is, when the SYSTEM folder is displayed and the LEFT key is pressed, the SETTINGS folder becomes active. The same is true when the SETTINGS folder is displayed and the RIGHT key is pressed, the SYSTEM folder becomes active. PAGE NAVIGATION To move among each folder’s pages, press the UP and DOWN keys. The page list is also circular. So, when page 1/4 (pronounced page 1 of 4) is active and the UP key is pressed, page 4/4 becomes active. Also, when page 4/4 is active and the DOWN key is pressed, page 1/4 becomes active. The current page for a folder is persistent. For example, if you begin on the SYSTEM folder page 2, change to the INFO folder and return to the SYSTEM folder, page 2 will be the page displayed. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 26 CMC TECHNICAL REFERENCE MANUAL Contrast Key This key changes the contrast of the backlight for the graphic LCD display. Pressing this key steps among each of the thirty two contrast levels. When stepped to the thirty second level, pressing the key again returns to the first contrast level. Graphic Display The 240x128-pixel graphic display allows us to provide a flexible interface between the user and the compressor. The display has three distinct regions as shown in the diagram below. Folders SYSTEM Page System Pressure Pressure Setpoint Motor Current Status Bar INFO SETTINGS 105.3 105.0 173.4 Loaded Compressor Operating State Inlet Valve Bypass Valve 22JUL96 95 0 12:00:00 Load Selected Remote 1/2 Compressor Control Location Page Number Compressor Status Graphics Display Area Definitions Folder and Page In the design of this system, it is important to provide much of the information required for operating and troubleshooting the compressor. The tabbed folder with multiple pages metaphor has been used to reduce the complexity of a traversing at least sixteen pages of information. For the standard design, the maximum number of keys required to get to any of the sixteen pages is six. The SYSTEM folder provides information about the compressor system, the INFO folder gives various types of information about the unit and the SETTINGS folder is used to perform compressor setup. Status Bar The Status Bar provides four distinct types of information (Compressor Operating State, Compressor Status, Compressor Control Location and Page Number). This region is always visible from any folder and page combination. This Field is displayed in large text so that the operator can determine the compressor’s current operating state at a glance. See Section titled “Compressor Operating Methodology” for a list of the messages provided. The Compressor Status Field messages are Trip, E-Stop (emergency stop button pressed), RMT-Stop (a remote stop has been pressed), Start Disabled (an optional permissive start condition has not been satisfied), Alarm, Unload Selected (the compressor will stay in “Unload” after “Starting” has been completed), and Load Selected (the compressor will go to “Minload” after “Starting” has been completed). 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL The Compressor Control Location Field messages are Local, Remote (remote hardwired commands i.e. start, stop, load, unload etc.), Network (MODBUS, DF1 or ASC communication with a UCM) and Remote/Net (both Remote and Network). This indication is provided to indicate to the operator that a remote location is in control of the compressor and the compressor may start, stop, load, unload, etc. without the local operator initiating any commands. These three fields combine to provide the operator with the necessary information to create a cursory determination of the status of the compressor. When a more thorough determination is required, the operator can get additional detail by looking through the other pages in the system. The Page Number indicates the current page for the current folder with the number of pages in the folder. The number of pages is given so that the user always knows where he is in the system. Navigation Mode Navigation mode is active when a folder name (SYSTEM, INFO or SETTINGS) is highlighted. Edit (Setpoint Changes) Mode Edit mode is activated by pressing the ENTER key. In Edit mode one can change Setpoints for a page. Once in this mode, the highlight will move from around the folder name to the item to be changed. Use the Right and Left arrow keys to move among the changeable items and the Up and Down arrow keys to change the value of the item. When changes are complete, press the Enter key again to return to Navigation mode. Scroll Mode Scroll mode is activated by pressing the ENTER key when a folder name INFO is highlighted and the Event Log or the Routine Start / Stop page is visible. The Scroll mode is used to page through the event log. To move among the pages, press the UP or DOWN keys. To deactivate the Scroll mode, press the Enter key. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 27 28 CMC TECHNICAL REFERENCE MANUAL Pop-up Message In the event of an Alarm or Trip, a pop-up message will appear providing the customer with the phone number of the local Ingersoll-Rand representative. If the event is a Trip, the event log on the SYSTEM folder will be displayed with the pop-up message centered over the displayed page. The message may be removed by pressing the ENTER key. The following are examples of the pop-up message in the event of an Alarm or Trip. Alarm Example SYSTEM INFO SETTINGS 105.1 100 Pressure 0 Setpoint 105.0 Motor 323.4 Current Press ENTER key to continue System Pressure Inlet For Parts orValve Service Please Call:Bypass Valve 39 02 950 56499 Running Hrs: 11445 Loaded 31-AUG-1999 12:00:00 Load Selected Remote 1/4 Trip Example SYSTEM 1 2 3 4 5 6 7 INFO SETTINGS Event Name Time Date Low Oil Pressure 09:18:44 0720 For PartsTrip or Service Low Oil Pressure Alarm 09:18:43 0720 Please Call: Reset key pressed 09:18:34 0720 39 02 950Trip 56499 09:08:43 0720 Low Oil Pressure Low Oil Pressure Alarm 08:58:23 0720 LoadPress key pressed 08:24:01 0720 ENTER key to continue Start key pressed 08:23:12 0720 Not Ready Trip Remote 2/3 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 29 CMC TECHNICAL REFERENCE MANUAL SYSTEM Folder SYSTEM System Pressure Pressure Setpoint Motor Current INFO 105.1 105.0 323.4 Inlet Valve Bypass Valve Temperature 95.8 93.5 115.3 80.1 Load Selected Remote 2/4 Loaded INFO RESET SETTINGS Digital Inputs Starter Feedback E-Stop Pressed Low Seal Air INFO SETTINGS Digital Outputs Prelube Pump Running CR1 Remote Trouble SYSTEM CONTRAST UP RIGHT DOWN 1 2 3 4 5 6 7 INFO SETTINGS Event Name Low Oil Pressure Trip Low Oil Pressure Alarm Reset key pressed Low Oil Pressure Trip Low Oil Pressure Alarm Load key pressed Start key pressed Not Ready SYSTEM INFO SYSTEM Date 0720 0720 0720 0720 0720 0720 0720 Trip Remote 2/6 Load Selected Remote 3/6 SETTINGS 39 02 950 56499 Loaded Load Selected Remote 4/4 SYSTEM Navigation and Enter Keys Load Selected Remote 4/6 Ready R E P Part No. 12345678 12345678 12345678 12345678 12345678 12345678 INFO Load Selected Remote 5/6 Ready SYSTEM INFO SETTINGS Ready 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Load Selected Remote 6/6 100.0 100.0 1.0 9.0 Load Selected Remote 2/6 INFO SETTINGS PB Inlet Valve Pressure MinLoad (TL) MaxLoad (HLL) Bypass Valve Pressure 10.00 25.00 99.99 10.00 INFO IT rep/sec D sec 0.50 0.50 0.50 0.00 0.00 0.00 0.50 0.00 Load Selected Remote 3/6 Loaded SETTINGS Control Mode Manual Modulate Autodual Reload Pressure, % of Setpoint Unload Point, BV % Open Unload Delay Time, seconds INFO SETTINGS Starting Timer, seconds Coasting Timer, seconds CT Ratio Inlet Unload Position, % Setpoint Ramp Rate, pressure/scan SETTINGS Stage 1 Temperature Stage 1 Vibration Stage 2 Temperature Stage 2 Vibration Oil Pressure High Oil Temperature Low Oil Temperature Loaded 20 240 60 15 5.0 Load Selected Remote 5/6 Loaded INFO 98 1 1 Load Selected Remote 4/6 Loaded SYSTEM R O U T I N E S T A R T / S T O P Prior to starting, the operator should become familiar with the operation of the main driver. Refer to the driver manufacturer's instructions in the Operation Manual. The operator should also be familiar with all the accessory and optional equipment contained on the 400.0 Loaded SYSTEM SETTINGS L A C E M E N T P A R T S Description Inlet Filter Element Primary Inlet Filter Element Secondary Oil Filter Demister Element Lubricant, 55 gallon drum Lubricant, 5 gallon drum SETTINGS Surge Absorber Enabled Surge Sensitivity SYSTEM For parts or service contact your local Ingersoll-Rand representative at the following number: INFO MaxLoad (HLL) MinLoad User Setpoint (TL) Control Setpoint Surge Index Increment SYSTEM 12338 11445 11223 35 2.51 INFO * 1999/08/31 12:30:00 Load Selected 1/6 Remote Loaded SYSTEM Time 09:18:44 09:18:43 09:18:34 09:08:43 08:58:23 08:24:01 08:23:12 SETTINGS Loaded SETTINGS Date, yyyy/mm/dd Time, hh:mm:ss Load Selected Remote 1/6 Loaded INFO Password * * * Setpoint Changes Enabled Language and Units English degF mils amps psi English degC mils amps kg/cm2 ENTER STOP BCM Ver: SYSTEM UNLOAD Power On Hours Running Hours Loaded Hours Number of Starts Load Selected Remote 3/4 Loaded LOAD SETTINGS Folder SETTINGS LEFT SYSTEM Vibration 0.25 0.22 INFO HORN SILENCE START SETTINGS Pressure Stage 1 30.1 Stage 2 106.6 Oil 18.8 Water SYSTEM 100 0 31-AUG-1999 12:00:00 Load Selected Remote 1/4 Loaded INFO SYSTEM SETTINGS Running Hrs: 11445 SYSTEM INFO Folder Alarm Trip 120 125 0.80 1.00 120 125 0.75 0.95 18 16 120 125 100 95 Load Selected Remote 6/6 30 CMC TECHNICAL REFERENCE MANUAL SYSTEM Folder The SYSTEM folder provides information about the compressor system. The number of pages in this folder is at least four; but could be more for two stage machines with special analog options purchased, or for compressors with three stages or SYSTEM INFO SETTINGS more. System Pressure 105.1 105.0 323.4 Inlet Valve 100 0 This page shows the main compressor operating parameters, running hours, date and time. The Motor System Pressure and Pressure Current Setpoint are in units as defined by 31-AUG-1999 12:00:00 Running Hours: 11445 the Settings page, Motor Current is Load Selected in Amps and valve positions are in Remote 1/4 percent open. Pressure Setpoint is always editable while the Inlet and System Folder – Page 1: System Pressure Bypass Valve positions are edit enabled when in the Manual mode only. These are the only editable settings in any folder other than the Settings Folder. Pressure Setpoint Bypass Valve Loaded Info Folder Page 1 Edit Parameters Table Variable Pressure Setpoint Minimum Value Maximum Value Step Size 0.0 999.9 0.1 Units pressure Inlet Valve Position (manual mode only) percent 0 100 1 Bypass Valve Position (manual mode only) percent 0 100 1 The Analog Input page provides the actual value for each stage pressure, temperature and vibration, oil pressure and temperature. If additional analog inputs have been purchased or more stages exist as standard, it is likely that an additional page or pages will be added. The units are as defined by the Settings page. There are no editable setpoints on this page. The Digital Input page shows the current state of the digital (discrete) inputs for the system. The number of inputs will vary depending upon the number of optional inputs purchased. A check in the box to the left of the text indicates a TRUE condition, whereas, no check indicates a FALSE condition. For example, a check mark in the “E-Stop Pressed” boxed means that the Emergency Stop push button has been pressed. It is possible to have multiple Digital Input pages. SYSTEM INFO Press 30.1 106.6 20.3 Stage 1 Stage 2 Oil Loaded SYSTEM SETTINGS INFO Temp 95.8 93.5 105.5 Vib 0.25 0.22 Load Selected Remote 2/4 SETTINGS Digital Inputs Starter Feedback E-Stop Pressed Low Seal Air Loaded Load Selected Remote 3/4 System Folder - Pages 2,3: Analog/Digital Inputs 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 31 CMC TECHNICAL REFERENCE MANUAL SYSTEM INFO SETTINGS Digital Outputs Prelube Pump Running CR1 Remote Trouble Loaded Load Selected Remote 4/4 System Folder - Page 4: Digital Outputs The Digital Output page is similar to the Digital Input page except that it shows the current state of the digital (discrete) outputs for the system. The number of outputs will vary depending upon the number of optional items purchased. A check in the box to the left of the text indicates a TRUE condition, whereas, no check indicates a FALSE condition. It is possible to have multiple Digital Output pages. The SYSTEM folder’s four pages give the current operating status for the compressor. The User is always within two keystrokes of all operating parameters. INFO Folder The INFO folder contains the OUI key map, the compressor event log, the hour meters, the phone number to call for parts or service, a list of part numbers for consumable parts and routine start/stop and maintenance instructions. There INFO SETTINGS SYSTEM are no editable setpoints in this Event Name Time Date folder. The OUI key map will be 1 Low Oil Pressure Trip 09:18:44 0720 the default page on power up. 2 Low Oil Pressure Alarm 09:18:43 0720 The keys are labeled in English 3 Reset key pressed 09:18:34 0720 4 Low Oil Pressure Trip 09:08:43 0720 and the local language, 5 Low Oil Pressure Alarm 08:58:23 0720 depending upon the current 6 Load key pressed 08:24:01 0720 language selected. 7 Start key pressed 08:23:12 0720 Trip The Event Log details the last Remote 2/6 two-hundred twenty four (224) “events” that have occurred. Each “event” has a date and time Info Folder - Page 2: Scrollable Event Log stamp. This log will list all Alarms and Trips and provides first-out indication. Any time an Alarm or Trip is indicated on the Status Bar, the detail for that fault is included here. Not Ready The event labeled as “1” is the newest event and “7” is the oldest event. For events that have identical Time and Date values, the order is still correct (newest to oldest, top to bottom). Once the list is full, each new event knocks off the last event. Pressing the Enter key to initiate Scroll Mode allows access to events 17 through 224. Scroll Mode is indicated by the reverse video of the event numbers. Each Down Arrow press displays the next seven events. An Up Arrow press will display the previous seven events. Any time a Trip occurs, the system will send the display to the first seven events. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 32 CMC TECHNICAL REFERENCE MANUAL Possible Events List Event Name Description * * End of List * * Displayed for the event name whenever the event list is not full. A/I Alarm The actual value for Analog Input “AI” is greater than the Alarm value. A/I Trip The actual value for Analog Input “AI” is greater than the Trip value. Acknowledge (Location) An Acknowledge command has been issued from Location. Auto Dual Mode Enabled The Auto Dual Mode has been enabled Auto Start An automatic start occurred (typically from Auto Hot or Cold Start). Auto Stop An automatic stop occurred (typically from Running Unloaded Shutdown Timer). BCM 2 Failure Alarm Communications have been lost to Base Control Module #2. BCM 3 Failure Alarm Communications have been lost to Base Control Module #3. Compressor Started The compressor has started. DI Alarm The Discrete Input “DI” is in an alarm condition. Discrete Surge A discrete surge switch has detected a surge. DI Trip The Discrete Input “DI” is in a trip condition. Driver Trip Drive controller feedback was not received after a start command was issued Edit-x AI Alarm SP The Analog Input “AI” Alarm setpoint value has been edited from location x. Edit-x AI Trip SP The Analog Input “AI” Trip setpoint value has been edited from location x. Edit-x A/D Reload Pct The AutoDual Reload Percent value has been edited from location x. Edit-x A/D Unload Dly The value has been edited from location x. Edit-x A/D Unload Pt The AutoDual Unload Point value has been edited from location x. Edit-x AHS Pressure The Auto Hot Start Pressure value has been edited from location x. Edit-x Auto Stop Time The Auto Stop Timer value has been edited from location x. Edit-x BV Position The Bypass Valve Position value has been edited while in Manual from location x. Edit-x BV-PID D The Bypass Valve Pressure PID Derivative value has been edited from location x. Edit-x BV-PID It The Bypass Valve Pressure PID Integral Time value has been edited from location x. Edit-x BV-PID Pb The Bypass Valve Pressure PID Proportional Band value has been edited from location x. Edit-x Coasting Timer The Coasting Timer value has been edited from location x. Edit-x CT Ratio The CT Ratio value has been edited from location x. Edit-x Day The Day value for the Date field has been edited from location x. Edit-x IV Position The Inlet Valve Position value when in Manual has been edited from location x. Edit-x IV Unload Pos The Inlet Valve Unload Position value has been edited from location x. Edit-x IV-PID D The Inlet Valve Pressure PID Derivative value has been edited from location x. Edit-x IV-PID It The Inlet Valve Pressure PID Integral Time value has been edited from location x. Edit-x IV-PID Pb The Inlet Valve Pressure PID Proportional Band value has been edited from location x. Edit-x MaxLoad SP The MaxLoad Setpoint value has been edited from location x. Edit-x MaxLoad-PID D The Inlet Valve MaxLoad PID Derivative value has been edited from location x. Edit-x MaxLoad-PID It The Inlet Valve MaxLoad PID Integral Time value has been edited from location x. Edit-x MaxLoad-PID Pb The Inlet Valve MaxLoad PID Proportional Band value has been edited from location x. Edit-x MinLoad Index The MinLoad Surge Index Increment value has been edited from location x. Edit-x MinLoad SP The MinLoad Setpoint value has been edited from location x. Edit-x MinLoad-PID D The Bypass Valve Pressure PID Derivative value has been edited from location x. Edit-x MinLoad-PID It The Bypass Valve Pressure PID Integral Time value has been edited from location x. Edit-x MinLoad-PID Pb The Bypass Valve Pressure PID Proportional Band value has been edited from location x. Edit-x Month The Month value for the Date field has been edited from location x. Edit-x PSP Ramp Rate The Pressure Setpoint Ramp Rate value has been edited from location x. Edit-x Process SP The Process Set Point value has been edited from location x. Edit-x Sensitivity The Surge Sensitivity value has been edited from location x. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Edit-x Starting Timer The Starting Timer value has been edited from location x. Edit-x Sys Press SP The System Pressure Setpoint value has been edited from location x. Edit-x Time The Time value has been edited from location x. Edit-x Waiting Timer The Wait Timer has be edited from location x. Edit-x Year The Year value for the Date field has been edited from location x. E-Stop pressed Emergency Stop push button has been pressed. Fail to Roll Did not achieve minimum slow roll speed in allotted time Illegal Rotation Unexpected rotation from driver Load (Location) A Load command has been issued from network communications. Loss of Motor Current Motor current feedback was lost while running. MinLoad Clamped The MinLoad Control or User Setpoint value has been limited to the MaxLoad Setpoint value. MinLoad Incremented The MinLoad Control Setpoint value has been incremented as a result of surge. MinLoad Reset The MinLoad Control Setpoint value has been reset to the MinLoad User Setpoint value. Modulate Mode Enabled The Modulate Mode has been enabled. Power Down The Base Control Module (BCM) was de-energized. Power Up The Base Control Module (BCM) was energized. Reset (Location) A Reset command has been issued from Location. Start (Location) A Start command has been issued from Location. Starter Failure Starter feedback was not received after a Start command was issued. Starter Fault-Closed Motor stopped but feedback present for 2 seconds Starting Fail Driver feedback was not received after a Start command was issued. Stop (Location) A Stop command has been issued from Location. Surge The controller has detected a Surge. Surge Unload Alarm The alarm condition when the compressor has unloaded as a result of multiple surges. TTV Switch Fault Trip Limit Switch Stuck Unload (Location) An Unload command has been issued from Location. NOTE 1: “Location” is replaced by “Comm” for communications network, “Local” for local compressor display and “Remote” for hardwired remote communications. NOTE 2: “x” is replaced by “C” for edits from a communication network and “L” for edits from the local display. NOTE 3: All Analog Inputs that have alarm and trip sepoints get edit local, edit communications, alarm and trip event messages. NOTE 4: All Discrete Inputs for Alarm or Trip get alarm and trip event messages. This next page of the INFO Folder shows the hour meters and number of starts. Power On Hours is the time that the panel INFO SETTINGS power has been on. The Running SYSTEM Hours are the amount of time that Power On Hours 12338 the compressor has been Running Hours 11445 Loaded Hours 11223 operating between all start and Number of Starts 35 stop sequence. The Loaded Hours is the amount of time that the compressor has been running BCM Ver: 3.00 and not running unloaded. It can also be defined as the number of Load Selected Remote 3/6 hours that the inlet valve is not in the Inlet Unload Position. The Info Folder – Page 3: Hour Meters and Version Number of (Compressor) Starts is self-explanatory. Loaded 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 33 34 CMC TECHNICAL REFERENCE MANUAL NOTE Most electric motors are only rated for two cold starts or one hot start per hour. It is the operator’s responsibility not to exceed the electric motor’s limitation. The control system allows the compressor to be started when the compressor is ready, not the motor. The last item on this page is the Base Control Module Version number. This will be used by field personnel for quick reference to determine if newer software is available. This page of the INFO folder shows the phone number to call for parts or service. This is the number of the local Ingersoll-Rand representative. The number can be changed only by use of Service Tool. INFO SYSTEM SETTINGS For parts or service contact your local Ingersoll-Rand representative at the following number: 39 02 950 56499 Trip Remote Ready 4/6 Info Folder – Page 4: Phone Number This page provides a list of consumable parts found on the compressor package. These parts may also be located in the compressor bill of materials. In the event of a discrepancy, the compressor’s bill of materials always takes precedence over this page. In the event that the part numbers are not available, such as retrofitting the CMC on a competitive machine, this screen may not be visible. INFO SYSTEM R E P Part No. 12345678 12345678 12345678 12345678 12345678 12345678 SETTINGS L A C E M E N T P A R T S Description Inlet Filter Element Primary Inlet Filter Element Secondary Oil Filter Demister Element Lubricant, 55 gallon drum Lubricant, 5 gallons Ready Trip Remote 5/6 Info Folder – Page 5: Replacement Parts 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 35 CMC TECHNICAL REFERENCE MANUAL Basic operator instructions are provided on the Routine Start/Stop and Maintenance pages. Pressing the Enter key to initiate Scroll Mode allows access to the entire instructions. Scroll Mode is indicated by the reverse video of a slide bar. Each Down Arrow INFO SETTINGS SYSTEM press displays the next eight lines of R O U T I N E S T A R T / S T O P instructions. An Up Arrow press will Prior to starting, the operator should display the previous eight lines of become familiar with the operation of the main driver. Refer to the driver instructions. The slide bar on the page manufacturer's instructions in the indicates current location within the text. Operation Manual. The operator should If a Trip occurs while on this page, the also be familiar with all the accessory system will send the display to the event and optional equipment contained on the log page. Trip Ready Remote 6/6 Info Folder – Page 6: Operator Instructions SETTINGS Folder The SETTINGS folder is used for compressor setup. In this folder, the User will enter performance and control operating parameters, analog health monitoring settings for Alarm and Trip conditions, control mode selection, setpoint changes, password, and user interface language. This folder is the primary location for editing setpoints. The Password is used for determining whether Setpoint Changes can be made. The Password takes four numbers. If the Password is entered properly, Changes will be enabled (a check will be in the box); otherwise, they are disabled. This enabling and disabling applies to all changeable setpoints except, Pressure Setpoint, Throttle Limit, language selection and the Password, these items are always modifiable. SYSTEM INFO SETTINGS Password * * * Setpoint Changes Enabled Language and Units English degF mils amps psi English degC mils amps kg/cm2 Date, yyyy/mm/dd Time, hh:mm:ss Loaded * 1999/08/31 12:30:00 Load Selected Remote 1/6 Settings Folder - Page 1: Password, Language, Each control system is shipped with Time and Date two languages and units of measure combinations. The first set is for the English language, pressures in units of PSIG, temperatures in units of degrees F and vibrations in units of mils. The other set will be localized for the customer. The default alternate language is English with Metric units. Language support will be provided for those listed in the Technical Specification located at the end of the manual. Others will be available as required and translations can be obtained. This system has the ability for any language because of the graphics display. Asian character support will require additional screens because these characters require four times the number of pixels. There are no limitations on the units of measure. Each analog input has its own scaling factor and offset. The Date is set with three separate values (1) Year, including century (2) Month and (3) Day. The Time is also set with three values (1) Hour, (2) Minutes and (3) Seconds. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 36 CMC TECHNICAL REFERENCE MANUAL Settings Folder Page 1 Edit Parameters Table Variable Units Minimum Value Maximum Value Step Size 1 Password Digit dimensionless 0 9 Date (Year) years 1990 2089 1 Date (Month) months 1 12 1 Date (Day) days 1 31 1 Time (Hour) hours 0 23 1 Time (Minute) minutes 0 59 1 Time (Second) seconds 0 59 1 The Anti-surge Settings and Driver Over-Load Protection Page has all of the settings for controlling and detecting surge conditions and protecting the main driver from over load conditions. The MaxLoad (HLL) setpoint prevents the compressor driver SYSTEM INFO from overloading. MinLoad User MaxLoad (HLL), amps 400.0 Setpoint (TL) is the value used to MinLoad determine what the initial (before User Setpoint (TL), amps 100.0 Control Setpoint, amps 100.0 indexing) motor current value will Surge Index Increment, amps 1.0 be when constant pressure control operation switches from the inlet Surge Absorber Enabled valve to the bypass valve. Surge Sensitivity 9.0 MinLoad Control Setpoint is the Load Selected Remote 2/6 actual value used to determine when the bypass valve begins Settings Folder - Page 2: Anti-Surge and Driver constant pressure control in lieu of Over-Load Protection the inlet valve. This value equals the MinLoad User Setpoint plus the number of surges times the index increment value. MinLoad Surge Index Increment is the value that the Control Setpoint is indexed after a surge has been detected. If the value for Surge Index Increment is equal to zero, Surge Indexing is disabled. SETTINGS Loaded To reset the MinLoad Control Setpoint to the MinLoad User Setpoint, hold the reset key for at least five seconds. The indication that it has been reset will be in the event log. The event message “MinLoad Reset” will be displayed. Another indication is when the MinLoad User Setpoint value equals the MinLoad Control Setpoint value. The Surge Absorber Enabled checkbox allows the user to turn off or on the Surge Absorber feature. When disabled, the compressor will Unload on any surge condition. The Surge Sensitivity setting has a range from zero (0.0) to ten point nine (10.9) where one is not sensitive (a “soft” surge condition could exist without being identified) and ten is very sensitive (a “soft” surge condition would be identified). We ship the machine with a default value of nine (9). This setting will pick up most surge conditions. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 37 CMC TECHNICAL REFERENCE MANUAL Settings Folder Page 2 Edit Parameters Table Variable Units Minimum Value Maximum Value Step Size MaxLoad (HLL) amps 0.0 9999.9 0.1 MinLoad User Setpoint (TL) amps 0.0 100.0 0.1 MinLoad Surge Index Increment amps 0.0 9999.9 0.1 Surge Sensitivity dimensionless 0.0 10.9 0.1 NOTE MinLoad Control Setpoint is the motor amperage value used to determine when the bypass valve opens. MinLoad Control Setpoint will always be equal to or greater than the Throttle Limit value. CAUTION The MaxLoad (HLL) value should not exceed the value determined in the section titled Setting MaxLoad. Failure to set this properly could result in damage to the motor. CAUTION When Surge Indexing is enabled and the compressor surges several times, the compressor will begin bypassing air sooner than when Surge Indexing is disabled. You should periodically reset the MinLoad Control Setpoint to prevent excessive air bypass. CAUTION Repeated surging can cause damage to the compressor; therefore, use caution when desensitizing the Surge Sensitivity setting. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 38 CMC TECHNICAL REFERENCE MANUAL The Control Parameters Page is used for matching the control SETTINGS SYSTEM INFO system to the local application. PB IT D The Proportional Band (PB), rep/sec sec Integral Time (IT) and Derivative Inlet Valve (D) settings are provided for Pressure 10.0 0.50 0.00 both the inlet valve and bypass MinLoad (TL) 25.00 0.50 0.00 MaxLoad (HLL) 99.99 0.50 0.00 valves. This gives the controller Bypass Valve precise control for modeling the Pressure 10.0 0.50 0.00 air system over the entire Load Selected operating range of the Remote 3/6 compressor. With this release, the Derivative constant has Settings Folder - Page 3: Control Parameters (PID Settings) been added to give even more capability to match the control system to the air system. However, we recommend that this value remain at zero unless you have full understanding of how this parameter works. Loaded Settings Folder Page 3 Edit Parameters Table Variable Minimum Value Units Maximum Value Step Size Each PB (Proportional Band) dimensionless 0.0 99.99 0.1 Each It (Integral Band) repeats/second 0.0 99.99 0.1 Each D (Derivative Band) seconds 0.0 99.99 0.1 CAUTION Setting the Derivative parameter to a value other than zero for any of the PID settings may cause the valve output to change rapidly. Please change this value with caution. The Control Mode Selection Page allows the User to select between the two standard control modes, Modulate and Autodual. This selection process is performed with the radio button selector. To change the selection, press the Up or Down arrow key. Reload Percent, Unload Point and Unload Delay Time are all setpoints for Autodual control. SYSTEM INFO SETTINGS Control Mode Manual Modulate Autodual Reload Pressure, % of Setpoint Unload Point, BV % Open Unload Delay Timer, seconds Loaded 98 1 1 Load Selected Remote 4/6 Settings Folder - Page 4: Control Mode Selection Checking the Manual checkbox enables manual valve control. In this mode, the inlet valve may be stroked when the compressor is not running, and the bypass valve can be stroked 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 39 CMC TECHNICAL REFERENCE MANUAL at any time. If a surge condition occurs while manually controlling these valves, the CMC will automatically take over the valves. Settings Folder Page 4 Edit Parameters Table Variable Units Minimum Value Maximum Value Step Size 1 Autodual Reload Pressure % of Setpoint 0 99 Autodual Unload Point BV % Open 1 99 1 Autodual Unload Delay Timer seconds 0 999 1 CAUTION Manual should only be used for compressor setup. Starting Timer is the length of time prior to enabling the loading of the compressor. Typically, this time includes the starter transition time (Y-D time) and the prelube pump shutdown. When this timer expires, the prelube pump will turn off and the compressor is enabled for loading. Coasting Timer is the length of time that it takes for the driver to stop rotating. SYSTEM INFO SETTINGS Starting Timer, seconds Coasting Timer, seconds CT Ratio Motor Failure Trip Enable Inlet Valve Unload Position, % Setpoint Ramp Rate, pressure/scan Loaded 20 240 60 15 5.0 Load Selected Remote 5/6 Settings Folder - Page 5: Miscellaneous CT Ratio is the ratio of the current transformer primary to the secondary; i.e., if the CT primary winding is 300 and the secondary winding is 5, then the CT Ratio is 60. When checked, Motor Failure Trip Enable tests that the zero_amp motor_current variable has been reached after a start command has been initiated and that motor current is not lost while the compressor is running. Uncheck this box for dry run conditions. The Inlet Unload Position is the position of the inlet valve when in the unload state. Setpoint Ramp Rate is used to prevent system pressure overshoot during compressor loading. Additional settings will be added to this page for “special” features. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 40 CMC TECHNICAL REFERENCE MANUAL Settings Folder Page 5 Edit Parameters Table Variable Minimum Value Units Maximum Value Step Size Starting Timer seconds 5 60 1 Coasting Timer seconds 60 9999 1 CT Ratio dimensionless 60 9999 1 Inlet Valve Unload Position percent 0 100 1 Setpoint Ramp Rate pressure/scan 0 999.9 0.1 WARNING Failure to set the Coast Timer for a period greater than or equal to the actual coasting time can result in compressor damage. The Alarm and Trip Settings Page provides the means for changing the analog health monitoring values. The number of inputs varies depending upon the number of compression stages and optional inputs. Additional pages will be added as needed after this page. All line items are changeable for the Alarm and Trip setpoints. SYSTEM INFO SETTINGS Stage 1 Temperature Stage 1 Vibration Stage 2 Temperature Stage 2 Vibration Oil Pressure High Oil Temperature Low Oil Temperature Loaded Alarm 120 0.80 120 0.75 18 120 100 Trip 125 1.00 125 0.95 16 125 95 Load Selected Remote 6/6 Settings Folder - Page 6: Alarm and Trip WARNING Setting Trip values outside the range specified on the drawings can result in compressor damage. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 41 CMC TECHNICAL REFERENCE MANUAL General Sequence of Operation To start and load a compressor follow steps 1, 2, 3 and 4 CENTAC Microcontroller SYSTEM System Pressure 1 Press Reset Pressure Setpoint Motor Current 2 Look for INFO SETTINGS 105.3 105.0 173.4 Inlet Valve Bypass Valve 22JUL96 Loaded "Ready" 95 0 12:00:00 Load Selected Remote 1/2 3 Press Start 4 Press Load Press Unload, 5 wait 20 seconds To unload and stop a compressor follow steps 5 and 6 6 Press Stop Compressor Operating States Motor Current Coasting Unloaded Unloading MaxLoad Setpoint Amps Motor Full Load Amps Load No Stops or Trips MinLoad Setpoint Amps Any Stops or Trips Start Unloaded Amps Zero Amp Offset 0 Power On MaxLoad Loaded Full Load Loaded Unload Motor Full Load Amps Plus Service Factor amps, % 100 MinLoad Loading Unloaded Starting Ready Not Ready Waiting for Motor Driven Packages Stopped 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Rotating 42 CMC TECHNICAL REFERENCE MANUAL Indicator, Switch and Light Layout In addition to the CMC OUI there may be a variety of indicators, switches, and lights mounted on the control panel door. In conjunction with the CMC OUI these devices make up the User Interface for the CMC. A typical device layout consists of the following lights, push buttons, and selector switches. Lights The lights provided are the green CONTROL POWER ON light, which is integral to the CONTROL POWER OFF/ON switch, the amber PRELUBE PUMP RUNNING light and the red TROUBLE INDICATION light. Push Buttons The red EMERGENCY STOP push button stops the compressor any time that it is pressed. This push button is used to initiate a stop in the case of an emergency. Switches The CONTROL POWER OFF/ON selector switch turns the panel power on or off CMC Tuning Procedures When commissioning a new compressor, troubleshooting an existing compressor, or tuning a system, the following procedures may be required. The procedures are performed, and any changes required are made through the CMC OUI. For instructions on how to use the OUI refer to the section titled User Interface. The following figure will be referenced in the procedures. PT 1 PT 2 Bypass Valve Pneumatic Tubing Check Valve 4-20 mA Base Control Module CT Block Valve Starter Motor Compressor Plant Air System 4-20 mA Inlet Valve Inlet Filter Figure 18: Plant Air System Setting MaxLoad The MaxLoad Setpoint keeps the motor within the allowable current range. To determine the value for MaxLoad, an Adjusted Service Factor (ASF) is multiplied by the motor full load 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 43 CMC TECHNICAL REFERENCE MANUAL amps (FLA). The (ASF) is found by obtaining the motor service factor from the motor nameplate and selecting the adjustment factor from the table below. The motor full load amps is found on the motor nameplate. Motor Service Factor 1.15 1.25 Example: FLA: Adjusted service factor: MaxLoad: Adjusted Service Factor 1.05 1.10 MaxLoad = FLA X ASF 134 Amps 1.05 140 Setting MinLoad MinLoad establishes the minimum flow through the machine when loaded; it is the maximum point of inlet valve throttling. If system demand is below this throttle point, the compressor must bypass air or unload. If flow were allowed to go below MinLoad, the machine would eventually cross the surge line and surge. By stopping inlet valve throttling at MinLoad the machine is kept out of surge. To find the MinLoad setting, the machine is run into the surge line, and the value of load (amps, kilowatts, SCFM) at surge is recorded. The recorded value is then incremented by five percent and set as the value for MinLoad. 1. Before continuing this procedure, verify the following: a) The inlet and bypass control valves have been calibrated. b) The machine is running unloaded. c) The block valve at the inlet to the plant air system (Figure 18) is closed. d) The pressure setpoint is set to the pressure at which the machine is going to operate. 2. Set initial MinLoad estimates. a) In the Settings Folder, select the Edit Data cell for MinLoad. b) Increment or decrement the value to achieve a value of approximately 95% of full load amps. 3. Preset the manual bypass valve position to 100. a) On the OUI select the Settings Folder and enable manual valve control by highlighting the manual check box. NOTE When Manual is enabled, both control valves can be positioned while stopped, while only the Bypass Valve can be positioned when Loaded. b) Switch to the System Folder Page 1 and press the Enter Key to enable edit mode. c) Use the horizontal navigation keys to select the bypass valve. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 44 CMC TECHNICAL REFERENCE MANUAL d) Increment the value to position the valve to 100 percent. 4. Load the compressor by pressing the Load Key. 5. Find the throttled surge point. a) Slowly decrement the bypass valve position until the last stage discharge pressure equals the pressure setpoint. b) Allow the system to stabilize at MinLoad. It the system does not stay at MinLoad, slightly decrement the valve position to force the machine to throttle to MinLoad. c) Decrement (MinLoad) 2%. d) Verify the last stage pressure equals the pressure setpoint and adjust the bypass valve position if necessary. e) Repeat c) and d) until the compressor surges. 6. Increase MinLoad by five percent. 7. Exit MinLoad editing by pressing the Enter Key. 8. Unload the machine. 9. Disable manual valve control by unchecking the manual check box. Setting MinLoad Surge Index Increment When Surge Indexing is enabled (MinLoad Surge Index Increment is greater than zero), the Index Increment value is the amount added to the MinLoad Control Setpoint upon a surge. The MinLoad Control Setpoint will stop being incremented when and if the value reaches MaxLoad. Setting Surge Sensitivity The Surge Sensitivity setting should be set sensitive enough to detect a surge, yet not trigger on spurious noise in the system. To set the surge sensor the machine is forced to surge by running the machine at MinLoad and the MinLoad setpoint is dropped until the machine audibly surges. The process is repeated until the correct setting is found. 1. Before continuing this procedure, verify the following: a) The plant can tolerate a pressure disturbance when the machine surges. b) Surge Indexing (by placing MinLoad Surge Index Increment to zero) is disabled. c) Surge Absorber is disabled. d) The pressure setpoint is set to the pressure at which the machine is going to operate. e) The machine is running unloaded. 2. Set the initial Surge Sensitivity setting to 9. a) In the Settings Folder, select the Edit Data cell for Surge Sensitivity. b) Increment or decrement the value to achieve a setting of 9. 3. Press the Load Key. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 4. Run the compressor at MinLoad and system pressure setpoint pressure. The machine can be forced to MinLoad and to maintain system pressure setpoint by either. a) Running the plant at a higher pressure than pressure setpoint. b) Decreasing load in the plant. c) Verify the compressor is at pressure by observing the last stage pressure on Page 2 of the Settings Folder. 5. Find the throttled surge point. a) Select the MinLoad cell in the Settings Folder and slowly decrement the value until the machine surges. Typically the machine will make a puffing or popping noise upon surge, this is your indication surge has occurred. 6. Press the Unload Key. 7. Determine if Surge was recorded. a) Inspect the Status Bar. If the message Surge Unload is displayed surge was recorded, if the message is not displayed surge was not recorded. 8. Check the Surge Sensitivity setting. a) If the surge was recorded, the setting may be correct or the Surge Sensor may be too sensitive, skip to the too sensitive step, which follows. b) If the surge was not recorded, the setting is not sensitive enough, skip to the not sensitive enough step, which follows. 9. Surge Sensor too sensitive. a) Select the Surge Sensitivity Setting in the Settings Folder. b) Decrease the value for Surge Sensitivity by 0.1. c) Press the Reset Key. d) Skip to step 11. 10. Surge Sensor not sensitive enough. a) Select the Surge Sensitivity Setting in the Settings Folder. b) Increase the value for Surge Sensitivity by 0.1. c) Press the Reset Key. 11. Repeat the procedure until the Surge Sensitivity setting is found which just catches a surge but does not miss a surge. a) Return to step 3. 12. Restore MinLoad value. Tuning Stability The CMC controls stability with four Proportion Integral Derivative (PID) control loops. When the machine is running above the MinLoad point and below the MaxLoad point, pressure is regulated with the Inlet Valve Pressure control loop. When the machine is running at the MinLoad point, pressure is regulated with the Bypass Valve Pressure control 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 45 46 CMC TECHNICAL REFERENCE MANUAL loop and motor current is regulated with the Inlet Valve MinLoad control loop. When the machine is running at MaxLoad motor current is regulated with the Inlet Valve MaxLoad control loop. For each PID loop, Proportional, Integral and Derivative parameters are used to stabilize the system. For a definition of the parameters and their effect on stability, refer to the section titled “How does Constant Pressure Modulation Work.” The proportional and integral terms are labeled by their respective loops, Inlet Valve, Bypass Valve, MinLoad, and MaxLoad. Calibrating the Control Valves The purpose of this procedure is to position the inlet and bypass valves by opening and closing each valve from the CMC analog outputs. The valves should be adjusted to physically correspond with the valve positions displayed on the OUI. 1. Stop the compressor. NOTE Performing this procedure while the compressor is operating may cause serious damage. 2. On the OUI enable Setpoint changes by entering the password on the Settings Folder. 3. Verify the OUI status bar displays “Ready” or “Not Ready”. 4. On the OUI select the Settings Folder and enable manual valve control by highlighting the manual check box. NOTE When Manual is enabled, both control valves can be positioned while stopped, while only the Bypass Valve can be positioned when Loaded. 5. Switch to the System Folder Page 1 and press the Enter Key to enable edit mode. 6. Use the horizontal navigation keys to select the valve requiring positioning. 7. Use the vertical arrows to increment and decrement the valve position sent to the valve. NOTE For the Inlet and Bypass Valves, the displayed position corresponds to percent open. 8. Disable manual valve control by blanking the manual check box. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 47 CMC TECHNICAL REFERENCE MANUAL Autodual Control Settings For a detailed definition of the Autodual control mode refer to the section titled “Control Methodology”. The procedure for tuning Autodual requires the setting of the following variables: Unload Point (Bypass Valve % Open) The Bypass Valve Unload Point is selected to correspond to the check valve closing as shown in Figure 18, since at this point the machine is not supplying the system. This position is found by running the machine at MinLoad and monitoring the System and Discharge pressures. When the System pressure is 5% of setpoint greater than the last stage pressure as shown in the System Folder, the check valve is assumed to be closed. Example: Given the following conditions the Unload Point would be set at 35. Variable Pressure Setpoint PT1 (system pressure) PT2 (last stage pressure) Bypass Valve Position Assumed check valve position Case 1 100 100 100 13 Open Case 2 100 100 94 35 Closed 1. Run the machine at MinLoad by elevating the system pressure no more than 3% or decrease the pressure setpoint no more than 3%. 2. Monitor the difference between the Discharge and System Pressures by using the System Folder Pages 1 and 2. 3. When the Discharge Pressure is approximately 95% of setpoint, record the Bypass Valve Position. 4. Enter the recorded Bypass Valve Position as the Unload Point. Unload Delay Time (seconds) The Unload Delay Timer should be set to prevent unloading during short excursions through the Unload Point. Typically, when the check valve closes, system demand requires the check valve to open again soon thereafter due to the demand being on the verge of requiring the compressor. If the compressor had unloaded when the check valve first closed, a reload would be immediately required and the machine would go through the automatic unload/load cycle until demand was consistently low enough to keep the check valve closed. For this reason, the timer is used to inhibit Unload until demand has consistently remained low. This value should be set according to the customer’s observation experience as to how often system demand changes impact the reloading of the compressor. Reload Percent The Reload Percent determines the System Pressure at which the machine will automatically load into the system. This value should be set according to the customer’s minimum acceptable system pressure. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 48 CMC TECHNICAL REFERENCE MANUAL Setting the Start Time The Start Time is set to the transition time of a built-in reduced voltage starter or the acceleration time of a customer supplied starter. This procedure requires the Inlet Unload Position to have been set. CAUTION Damage to the starter contacts could result if starter transition occurs before the compressor is up to full speed. 1. Initially set the Start Time to 25 Seconds. 2. Stop the compressor. Allow compressor to coast to a stop. 3. On the OUI record the time and press the start button. 4. Wait for the compressor to stop accelerating and again record the time. 5. Calculate the difference between the two values and enter as the Start Time. Setting the CT Ratio Locate the CT and find the rating, which is typically printed, on the side of the CT. Divide the primary by the secondary and enter the value as the CT Ratio. Example: CT is printed with 600:5, the value entered is 120. Inlet Unload Position The purpose of this variable is to set the inlet valve position when the machine is running unloaded. For a description of the Unloaded state refer to the section titled “Unload”. 1. If the inlet valve is a butterfly type, enter an initial value for Inlet Unload Position of 15. If the inlet valve is a inlet guide vane type, enter an initial value for Inlet Unload Position of 5. 2. Start the machine. If during startup the motor trips on overload, draws what is considered excessive amperage or sounds labored, stop the machine and decrease the Unload Position by 2 and restart the machine. 3. Run the machine in the Unloaded state and monitor the first stage pressure. 4. Adjust the Unload Position to achieve 1 PSIG on the first stage discharge, or until a positive pressure is felt at the first stage condensate trap bypass. 5. If the inlet air temperature is relatively cold, increase the setting 2%, this will accommodate hot day operation. Setting Set Point Ramp Rate Setpoint ramp rate determines the rate at which the machine transitions from unloaded to loaded. The setting should be set as high as possible without creating excessive overshoot when the machine enters the system. 1. Verify the machine is unloaded by the “Unloaded” message in the OUI Status Bar. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 2. 3. 4. 5. Determine overshoot. a) Load the machine. b) Monitor the pressure overshoot. If overshoot is excessive. a) Decrease the Setpoint Ramp Rate. b) Repeat step 2. If overshoot is satisfactory and time to load is excessive. a) Increase the Setpoint Ramp Rate. b) Repeat step 2. If overshoot is satisfactory and time to load is satisfactory the Setpoint Ramp Rate is correct. Alarm and Trip Settings The values for vibration, temperature, pressure etc. alarm and trip setpoints are located on the electrical schematic. These values determine when the controller will indicate an alarm or trip condition. WARNING Setting Trip values outside the range specified on the drawings can result in compressor damage. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 49 50 CMC TECHNICAL REFERENCE MANUAL Troubleshooting The following procedures provide direction on troubleshooting the CMC System, control panel, and associated instrumentation. Faults are either Event Logged, which means the fault is displayed in the INFO Folder on the OUI, or Non-Event Logged. The distinction helps to expedite the troubleshooting process. When a control system fault is suspected, the following diagram is used to categorize the fault. The section following the diagram breaks each category down into specific items, which can cause a particular fault. A CONTROL SYSTEM FAULT IS SUSPECTED THE FAULT IS LOGGED IN THE EVENT LOG. COMPRESSOR RELATED I/O FAULT Event correctly indicates a problem. Temperature, pressure, load, valve, etc. readings incorrect. (Refer to the compressor operating manual) THE FAULT IS NOT LOGGED IN THE EVENT LOG CONTROL PROBLEMS Compressor fails to Load, fails to trip, fails to start, surging, etc. (Refer to the CMC Tuning Procedures section) (Refer to the Input/Output (I/O) System) STABILITY PROBLEMS CONTROLLER PROBLEMS Inlet valve, bypass valve, or control variables (mass flow, system pressure, Kw, amps) are unstable. OUI failed, BCM failed, UCM failed, Communications failed. (Refer to Controller Problems Section) (Refer to the CMC Tuning Procedures Section) Figure 19: Troubleshooting Tree 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 51 CMC TECHNICAL REFERENCE MANUAL Troubleshooting Example The following example will serve as a guide to follow when troubleshooting specific problems. Problem Indication: Plant air pressure is low and the CMC OUI is found as shown. Probable Cause Determination: 1. SYSTEM 1 2 3 4 5 6 7 INFO SETTINGS Event Name Low Oil Pressure Trip Low Oil Pressure Alarm Reset key pressed Low Oil Pressure Trip Low Oil Pressure Alarm Load key pressed Start key pressed Not Ready Time Date 09:18:44 0720 09:18:43 0720 09:18:34 0720 09:08:43 0720 08:58:23 0720 08:24:01 0720 08:23:12 0720 Trip Remote 2/6 The machine Tripped on Low Oil Pressure, which means the oil pressure, was below the Oil Pressure Trip Value. Figure 19 leads to the assumption that the problem is either compressor or I/O related, because the fault is Event Logged. There are two most likely causes for this event. a) Actual oil pressure is low. i) The prelube pump is found to be running and installation of a calibrated pressure sensor shows the actual oil pressure to be above the Oil Pressure Trip Value. Therefore, the mechanical system is operating correctly. b) The value read by the CMC is incorrect. i) The oil pressure value displayed on Page 2 of the System Folder shows the oil pressure to be below the test sensor reading and erratic. Additionally, all other analog input readings are normal and not erratic. Therefore, the problem can be isolated to the oil pressure, analog input circuit. ii) The Pressure Monitoring System (PMS) troubleshooting table, found in the following section “The Pressure Monitoring System” identifies the probable cause for an erratic reading as a loose wire/terminal/connector and specifies Troubleshooting Procedure PMS #1 and 2 as the appropriate procedures. Trouble Procedure Execution: Step 1 of PMS #1 requires disconnecting of the pressure transducer (PT) wires at the terminal strip. When this step is performed, one of the connections is found to be intermittent. When the poor connection is corrected, the erratic reading on the OUI becomes solid. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 52 CMC TECHNICAL REFERENCE MANUAL Input/Output (I/O) System Vibration Monitoring System (VMS) Description: The vibration transmitter is used to convert the proximity probe signal into a 4 -20 mA signal, which is monitored by the CMC. The system is based on a 5 meter total electrical length (vibration probe electrical length plus extension cable electrical length). Component specifications: (5 meter) Transmitter: • 200 mv/mil = 0.2 volt per 0.001 in (0.0254 mm) • 4 mil (0.1016 mm) scale • 4-20 mA output Probe: • Gap setting 0.030 to 0.060 in (0.762 to 1.524 mm), see Service Hints for nominal gap • Probe gap corresponds to 6 to 12 volts VDC • Ohm value of 0.5 meter Probe is 4 ohms, +/- 0.5 ohm Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Zero OUI readout (when compressor is running) Erratic OUI readout Incorrect OUI readout Probable Cause Open circuit/cable disconnected Loss of power to transmitter Malfunctioning transmitter Transmitter not calibrated Loose wire/terminal/connector Any Troubleshooting Procedure VMS #2, 3, 4 VMS #1 VMS #2 VMS #2 VMS #2, 3, 4 VMS #1, 2, 3, 4, 5 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 53 CMC TECHNICAL REFERENCE MANUAL Checking Vibration Transmitter Power VMS #1 1. Connect a DC voltmeter to the + and terminals of the transmitter. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present; see the section titled “Control Power System”. XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω mA COM V Ω NOTE: Under no circumstances should the vibration transmitter zero or span be adjusted. Calibration of the vibration transmitter requires special tooling and calibration fixtures. Contact the factory if calibration is required. (See electrical schematic for point). Vibration transmitter Checking Vibration Circuit 1. With control power on, check the dc voltage at the COM and TEST terminals on the transmitter. A reading of 6 to 12 VDC should be present [this corresponds to a 0.030 to 0.060 inches (0.762 to 1.524 mm)] probe gap. 2. If less than 6 volts is present the probe gap may be incorrect, or a short circuit may exist. Check the cable connections and cable. 3. If more than 12 volts is present the probe gap may be incorrect, or an open circuit may exist. Check the cable connections and cable. 4. If no voltage exists, the transmitter may be faulty. Remove control power and swap connections with another transmitter and test. VMS #2 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω mA COM V Ω Compressor casing Vibration transmitter Vibration probe Probe extension cable 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 54 CMC TECHNICAL REFERENCE MANUAL Check the Vibration Probe, and Cable VMS #3 1. Turn control power off and disconnect the probe extension cable from the transmitter. 2. Check resistance of the extension cable and probe together, the reading should be 5.3 ohms, +/- 0.7 ohm (5 meter system) Probe connector XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω Probe cable mA COM V Ω Compressor casing Connect test lead to outer shell. Connect test lead to inner pin. Probe extension cable Vibration probe Checking the Vibration Probe 1. Turn control power off and disconnect the probe extension cable from the transmitter. 2. Check resistance of the probe alone, the reading should be 4.0 ohms, +/- 0.5 ohm (0.5 meter probe) VMS #4 Connect test lead to outer shell. XXXXX XXXXX XXXXX XXXXX Probe connector XXXXX XXXXX VDC mA VAC Ω Probe cable mA COM V Ω Vibration probe Connect test lead to inner pin. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 55 CMC TECHNICAL REFERENCE MANUAL Check the BCM VMS #5 1. With control power off connect a 4-20 mA simulator at the input points of the suspected faulty device at connector J1, (see electrical schematic for connection points). 2. Turn control power on and vary the signal. If the value tracks according to the table below, the wiring is faulty. 3. Verify the connector at J1 is fully seated. If the value does not track correctly, the BCM may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 4-20 mA SURCE OR 2 WIRE SIMULATOR LOOP ON DIAL 100% BATTERY CHECK OFF 2 WIRE mA OUT 00.0% - 100% 00.0% XXXXXX MODEL CL-XXX 555 mA percent (from simulator) 100% 50% 0% Conversion chart Mils (on OUI) 4.0 2.0 0.0 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 mA (from simulator) 20 12 4 56 CMC TECHNICAL REFERENCE MANUAL Temperature Monitoring System (TMS) Description: An RTD (Resistance Temperature Detector-2 Wire) with external transmitter is used by the CMC for temperature monitoring. An RTD resistance (ohmic value) varies with temperature. A transmitter for monitoring by the CMC analog input channel converts the resistance to a 4-20 mA signal. Component specification: Probe: • 100 ohm Platinum resistance at 32 °F (0°C) with Temperature Coefficient Rating (TCR) of 0.00385 Ohm/Ohm/Deg C Transmitter: • The transmitter may be mounted in the RTD connection head fitting or in the control panel enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of either 0 to 200°F (-17.7 to +93.3°C), or 0-500°F (-17.7 to +260°C). Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem High OUI readout Probable Cause High resistance connection Transmitter not calibrated RTD failure Transmitter failure Low OUI readout Transmitter failure RTD failure Transmitter not calibrated Erratic OUI readout Loose terminal connection RTD internal wire fault Transmitter failure Incorrect OUI readout Transmitter not calibrated RTD or transmitter failure Any Troubleshooting Procedure TMS #4 TMS #3 TMS #2 TMS #3 TMS #3 TMS #2 TMS #3 TMS #4 TMS #2 TMS #3 TMS #3 TMS #2, 3 TMS #1, 2, 3, 4 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 57 CMC TECHNICAL REFERENCE MANUAL Checking for Power to the Temperature Transmitter TMS #1 1. Disconnect the wires at terminals #1 and #2 on the transmitter and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled “Control Power System”. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 XXXXX XXXXX XXXXX XXXXX VDC XXXXX XXXXX mA 123 4 VAC Ω mA COM V Ω RTD Temperature transmitter 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 58 CMC TECHNICAL REFERENCE MANUAL Checking for a Faulty RTD TMS #2 1. Turn control power off. 2. Check ohms versus temperature. Use an Ohmmeter and the following tables to determine if the RTD is faulty. Vary the temperature to the RTD and check the ohms around the normal operating range. XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω mA COM V Ω Thermometer RTD 32 DEGF Ice water 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 59 CMC TECHNICAL REFERENCE MANUAL Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTD °F 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 0 93.01 95.20 97.38 99.56 101.70 103.90 106.10 108.20 110.40 112.50 114.70 116.80 119.00 121.10 123.20 125.40 127.50 129.60 131.70 133.90 136.00 138.10 140.20 142.30 144.40 146.50 148.60 150.70 152.70 154.80 156.90 159.00 161.00 163.10 165.20 167.20 169.30 171.30 173.40 175.40 177.50 179.50 181.50 183.60 185.60 187.60 189.70 191.70 193.70 195.70 197.70 1 93.22 95.42 97.60 99.78 102.00 104.10 106.30 108.40 110.60 112.70 114.90 117.00 119.20 121.30 123.40 125.60 127.70 129.80 132.00 134.10 136.20 138.30 140.40 142.50 144.60 146.70 148.80 150.90 153.00 155.00 157.10 159.20 161.30 163.30 165.40 167.40 169.50 171.50 173.60 175.60 177.70 179.70 181.80 183.80 185.80 187.80 189.90 191.90 193.90 195.90 197.90 2 93.44 95.63 97.82 100.00 102.20 104.30 106.50 108.70 110.80 113.00 115.10 117.30 119.40 121.50 123.60 125.80 127.90 130.00 132.20 134.30 136.40 138.50 140.60 142.70 144.80 146.90 149.00 151.10 153.20 155.20 157.30 159.40 161.50 163.50 165.60 167.60 169.70 171.80 173.80 175.80 177.90 179.90 182.00 184.00 186.00 188.00 190.10 192.10 194.10 196.10 198.10 3 93.66 95.85 98.04 100.20 102.40 104.60 106.70 108.90 111.00 113.20 115.30 117.50 119.60 121.70 123.90 126.00 128.10 130.30 132.40 134.50 136.60 138.70 140.80 142.90 145.00 147.10 149.20 151.30 153.40 155.40 157.50 159.60 161.70 163.70 165.80 167.80 169.90 172.00 174.00 176.00 178.10 180.10 182.20 184.20 186.20 188.20 190.30 192.30 194.30 196.30 198.30 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 4 93.88 96.07 98.26 100.40 102.60 104.80 106.90 109.10 111.20 113.40 115.50 117.70 119.80 122.00 124.10 126.20 128.30 130.50 132.60 134.70 136.80 138.90 141.00 143.10 145.20 147.30 149.40 151.50 153.60 155.70 157.70 159.80 161.90 163.90 166.00 168.10 170.10 172.20 174.20 176.30 178.30 180.30 182.40 184.40 186.40 188.40 190.50 192.50 194.50 196.50 198.50 5 94.10 96.29 98.47 100.70 102.80 105.00 107.10 109.30 111.50 113.60 115.80 117.90 120.00 122.20 124.30 126.40 128.60 130.70 132.80 134.90 137.00 139.10 141.20 143.30 145.40 147.50 149.60 151.70 153.80 155.90 157.90 160.00 162.10 164.10 166.20 168.30 170.30 172.40 174.40 176.50 178.50 180.50 182.60 184.60 186.60 188.60 190.70 192.70 194.70 196.70 198.70 6 94.32 96.51 98.69 100.90 103.00 105.20 107.40 109.50 111.70 113.80 116.00 118.10 120.20 122.40 124.50 126.60 128.80 130.90 133.00 135.10 137.20 139.30 141.40 143.50 145.60 147.70 149.80 151.90 154.00 156.10 158.10 160.20 162.30 164.30 166.40 168.50 170.50 172.60 174.60 176.70 178.70 180.70 182.80 184.80 186.80 188.80 190.90 192.90 194.90 196.90 198.90 7 94.54 96.73 98.91 101.10 103.30 105.40 107.60 109.70 111.90 114.00 116.20 118.30 120.50 122.60 124.70 126.90 129.00 131.10 133.20 135.30 137.40 139.60 141.70 143.80 145.90 147.90 150.00 152.10 154.20 156.30 158.40 160.40 162.50 164.60 166.60 168.70 170.70 172.80 174.80 176.90 178.90 180.90 183.00 185.00 187.00 189.00 191.10 193.10 195.10 197.10 199.10 8 94.76 96.95 99.13 101.30 103.50 105.60 107.80 109.90 112.10 114.30 116.40 118.50 120.70 122.80 124.90 127.10 129.20 131.30 133.40 135.50 137.70 139.80 141.90 144.00 146.10 148.20 150.20 152.30 154.40 156.50 158.60 160.60 162.70 164.80 166.80 168.90 170.90 173.00 175.00 177.10 179.10 181.10 183.20 185.20 187.20 189.20 191.30 193.30 195.30 197.30 199.30 9 94.98 97.17 99.35 101.50 103.70 105.80 108.00 110.20 112.30 114.50 116.60 118.80 120.90 123.00 125.20 127.30 129.40 131.50 133.60 135.80 137.90 140.00 142.10 144.20 146.30 148.40 150.50 152.50 154.60 156.70 158.80 160.80 162.90 165.00 167.00 169.10 171.10 173.20 175.20 177.30 179.30 181.30 183.40 185.40 187.40 189.40 191.50 193.50 195.50 197.50 199.50 60 CMC TECHNICAL REFERENCE MANUAL Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTD °C -17.78 -12.22 -6.67 -1.11 4.44 10.00 15.56 21.11 26.67 32.22 37.78 43.33 48.89 54.44 60.00 65.56 71.11 76.67 82.22 87.78 93.33 98.89 104.44 110.00 115.56 121.11 126.67 132.22 137.78 143.33 148.89 154.44 160.00 165.56 171.11 176.67 182.22 187.78 193.33 198.89 204.44 210.00 215.56 221.11 226.67 232.22 237.78 243.33 248.89 254.44 260.00 0.00 93.01 95.20 97.38 99.56 101.74 103.90 106.07 108.22 110.38 112.53 114.68 116.83 118.97 121.11 123.22 125.37 127.50 129.62 131.74 133.86 135.97 138.08 140.18 142.29 144.39 146.48 148.57 150.66 152.74 154.82 156.90 158.98 161.05 163.11 165.17 167.23 169.29 171.34 173.39 175.44 177.48 179.51 181.55 183.58 185.60 187.63 189.65 191.67 193.68 195.69 197.69 0.62 93.22 95.42 97.60 99.78 101.95 104.12 106.28 108.44 110.60 112.75 114.89 117.04 119.18 121.32 123.43 125.58 127.71 129.83 131.95 134.07 136.18 138.29 140.39 142.50 144.59 146.69 148.78 150.87 152.95 155.03 157.11 159.18 161.25 163.32 165.38 167.44 169.49 171.55 173.59 175.64 177.68 179.72 181.75 183.78 185.81 187.83 189.85 191.87 193.88 195.89 197.89 1.23 93.44 95.63 97.82 100.00 102.17 104.34 106.50 108.66 110.81 112.96 115.11 117.25 119.39 121.53 123.65 125.79 127.92 130.04 132.16 134.28 136.39 138.50 140.60 142.71 144.80 146.90 148.99 151.08 153.16 155.24 157.32 159.39 161.46 163.52 165.59 167.64 169.70 171.75 173.80 175.84 177.88 179.92 181.95 183.98 186.01 188.03 190.05 192.07 194.08 196.09 198.09 1.85 93.66 95.85 98.04 100.22 102.39 104.55 106.71 108.87 111.03 113.18 115.32 117.47 119.61 121.75 123.87 126.01 128.13 130.26 132.38 134.49 136.60 138.71 140.81 142.92 145.01 147.11 149.20 151.28 153.37 155.45 157.52 159.60 161.67 163.73 165.79 167.85 169.90 171.96 174.00 176.05 178.09 180.12 182.16 184.19 186.21 188.24 190.25 192.27 194.28 196.29 198.29 2.47 93.88 96.07 98.26 100.43 102.60 104.77 106.93 109.09 111.24 113.39 115.54 117.68 119.82 121.96 124.08 126.22 128.35 130.47 132.59 134.70 136.81 138.92 141.02 143.13 145.22 147.32 149.41 151.49 153.58 155.66 157.73 159.80 161.87 163.94 166.00 168.06 170.11 172.16 174.21 176.25 178.29 180.33 182.36 184.39 186.41 188.44 190.46 192.47 194.48 196.49 198.49 3.09 94.10 96.29 98.47 100.65 102.82 104.98 107.14 109.30 111.46 113.61 115.75 117.90 120.04 122.17 124.30 126.43 128.56 130.68 132.80 134.91 137.02 139.13 141.24 143.34 145.43 147.53 149.61 151.70 153.78 155.86 157.94 160.01 162.08 164.14 166.20 168.26 170.32 172.37 174.41 176.46 178.49 180.53 182.56 184.59 186.62 188.64 190.66 192.67 194.68 196.69 198.70 3.70 94.32 96.51 98.69 100.87 103.04 105.20 107.36 109.52 111.67 113.82 115.97 118.11 120.25 122.39 124.51 126.65 128.77 130.89 133.01 135.12 137.24 139.34 141.45 143.55 145.64 147.73 149.82 151.91 153.99 156.07 158.15 160.22 162.29 164.35 166.41 168.47 170.52 172.57 174.62 176.66 178.70 180.73 182.77 184.80 186.82 188.84 190.86 192.87 194.88 196.89 198.90 4.32 94.54 96.73 98.91 101.08 103.25 105.42 107.58 109.73 111.89 114.04 116.18 118.32 120.46 122.60 124.73 126.86 128.98 131.10 133.22 135.34 137.45 139.55 141.66 143.76 145.85 147.94 150.03 152.12 154.20 156.28 158.35 160.42 162.49 164.56 166.62 168.67 170.73 172.78 174.82 176.86 178.90 180.94 182.97 185.00 187.02 189.04 191.06 193.08 195.09 197.09 199.10 4.94 94.76 96.95 99.13 101.30 103.47 105.63 107.79 109.95 112.10 114.25 116.40 118.54 120.68 122.81 124.94 127.07 129.20 131.32 133.43 135.55 137.66 139.76 141.87 143.97 146.06 148.15 150.24 152.33 154.41 156.49 158.56 160.63 162.70 164.76 166.82 168.88 170.93 172.98 175.03 177.07 179.11 181.14 183.17 185.20 187.22 189.25 191.26 193.28 195.29 197.29 199.30 5.56 94.98 97.17 99.35 101.52 103.69 105.85 108.01 110.16 112.32 114.47 116.61 118.75 120.89 123.03 125.16 127.28 129.41 131.53 133.65 135.76 137.87 139.97 142.08 144.18 146.27 148.36 150.45 152.54 154.62 156.69 158.77 160.84 162.91 164.97 167.03 169.08 171.14 173.19 175.23 177.27 179.31 181.35 183.38 185.40 187.43 189.45 191.46 193.48 195.49 197.49 199.50 NOTE: This chart converted from Fahrenheit chart using formula °C= ((°F-32)/1.8) 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 61 CMC TECHNICAL REFERENCE MANUAL Checking the RTD Transmitter TMS #3 1. With control power off, connect a 100-ohm resistor to terminals #3 and #4 of the transmitter. 2. Turn control power on, the OUI reading should be 32°F (0°C) ±5%. 3. If the reading is not within specification, the transmitter may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 100 123 4 OHM 5% Temperature transmitter 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 62 CMC TECHNICAL REFERENCE MANUAL Checking proper operation of the BCM and wiring TMS #4 1. Ensure control power is off. At the affected RTD transmitter, disconnect the wires at transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals (Observe correct polarity). Power up the control panel and then vary the simulator output. 2. At 12 mA (50%) the OUI should read 1/2 the RTD transmitter range; 100 or 250°F (37.7 or 121.1°C). The readout should change as the simulator output is varied. 3. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4 to 20 mA simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 4. Turn control power on and observe the OUI readout while varying the 4-20mA. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the RTD transmitter. If reading is not correct the BCM may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 4-20 mA SURCE OR 2 WIRE SIMULATOR LOOP ON DIAL 100% BATTERY CHECK OFF 2 WIRE mA OUT 00.0% - 100% 00.0% XXXXXX MODEL CL-XXX 555 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 63 CMC TECHNICAL REFERENCE MANUAL Valve Control System (VCS) Description: The BCM generates a 4-20 mA signal for valve control. The signal is wired to the I/P (current to pressure) transducer for conversion to a pneumatic signal for positioning the inlet or bypass control valve. Specification: • 4-20mA input = 3 to 15 psi output • 60 to 120 PSIG instrument air input to I/P Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem IV or BV not operating Probable Cause Failure of BCM Positioner or actuator malfunction Failure of I/P 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Troubleshooting Procedure VCS #1 VCS #2 VCS #2 64 CMC TECHNICAL REFERENCE MANUAL Checking proper operation of the BCM and wiring VCS #1 1. With control power off, lift the wires at J3 for the suspected circuit and install a test meter capable of reading milliamps as shown below, (the pin numbers are found on the electrical schematic). 2. Restore control power. 3. If the meter reads 4 mA , the BCM is satisfactory. 4. If 4 mA is not present, refer to the section titled “Control Power System”. 5. Restore connections. 6. Remove control power. 7. Lift wires at suspected I/P, and install meter as in previous step. 8. Restore control power. If the meter reads 4 mA, the BCM and wiring is satisfactory. BCM J3-Analog Outputs, (4-20mA) Channels 1-4 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 Pin 1 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω mA COM V Ω 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 65 CMC TECHNICAL REFERENCE MANUAL Checking proper operation of the I/P and positioner VCS #2 1. Connect a 4-20 mA simulator to the I/P. 2. Ensure instrument air is present at the supply connection on the I/P. 3. Vary the simulator between 4-20 mA. The output of the I/P and the positioner should follow. If the valve tracks the 4-20 mA signal correctly the I/P and the positioner are satisfactory. BATTERY CHECK LOOP ON mA OUT 100% OFF DIAL 2 WIRE 00.0% XXXXXX MODEL CL-XXX 4-20 mA SURCE OR 2 WIRE SIMULATOR 00.0% - 100% 555 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 INGERSOLL-RAND Centrifugal Compressor Division Highway 45 South Mayfield, KY. 42066 Parts Service (800) 247-8640 66 CMC TECHNICAL REFERENCE MANUAL Pressure Monitoring System (PMS) Description: A Pressure Transducer (PT) is used to convert pressure (psi) to a 4-20 mA signal for monitoring by the CMC. Component specification: • 0-50 PSIG (344.75 kPa) range • 0-200 PSIG (1379 kPa) range • Power = 24 VDC Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Zero OUI readout Erratic OUI readout Incorrect OUI readout Probable Cause Open circuit/cable disconnected Loss of power to transmitter Malfunctioning transmitter Loose wire/terminal/connector Any Troubleshooting Procedure PMS #1, 2 PMS #1 PMS #3, 4 PMS #1,2 PMS #1, 2, 3, 4 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 67 CMC TECHNICAL REFERENCE MANUAL Checking for Power to the Pressure Transmitter PMS #1 1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a voltmeter to these wires. 2. With control power on, there should be approximately 24 VDC present at the terminals. 3. If approximately 24 VDC is not present, see the section titled “Control Power System”. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX SPAN VDC mA ® VAC Ω mA COM V Ω 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 INGERSOLL RAND 68 CMC TECHNICAL REFERENCE MANUAL Checking proper operation of the BCM and wiring PMS #2 1. Ensure control power is off. Disconnect the wires at the suspect PT and connect a 4-20 mA source to the lifted wires (Observe correct polarity). 2. Restore control power and then vary the simulator output. 3. At 12 mA (50%) the OUI should read 1/2 the PT range. The readout should change as the simulator output is varied. 4. If the reading on the OUI is incorrect or does not change, turn control power off and reconnect the transmitter, remove the wires for this transmitter from J1 and move the 420 mA simulator to the respective terminals at connector J1, (see electrical schematic for connection points). 5. Turn control power on and observe the OUI readout while varying the 4-20 mA. If the reading is correct there is an open or short in the wire or terminals connecting the CMC to the PT. If the reading is not correct the BCM may be faulty. BCM J2-Floating Analog Inputs, (4-20mA) Channels 1-2 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 Pin 25 Pin 1 4-20 mA SURCE OR 2 WIRE SIMULATOR LOOP ON DIAL 100% BATTERY CHECK OFF 2 WIRE mA OUT 00.0% - 100% 00.0% XXXXXX MODEL CL-XXX 555 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 69 CMC TECHNICAL REFERENCE MANUAL Quick check of the PT PMS #3 1. Connect an ohmmeter to the disconnected wires coming from the PT. 2. If there is no continuity either the wiring or the PT is faulty. M XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω mA COM V Ω SPAN ® INGERSOLL RAND Functional PT test PMS #4 1. Remove control power. 2. Remove the PT and connect a regulated air supply to the pressure connection. Power up the CMC and vary the regulated air supply. The OUI should read the pressure being applied. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 70 CMC TECHNICAL REFERENCE MANUAL Digital Input System (DIS) Description: The digital input devices associated with the CMC are on/off devices that turn on or off the associated CMC digital input. Typical digital device name and type: 1. Low seal air pressure (Pressure) 2. Low cooling water flow (Flapper) 3. Low oil level (Float) 4. High condensate level (Float) 5. Dirty inlet filter (Differential pressure) 6. Dirty oil filter (Differential pressure) 7. High motor temperature (Thermistor) Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem False alarm or trip Probable Cause Faulty device Faulty wiring Troubleshooting Procedure DIS #1 DIS #1 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 71 CMC TECHNICAL REFERENCE MANUAL Checking proper operation of the digital devices DIS #1 1. Verify approximately 24 VDC is present as described in the section titled “Troubleshooting the Power System”. 2. If approximately 24 VDC is present, install a multimeter with VDC selected between J4 or J5 pin1 and the input pin (the input pin can be determined from the electrical schematic, or wire number). 3. Ensure the digital device is not in the trip condition, the meter should read 0 VDC. 4. Actuate the switch, the meter should read approximately 24 VDC. J6-RS232 Serial Data Link (Display), Female DB9 BCM J5-Digital (Discrete) Inputs (24 VDC), Channels 9-16 Pin 1 XXXXX XXXXX XXXXX XXXXX J4-Digital (Discrete) Inputs (24 VDC), Channels 1-8 XXXXX XXXXX VDC mA VAC Ω mA COM V Ω Pin 1 Seal Air Switch J3-Analog Outputs (4-20mA) Channels 1-4 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 72 CMC TECHNICAL REFERENCE MANUAL Control Power System (CPS) Description: The control power system provides 24 VDC to the CMC system for processing logic, displaying data, and monitoring instrumentation. The 24 VDC power supply feeds the Base Control Module (BCM) at connector J10. Over current protection and power distribution are performed as shown below: J2 +24 VDC pins 11 thru 14 J1 AC2 pin 3 Power Supply F1 AC1 pin 1 Return pins 7 thru 10 BCM shown cover removed Fuse 5A/250VAC, normal blo. J12-Digital Output Power 120 VAC (Pin 1) To OUI J2 pin 2 To OUI J2 pin 1 OUI Power To Ground Bar J10-Power Input (24 VDC) F100 F101 F102 F103 J9-Current Transformer (0-5 amp) CPU Power All BCM Fuses are 5x20mm, GMA 1.5 amp, Fast Blow BCM Digital Input Power J4 & J5 - Digital Input Power 24 VDC (pin 1) Analog Input/Output Power LEGEND: Trace Wire J3- Analog Output Power 24 VDC (pins 2 & 8) J1- Analog Input Power 24 VDC (pin 26) 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 73 CMC TECHNICAL REFERENCE MANUAL Power Supply: • Input power: 85-132 VAC, or 180-264 VAC (auto-selecting input), 2.5A RMS max, 47-63 Hz. • Output power: 24 VDC, 4.3 A maximum at 50 °C. Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause All analog inputs are zero or negative on System Page No AC power No DC power No analog input power No CPU power OUI displays: “INGERSOLL-RAND Centrifugal Compressor Division” OUI is black Event Log indicates all digital alarms and trips active All digital outputs not working All analog outputs not working BCM problems No AC power No DC power No OUI power No AC power No DC power No digital input power No AC power No DC power No digital output power No AC power No DC power No analog output power Troubleshooting Procedure CPS #1 CPS #2 CPS #5 CPS #8 CMCS #3 CPS #1 CPS #2 CPS #7 CPS #1 CPS #2 CPS #3 CPS #1 CPS #2 CPS #4 CPS #1 CPS #2 CPS #6 No AC power CPS #1 1. Ensure control power is off. 2. Install a multimeter set for VAC between pins 1 and 3 at connector J1 on the power supply. 3. Restore control power, the meter should read 120 VAC or 220 VAC depending upon the rated supply power. The rated supply power can be verified from the electrical schematic. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 74 CMC TECHNICAL REFERENCE MANUAL No DC power CPS #2 1. Ensure control power is off. 2. Install a multimeter set for VDC between pins 11-14 and 7-10 at connector J2 on the power supply. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F1 on the power supply, if fuse is good, the power supply may be faulty. 4. Ensure control power is off. 5. Install a multimeter set for VDC between pins 1 and 2 at connector J10 on the BCM. 6. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check the wiring between the power supply and the BCM. No digital input power CPS #3 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 1 at connector J4 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F103 on the BCM, if F103 is good, check for DC power. No digital output power CPS #4 1. Ensure control power is off. 2. Install a multimeter set for VAC between pin 1 at connector J12 on the BCM and the ground bar. 3. Restore control power, the meter should read 120 VAC. No analog input power CPS #5 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 26 at connector J1 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F102 on the BCM, if F102 is good, check for DC power. No analog output power CPS #6 1. Ensure control power is off. 2. Install a multimeter set for VDC between pin 2 at connector J3 on the BCM and the ground bar. 3. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F102 on the BCM, if F102 is good, check for DC power. No OUI power CPS #7 1. Ensure control power is off. 2. Install a multimeter set for VDC between pins 1 and 2 at connector J2 on the OUI. 3. Restore control power, the meter should read approximately 24 VCD. If approximately 24VDC is present, check F2 on the OUI. If F2 is good, go to next step. 4. Restore control power, the meter should read approximately 24 VDC. If approximately 24 VDC is not present, check F101 on the BCM, if F101 is good, check for DC power. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL No CPU power CPS #8 1. Ensure control power is off. 2. Verify approximately 24 VDC is present at J10. 3. Check F100, if F100 is blown the BCM must be replaced, not the fuse. 4. If F100 is not blown, and the BCM is not functioning, the BCM must be replaced. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 75 76 CMC TECHNICAL REFERENCE MANUAL Controller Problems Description: The CMC System is generally comprised of a Base Control Module (BCM), Operator User Interface (OUI), and Power Supply (PS). There are few user serviceable components within the system; however, a brief understanding of the system will help in overall troubleshooting. All components require 24 VDC and rely on hardware and software to perform correctly, if the problem cannot be isolated to a power problem it is most likely a hardware or software problem, which will require Ingersoll-Rand support to correct. Component Specification: • VDC power required • Software required Troubleshooting: The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause: Typical Problem Probable Cause BCM fault suspected OUI is dim No power Wrong contrast selected Backlight failing No power Cable disconnected OUI is black OUI displays “INGERSOLL-RAND Centrifugal Compressor Division” OUI displays “Status XXH” Where XX is a specific number Many MODBUS communications problem No power Many Troubleshooting Procedure CMCS #4 CMCS #1 CMCS #1 CMCS #2 CMCS #3 Refer to Status Codes under System Information Section. CMCS #5 Refer to the UCM Section. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 77 CMC TECHNICAL REFERENCE MANUAL BCM Problems BCM is not controlling CMCS #4 1. Check the CPU power as described in the section titled “Control Power System”. OUI Problems OUI is dim CMCS #1 1. Depress the contrast key to step to the desired brightness. 2. Replace the OUI backlight as described in the section titled “Backlight Replacement Procedure”. If the backlight does not fix the problem the OUI may be faulty. OUI is black CMCS #2 1. Check for OUI power as described in the section titled “Control Power System”. If approximately 24 VDC is present, check F2. If F2 is O.K. the OUI may be faulty. OUI displays “INGERSOLL-RAND Centrifugal Compressor Division” 1. Check the cabling between OUI J1 and BCM J6. 2. The BCM may require programming. 3. Check the BCM CPU power. 4. The BCM may be faulty. CMCS #3 UCM Problems All UCM LED’s are not lit 1. Check for approximately 24 VDC at pins 1 and 2 at J3 on the UCM. 2. If power is present at J3 the UCM may be faulty. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMCS #5 78 CMC TECHNICAL REFERENCE MANUAL Options This section details the various standard options that are available for the CMC. Some of the options listed are provided standard on some models, and will be indicated as such. Enclosures The CMC has three panel enclosures available; NEMA 12 (IP 64), which is standard, and optional NEMA 4 (IP 65) and NEMA 4X (IP 65). The panel is machine mounted. All electrical devices are mounted and wired where practical. NEMA 12 (IP 64) NEMA 12 is the standard enclosure for all compressors with CMC panels. NEMA defines this rating as "... intended for indoor use primarily to provide a degree of protection against dust, falling dirt, and dripping non-corrosive liquids. They shall meet drip, dust, and rustresistance design tests. They are not intended to provide protection against conditions such as internal condensation.” Typically this type of enclosure is applied for most indoor applications. Cooling Fan The cooling fan is supplied on all standard CMC enclosures, where a wye-delta motor starter is present, the Control Electrical Package is included, or the ambient temperature exceeds 40°C keeps the internal temperature below the maximum operating temperature allowed. This action effectively extends the operating life of the control components. A filter and gasket are added to attain a NEMA 12 rating. NEMA 4 (IP 65) This optional enclosure type is applied for most outdoor applications. Indoor applications that are subject to hose washing would also apply to this standard. NEMA defines this rating as "... intended for indoor and outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, and hose directed water; and to be undamaged by the formation of ice on the enclosure. They shall meet hose down, external icing, and rust-resistance design tests. They are not intended to provide protection against conditions such as internal condensation or internal icing." The standard panel enclosure is replaced with a new box that meets the above requirements. The User Terminal vinyl overlay and sealing bezel is door mounted and allows direct interface with the environment. NEMA 4 rated lights, switches and buttons are mounted directly through the panel door. A panel space heater and Vortex Tube Cooler are added to accommodate changes in ambient temperatures. NEMA 4X (IP 65) Also an optional enclosure type that should be applied in the same type of NEMA 4 applications within corrosive environments. The basic difference between NEMA 4 and NEMA 4X is that the panel enclosure is constructed with stainless steel. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Space Heater Required for NEMA 4 and NEMA 4X panels to protect the panel from internal condensation. This option should also be used with NEMA 12 for unheated building applications. Vortex Tube Cooler This panel cooler is required on NEMA 4 and NEMA 4X enclosures to maintain the operating temperature below the maximum. An adjustable thermostat is provided to open and close a solenoid operated valve from the instrument air header in the panel. The cooler works by converting filtered compressed air into a hot air stream and cold air stream. The hot air stream is vented external to the enclosure and the cold air stream is directed into the enclosure. Type Z Purge The CMC requires a Type Z Purge when the customer environment is Division 2. A Type Z Purge reduces the classification within an enclosure from Division 2 too non-hazardous. When provided, a NEMA 4 or NEMA 4X enclosure is required. Hand valve selectable quick and slow purges, with flow meters are provided to regulate the amount of gas entering the panel. A differential pressure switch is wired to a light on the front of the panel to indicate if there is a loss of purge gas. A relief valve is installed to prevent over-pressurization and a warning label, text below, is affixed to the front of the panel. WARNING Enclosure shall not be opened unless the area is known to be non-hazardous or unless all devices within the enclosure have been de-energized. Power shall not be restored after the enclosure has been opened until combustible dusts have been removed and the enclosure re-pressurized. Fused Control Power Disconnect As a safety precaution, this option removes power from the panel before the door is opened. By turning the rotary door handle, the panel power is terminated. If the disconnect is to include fuse size provisions for the main motor starter, additional information is required. The disconnect would have to be mounted external to the panel enclosure. The short circuit capacity, maximum ground fault, motor full load amps, motor locked rotor amps and motor voltage must be known to size the disconnect properly. Pricing varies depending upon the size, amp rating of the fuse, which is required for protection. NOTE This option does not make fuse size provisions for the main motor starter. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 79 80 CMC TECHNICAL REFERENCE MANUAL Control Electrical Package The Control Electrical Package consists of a Control Transformer, Prelube Pump Starter, Oil Heater Contactor(s) and Transient Voltage Surge Suppressor. This option allows the customer to bring a single source of electrical power to the compressor to run all of the compressor package accessories; thereby, making compressor installation easier. Stage Data Package For monitoring of interstage pressure and temperatures, the Stage Data Package can be added. As standard, the CMC comes with temperature readout, alarm and trip for the next to last compression stage and compressor discharge pressure indication. When selected, each stage gets temperature and pressure measurements on the downstream side of each stage's cooler. For compressors without built-in aftercoolers, the last stage diffuser temperature is measured. Each temperature has readout, alarm and trip capability while the pressures are readout only. Alarm Horn The optional alarm horn sounds any time there is an alarm or trip situation. The horn output will pulse for an alarm and remain constant for a trip. This allows the operator to distinguish between each fault type without viewing the OUI. The horn silence push-button is located on the CMC faceplate to silence any audible devices connected to the CMC board. Running Unloaded Shutdown Timer The intent of this option is to save energy by shutting the compressor off during extended periods of unloaded operation. When the running unloaded shutdown timer is enabled with the RUNNING UNLOADED SHUTDOWN TIMER DISABLED/ENABLED selector switch, the auto-dual control mode should be selected, this provides for automatic unloading of the machine during periods of low demand. Water Solenoid Post Run Timer This optional panel function is used to shut off water flow to the air and oil coolers after the compressor is stopped. It is accomplished by sending a signal to close the solenoid operated water valve(s). Panel Mounted Wye-Delta Starter Main motor starter enclosed in the CMC panel. This feature allows the customer to wire the compressor from a single source; thereby, eliminating most electrical wiring and starter installation expense. These starters are available for compressors with motors up to 350 HP and 575 Volts. N.O. Contact for Remote Indication of Common Alarm and Trip A normally open contact for individual remote indication closes whenever an alarm or trip occurs. This allows a customer to have remote indication of compressor alarm, trip or both. Power Regulating Constant Voltage Transformer If the electrical power supplied to the CMC varies more than ten percent, this transformer must be added to bring the voltage within the specification requirements. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Automatic Starting NOTE Most electric motors are only rated for two cold starts or one hot start per hour. It is the operator’s responsibility not to exceed the electric motor’s limitation. The control system allows the compressor to be started when the compressor is ready, not the motor. Remote start and stop through hard wiring to the compressor control panel, communicating through the MODBUS port via RS422/485, Auto-Hot Start and Auto-Cold Start are the four options for automatically starting and stopping with the CMC. With each of these options a REMOTE COMMUNICATIONS DISABLED/ENABLED or REMOTE FUNCTIONS DISABLED/ENABLED, selector switch is provided on the device plate with a REMOTE ENABLED light. Since each option performs basically the same function, only one should be purchased for a single CMC. The specific method selected depends upon the application. Remote Start and Remote Stop – Hardwired When this option is purchased, two digital inputs are configured on the CMC Base Control Module, one for remote start and one for remote stop. Remote Start Digital Input This input is driven by a momentary contact closure of at least 120 milliseconds. For the start to proceed, the panel power must be on, the compressor must be in the Ready state (all utilities must be running and permissive functions satisfied) and the REMOTE FUNCTIONS DISABLED/ENABLED selector switch is in ENABLED mode prior to energizing the input. Remote Stop Digital Input This input is driven by a maintained contact closure. The remote stop input is always active; that is, the remote stop can be initiated regardless of the REMOTE FUNCTIONS DISABLED/ENABLED selector switch position. Communications Remote starting and stopping can be accomplished through the MODBUS communication port in various ways. See the section on Communications that follows for these options. Again, panel power must be on, all utilities must be running and permissive functions satisfied in order for the start-up to proceed. Auto-Hot Start Normally purchased in multiple compressor applications where backup air is required, this automatic starting option allows the compressor to be started when the system air pressure is below a user selected set point pressure. Panel power must be on, all utilities must be running, the AUTO HOT START DISABLED/ENABLED selector switch must be in the ENABLED position and all permissive functions satisfied in order for the start-up to proceed. Solenoid water valve(s) are provided for the intercooler(s) to reduce water consumption when the compressor is not running. A 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 81 82 CMC TECHNICAL REFERENCE MANUAL post run timer is also included in the Auto Hot Start logic to de-energize the water solenoid valves twenty minutes after a compressor stop or trip to allow the oil to cool. Auto-Cold Start This option is very similar to Auto-Hot Start with the exception that the compressor starts with no initial panel power. An additional timer is added to simulate the start button being pressed and another timer is added to bypass the low oil temperature function on start-up. One additional solenoid valve is included for instrument air supply. The CONTROL POWER OFF/ON selector switch label is modified to CONTROL POWER LOCAL/OFF/COLD START. When in the COLD START position, the compressor is OFF and can be started through the Auto-Cold Start function. As a safety precaution, an optional strobe light can be provided to indicate that an automatic start is about to begin. Remote 4-20 mA Pressure Setpoint When the REMOTE FUNCTIONS DISABLED/ENABLED selector switch is in the ENABLED position, the CMC will monitor the specified analog input for pressure setpoint. If this analog input’s value minus the Pressure Setpoint (from the display) is greater than or equal to the display’s Pressure Setpoint step value (default 0.1 psi), a remote setpoint change will be requested. This request will be initiated, as long as there are no analog input error faults for this channel, and the change made will rounded to the nearest step value (0.1) size. This methodology prevents the control system from chasing an ever-changing analog input value. Ambient Control plus Parallel Valve Control Logic Ambient Control This feature uses Polytropic Head (or just Head) as the MinLoad control variable. By using Head, a more conservative MinLoad setting can be established which contributes to energy efficiency. For additional information on Polytropic Head, see section under SURGE CONTROL / Control Methodology. Polytropic Head may be selected as the MinLoad control variable for Pressure Control (the standard process control for the CMC), or optional Flow Control. Polytropic Head may also be selected as the MinLoad control variable for Steam and Gas Turbine Driven and Diesel Driven Compressors. Parallel Valve Control Logic This feature includes a number changes to control logic to improve valve transitions. • One feature is improved State Transitions. The overall effect will be better response to system dynamics requiring state changes. An example of this is inlet valve throttling. When the machine is rapidly throttling from Loaded State to the MinLoad state, the inlet valve will transition to MinLoad before actually reaching the Minload setpoint. The valve transition offset is a function of the PID settings for the MinLoad and Loaded loops and the rate at which the process control variable is rising. By making this transition early, improved control response is achieved. In this case, undershoot of MinLoad would be decreased and overshoot of the process variable would be decreased relative to previous CMC releases. • For installations with big, quick swings in load that get the check valve opened and closed frequently a new Discharge Pressure Regulation feature may be selected 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL to provide better pressure control. Previously these large changes required the MinLoad to be set more conservatively. Otherwise if the controller could not react fast enough the system would decay while closing the bypass valve. This new control loop will regulate compressor discharge pressure when the discharge check valve is closed. Adding this loop also eliminates windup of the bypass valve and allow for quicker reentry into the system. This feature requires configuration by an Ingersoll-Rand service technician. • Typically, overshoot can occur when the system being regulated has a significant change in dynamic response and the PID parameters are not changed accordingly. For compressor control, this happens when the controller used the same bypass valve PID values for control regardless of the check valve state. One way to handle this is with the above Discharge Pressure Regulation feature previously described. If the installation does not warrant setting up Discharge Pressure Regulation, the Loading Ramp rate feature is used to accommodate this check valve complication. The Loading Ramp feature minimizes overshoot upon a load command. • An additional feature called Unloading Interrupt is also a part of the CMC. The unloading state can now be interrupted by a load command and reload the machine without completely unloading it. • Deadband on Control Variables is another feature of Parallel Valve Control Logic. This feature prevents valve oscillations when the Process Variable is steady state. Steady state valve oscillation is primarily a result of the control valve’s inability to position as finely as required by the PID control loop. A typical scenario would be when the CMC commands the valve to open 0.05% and the valve opens 0.1%. The valve now needs to close 0.05% but will likely close 0.1% causing the cycle to start over. This feature requires configuration by an Ingersoll-Rand service technician. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 83 84 CMC TECHNICAL REFERENCE MANUAL Mass Flow Control Constant flow control is a performance control method for Centac air compressors. Uncontrolled, the compressor's discharge flow would rise and fall along the natural performance Surge Line curve as system flow demand changed. Constant Flow control Maximum satisfies the constant flow Throttle Points (MinLoad) Discharge requirement. Pressure This performance map shows Constant Flow control. Constant Flow control maintains the compressor discharge flow into the system at the Flow Setpoint as entered into the CMC by the user. Once loaded, the compressor will operate along the constant flow line until the user presses the Unload or Stop button. Natural Pressure Curve Design Point Constant Flow Line Unloaded Natural Power Curve Surge Line Power at Control is accomplished by Coupling modulating the inlet valve within the compressor's operating range. When the compressor’s demand is Unloaded less than the minimum throttled capacity, constant flow is Capacity maintained by modulating the bypass valve and venting some or all of the air to atmosphere. This Figure 20: Constant Flow Control valve is opened just prior to reaching the surge line. Whenever the bypass valve is open, the inlet valve maintains its position at the minimum throttled capacity setting. Constant Flow provides a constant discharge flow with variable pressure up to the natural surge point. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 85 CMC TECHNICAL REFERENCE MANUAL Measuring the Flow In order to maintain constant flow, the system discharge airflow must be measured. A flow transducer is mounted in the customer’s piping upstream of the check valve. CMC 4-20 mA Bypass Valve FT 4-20 mA Base Control Module CT Starter Motor 4-20 mA Check Valve FE Compressor PT x Inlet Valve 4-20 mA Figure 21: Measuring Flow This transducer sends a 4-20 mA signal to the CMC board. The CMC compares the measured flow to the flow setpoint entered into the CMC by the user through the Operator User Interface (OUI). Depending upon the difference between these two values the CMC will send a 4-20 mA signal to open or close the inlet and/or bypass valve to maintain the specified compressor flow setpoint. Steam and Gas Turbine Driven Compressors The following describes the differences between the motor and turbine driven compressor logic. Performance Control Motor Current, MinLoad and MaxLoad Steam and gas turbines do not have motor current, MinLoad and MaxLoad operate differently form the normal motor driven compressor. MinLoad uses an inlet valve position, instead of amps, to determine when to transition from Inlet Valve Pressure control to Bypass Valve Pressure control. When in MinLoad, the controller uses this valve position as the setpoint for the Inlet Valve MinLoad PID loop. Since the controlled variable and the setpoint variable are identical, the goal of tuning this loop is to get a steady output. The default parameters will satisfy most all applications. The procedure for determining the MinLoad point is the same for both motor and turbine driven units, except inlet valve position is recorded instead of motor amps. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 86 CMC TECHNICAL REFERENCE MANUAL CAUTION Improperly tuning MinLoad PID values will result in unpredictable compressor operation. If this situation arises, reset the PID values to the default values. MaxLoad situations are detected on turbine driven compressors by low speed. The MaxLoad setpoint is a speed below the rated speed and above the low speed alarm. This speed is determined by adding an offset to the low speed alarm. This offset is the speed that the governor can accurately control. Surge Control All surge related issues are identical to motor driven units with the exception of the detection methodology. How Surge is Detected The CMC senses surge when the rate of change in last stage discharge pressure is greater than the surge sensitivity setpoint value. The difference between this and motor Compressor Operating States driven units is that the motor driven units Turbine Driven Packages uses rate of change in motor amps also. Compressor Operating Methodology Comparing the chart to the right for Turbine driven compressor and Motor driven compressor, the only state differences are the addition of the first three states under Rotating. These are Accelerate-1, Accelerate-2 and Slow Rolling. Accelerate-1 + Compressor + Stopped Waiting Not Ready Ready + Rotating Accelerate-1 Accelerate-2 Slow Rolling This state is provided to give the operator Starting five minutes from the time the Start button Unloaded is pressed to get enough steam to the turbine to get the speed above the Zero A-D Unloaded Offset Speed. This speed is defaulted to Surge Unload 15 rpm. If this speed is not achieved in Loading this time period, the event message MinLoad “Accelerate-1 Fail” will appear and the controller will trip the compressor. As Loaded always, the compressor must be “Ready” Full Load before the start button is pressed. The MaxLoad reason for the five-minute limitation is to Unloading prevent the compressor from being ready for an indefinite period of time. This Coasting prevents the operator from forgetting that the compressor is ready to accelerate. “Accelerate-1” could also be explained as “accelerating to zero speed offset” or “waiting for compressor rotation”. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL Accelerate-2 After the transition to Accelerate-1 is complete, this state is initiated when rotation is detected and the turbine has not reached the low trip speed. This state may be bypassed if the turbine accelerates very quickly. Once in this state, a sixty (60) second timer is initiated. If the speed does not get to the minimum slow roll speed within this time period, the event message “Accelerate-2 Fail” will appear and the controller will trip the package. This state is limited sixty (60) seconds to prevent bearing damage from rolling the compressor at too low a speed. The bearing design requires a minimum speed to form the oil film thickness required for proper bearing operation. “Accelerate-2” could also be explained as “accelerating to minimum slow roll speed”. Slow Rolling After the transition to Accelerate-2 is complete, this state is entered after the previous sixtysecond timer has elapsed and the speed is less than the low trip speed. The compressor can operate in this “Slow Rolling” state indefinitely. While in this state, if the speed drops below the minimum slow roll speed, the event message “Slow Roll Fail” will appear and the controller will trip the compressor. If at any time during “Slow Rolling” the speed exceeds the maximum slow roll speed, the compressor will transition to “Starting”. The Starting state for turbine driven compressors is the same as for motor driven compressors. Quick Start Turbines Quick Start turbines may skip “Accelerate-2” and “Slow Rolling” or just “Slow Rolling” because of the acceleration characteristics. The acceleration sequence depends upon the acceleration characteristics for a given turbine. Operator User Interface (OUI) Status Bar Motor driven compressors have an optional Compressor Status Field for Start Disabled. This field is standard for turbine driven compressors and it means that the turbine trip and throttle valve limit switch has not been made. System Folder Replacing “Motor Current “with” Compressor Speed” on Page 1 is the only modification to this folder. Info Folder The events “Starter Failure” and ”Loss of Motor Current have been deleted from the possible event list. The following events have been added. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 87 88 CMC TECHNICAL REFERENCE MANUAL Possible Events List Event Name Description Accelerate-1 Fail The zero offset speed has not been achieved before the end of the five-minute timer. Accelerate-2 Fail The minimum slow roll speed has not been achieved before the end of the one-minute timer. Driver Trip The trip and throttle valve limit switch has been latched, then unlatched. Governor Common Trip The governor has tripped. High Speed Alarm The indicated speed is greater than or equal to the High Speed Alarm setting. High Speed Trip The indicated speed is greater than or equal to the High Speed Trip setting. Illegal Rotation Rotation has been detected when in “Stopped”. Low Speed Alarm The indicated speed is less than or equal to the Low Speed Alarm setting. Low Speed Trip The indicated speed is less than or equal to the Low Speed Trip setting. Slow Rolling Fail The minimum slow roll speed was not maintained during “Slow Roll”. Starting Fail The low trip speed was not achieved before the end of the Starting Timer. TTV Switch Fault The trip and throttle valve (TTV) limit switch is made when the (TTV) solenoid is de-energized. Settings Folder For Page 2, Anti-Surge and Driver Over-Load Protection … 1. “MaxLoad (HLL), amps” is replaced with “MaxLoad (HLL), rpm”. 2. “User Setpoint (TL), amps” is replaced with “User Setpoint (TL), IV Pos %”. 3. “Control Setpoint, amps” is replaced with “Control Setpoint, IV Pos %”. 4. “Surge Index Increment, amps” is replaced with “Surge Index Increment, IV Pos %”. For Page 5, Miscellaneous 1. “CT Ratio” is removed. 2. “Motor Failure Trip Enable” checkbox is removed. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 89 CMC TECHNICAL REFERENCE MANUAL General Sequence of Operation Compressor Operating States Coasting Unloaded Unloading MaxLoad Full Load Loaded MinLoad Loading Unloaded Starting Ready Not Ready Waiting for Turbine and Diesel Driven Packages Any Stops or Trips Mechanical Trip (110%) Overspeed Trip (108%) Overspeed Alarm (105%) Rated "Full Load" (100%) MaxLoad (HLL) Low Alarm (95%) Low Trip (93%) SPEED Maximum Slow Roll (50%) Minimum Slow Roll (25%) No Stops or Trips and Latch Start Zero Speed Offset (15 rpm) (0%) Power On Stopped Rotating Starting Methodology 1. The panel power is turned on. The compressor is WAITING. 2. The CMC Panel mounted switch for DRIVER SPEED RATED/IDLE (when supplied for an electronic governor) should be put into the IDLE position. This switch is wired to a discrete input (Driver Speed Rated/Idle) in the CMC and is sent on the discrete output (Driver Speed Rated/Idle) to the governor. 3. When the two-minute waiting timer has expired, the compressor is NOT READY. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 90 CMC TECHNICAL REFERENCE MANUAL 4. Reset the governor to clear any trip signals. This may be accomplished with the digital output (Reset – Momentary). If an electronic governor exists, a discrete output signal (Common Trip) is sent from the governor to a discrete input signal on the CMC when the governor needs to trip the compressor. If no electronic governor exists, a jumper must be installed on the CMC board. Adaptive StartingTM Techniques Low Trip (93%) Starting Starting Starting SPEED Slow Rolling Maximum Slow Roll (50%) Accelerate-2 Accelerate-2 Minimum Slow Roll (25%) Accelerate-1 Accelerate-1 Accelerate-1 Zero Speed Offset (15 rpm) (0%) 5. When NO Trips exist (compressor and turbine), the CMC energizes the turbine’s trip and throttle valve (TTV) solenoid. This is accomplished through a discrete output (Driver Permissive) from the CMC to the TTV solenoid. 6. At this point, the compressor is NOT READY, Driver Disabled. 7. When the TTV solenoid is energized, the turbine trip valve can be latched. 8. When the turbine trip valve is manually latched, the turbine trip valve’s limit switch will be energized. This signal is sent to a discrete input (Trip and Throttle Valve Limit Switch) on the CMC. 9. When the limit switch is energized and no stop command is pending, the compressor will be READY. This state may be maintained indefinitely. 10. The Start Key is pressed on the compressor. The digital output (CR1) is energized to actuate the solenoid operated steam valve and the digital output (Start – Momentary) is energized. A timer (five minute maximum) is started. At this point, enough steam should be applied to the turbine to get the speed above the zero speed offset. This period is ACCELERATE-1. 11. Once the zero speed offset has been established, a one minute timer is provided to prevent compressor pinion damage from rotating the pinions at too low a speed for an excessive time. The compressor bearings are designed to have a minimum oil film pressure created by a minimum rotating pinion speed. Therefore, we must not stay at 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 91 CMC TECHNICAL REFERENCE MANUAL too slow a speed for an extended period. This is ACCELERATE-2. The turbine must reach the Minimum Slow Roll Speed (approximately 25% of Full Speed) to continue. 12. Once the turbine gets past the Minimum Slow Roll Speed and is less than the Maximum Slow Roll Speed (approximately 50% of Full Speed), the turbine is in the slow rolling zone and the compressor is SLOW ROLLING. The User may leave the compressor in this mode indefinitely. The CMC monitors the compressor speed (through the speed analog input) in this mode. The Idle/Rated Driver Speed switch is turned to the Rated position. 13. When the turbine speed exceeds Maximum Slow Roll Speed, the Starting Timer begins (60 seconds maximum) and is STARTING. This is the same time for motor driven compressors; therefore, the User must put enough steam to the turbine to get the speed above the low trip speed before the timer expires. At this point, the compressor has started and runs as described elsewhere. Instrumentation for Turbine Driven Compressors Centac Microcontroller Discrete Outputs (DO) CR1 TTV Solenoid Energize (Driver Permissive) TTV Limit Switch Start - Momentary Stop - Momentary Reset - Momentary Driver Speed Rated/Idle DI Discrete Inputs (DI) DO Common Trip Electronic Governor AO Driver Speed Rated/Idle Switch on Panel Door Analog Input (AI) Speed AI Speed Turbine TTV Solenoid Manual Latch Limit Switch Steam Throttle Valve Trip Valve Solenoid Steam Valve 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Compressor 92 CMC TECHNICAL REFERENCE MANUAL Diesel Driven Compressors Diesel driven compressors have similar characteristics as the turbine driven compressors. The differences are… 1. “Idle/Rated Driver Speed” discrete input and discrete output are eliminated. 2. “Start – Momentary”, “Stop – Momentary” and “Reset – Momentary” discrete outputs are eliminated. 3. “Driver Permissive” discrete output is wired to the “Trip and Throttle Valve Limit Switch” discrete input. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 93 Communication Customers may want to communicate to the CMC control systems for remote compressor control and monitoring. This communication capability provides for flexibility in the customer's compressed air operation through remote start and stop, data gathering for preventative maintenance, and incorporation into plant-wide control system. The major avenue for communicating with the CMC is via MODBUS protocol over an RS422/485 hardware link. This requires hardware for the control panel, and a communications device with the appropriate driver software to perform the desired panel functions. The RS422/485 interface can communicate with any serial device that has an RS422 or RS485 port. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires. Human Machine Interface (HMI) Systems Air System Controller (ASC) and Air System Manager (ASM) are software packages available for compressors with CMC panels. ASC and ASM are graphical integration software specifically developed for air compressor systems. Both provide energy management through load sharing and reduction of air bypass by using a minimum amount of energy to meet the system demand. The primary goal of both systems is to maintain stable system pressure, to integrate, monitor and control the compressed air system. ASM is the integration of compressor control software in an off-the-shelf Supervisor Control and Data Acquisition (SCADA) package that is available from various manufacturers. The ASM provides more custom features than does ASC. Both ASC and ASM provide a window into the compressor room by making the raw data from compressors and other equipment available to plant operators and managers in formats that are easy to understand. Implementing the CMC in any HMI system may require additional hardware and/or software upgrade. Direct CMC Communications with RS422/485 For the descriptions that follow, a serial device can be a Personal Computer (PC), Programmable Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit, receive and interpret an RS422/485 formatted signal over a hardware link. In the descriptions that follow, the PC and PLC serial devices are not specific to manufacturers or operating systems. There are many ways of interfacing to CMC control systems through an RS422/485 port. Most of the following methodologies are currently available; but please be aware, other possible configurations can exist. All RS422/485 interfaces require custom interface software and custom application software. The interface software allows a specific serial device and operating system to transmit, receive and interpret data from a CMC control system. The application software tells the CMC control system what to do; for example, start compressor when ready, stop compressor after midnight and retrieve the current data and save to a disk file. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 94 CMC TECHNICAL REFERENCE MANUAL Currently there are hundreds of different serial devices using different operating systems and languages in the industrial equipment world. Therefore, the practicality of having an interface for many systems is limited. Custom interfaces must be written as required by the hardware and operating system used. The capabilities of the hardware and the imagination of the developer only limit the application software. For example, one developer may have two compressors. In this application the developer wants a screen to display the compressor interstage pressure and temperatures for both machines with various other compressor data. A second developer has five compressors. He also wants to display the same data, but this time for all five machines. The only way this is done is through changing the application software (custom modification). The developer may write functions to read and display data, log that data to some magnetic media for storage, change compressor set points, sequence the compressors for efficient operation and network additional devices, such as pumps, dryers, etc., into the system. All of these functions require specially written application software for the intended use. The CMC-MODBUS Interface Introduction The CMC can communicate with other devices over a variety of communications standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), and Modicon’s MODBUS. The built-in ports on the CMC’s optional Universal Communication Adapters access communications. The CMC-MODBUS Interface defines the message structure that a CMC uses to exist on a MODBUS network. This interface will allow the MODBUS network to gather information and control the compressor. NOTE Unless specified otherwise, numerical values (such as addresses, codes, or data) are expressed as decimal values in the text of this section. They are expressed as hexadecimal values in the message fields of the examples. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 95 CMC TECHNICAL REFERENCE MANUAL In order to communicate over other types of networks, a network adapter must be used. The information presented in the following sections does not include MODBUS protocol details like framing messages and calculating checksums. This detailed information can be obtained from Schneider Automation’s MODBUS PROTOCOL Manual, Chapters 1 through 6. This can be obtained through the Internet at “www.modicon.com”. Query Master Slave Device Address Device Address Function Code Function Code Data Address Byte Count Data Data CRC CRC Serial Modes MODBUS Controllers can be setup to communicate on MODBUS networks using either of two transmission modes: ASCII or RTU. The CMC supports only the RTU mode. The user must specify the serial port communication parameters (baud rate, parity mode, etc.) during configuration of each CMC. The mode and serial parameters must be the same for all devices on a MODBUS network. Response Figure 22: MODBUS Messages MODBUS Messages A MODBUS network uses a master-slave relationship. The CMC always acts as a slave device. The slave cannot initiate a message, and returns a message (response) only to queries (reads) that are addressed to them individually. For example, a force coil command (write to module) that is broadcast to all MODBUS devices would not get a response. Responses are not returned to broadcast writes from the master. Device Address This address is the physical address of the Universal Communication Module (UCM) for the compressor. This address must be unique in the MODBUS network. The valid range for this address is 01-FF (hexadecimal). NOTE: 00 (hexadecimal) is reserved for broadcast. Configuration of the slave address is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative. Function Code The listing below shows the function codes that are supported by the CMC. Additional detail about each function is provided in sections that follow. Function Code (decimal) 1 2 3 4 5 6 15 16 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Function Code (hex) 01 02 03 04 05 06 0F 10 Function Name Read Coil Status Read Input Status Read Holding Registers Read Input Registers Force Single Coil Preset Single Register Force Multiple Coils Preset Multiple Registers 96 CMC TECHNICAL REFERENCE MANUAL Data Addresses Addresses that contain the data type and a four-digit number are referred to as absolute (e.g., address 30232, where 3 is the data type for a input register and 0232 or 232 is the address). Software products at the operator or user level use absolute addresses most frequently. The addresses that do not contain the type and are referenced to zero are referred to as relative (e.g., absolute address 30232 would be relative address 231, remove the data type 3, holding register, and subtract 1 for referencing to zero). All data addresses in MODBUS messages (typically, behind the scenes at the programming communication level) are referenced to zero; that is, the first occurrence of a data item is addressed as item number zero. Reference Data Type 0x 1x 3x 4x Coils Discrete Inputs Input Registers Holding Registers MODBUS Range Absolute Addresses 00001-09999 10001-19999 30001-39999 40001-49999 MODBUS Range Relative Addresses 0000-9998 0000-9998 0000-9998 0000-9998 CMC Range Absolute Addresses 00001-09000 10001-19000 30001-39000 40001-49000 CMC Range Relative Addresses 0000-8999 0000-8999 0000-8999 0000-8999 • Absolute address for Coil 00127 decimal is relatively addressed as coil 007E hex (126 decimal) • Input register with absolute address of 30001 is relatively addressed as register 0000 in the data address field of the message. The function code field that specifies reading or writing data already specifies an input register operation; therefore, the 3x reference is implicit. • Holding register with an absolute address of 40108 is relatively addressed as register 006B hex (107 decimal) Single Module Addresses The addresses provided in this document are for compressors with a single Base Control Module. Multiple Module Addresses For those systems that require multiple Base Control Modules, the addresses for the first module will be as provided within this document. The addresses for the second module will be provided as an engineering submittal. Data For both queries and responses, the data is in sixteen bit (two bytes, one word) chunks. For each two byte word, the left most byte is the most significant. For each byte, the left most bit is the most significant. This portion of the message changes with each function code. See the detail that follows for each function for the specifics of this message component. Byte Count The number of bytes contained in the data portion of the message. This is used on both queries (reads) and responses. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 97 CMC TECHNICAL REFERENCE MANUAL Cyclical Redundancy Check (CRC) This portion of the message is used to prevent incorrect data from being used in the Master or Slave because of communication errors. Function Details Function 01 - Read Coil Status This function reads the state of one or more coils (MODBUS 0x references) in the slave (CMC Base Control Module). For the CMC, these coils represent the Discrete (Digital) Outputs, compressor operating state (see the Operator User Interface Status Bar for definition), any compressor Trip condition and any compressor Alarm condition. If the function returns a 1, the discrete output is on. If the function returns a 0, the discrete output is off. Broadcast is not supported. Refer to the table on the next page for MODBUS Absolute Addresses for each coil supported by the CMC-MODBUS Interface. Absolute Address (decimal) 00187 00188 00189 00190 00191 00192 00193 00194 00195 00196 00197 00198 00199 00200 00201 00202 Relative Address (hex) 00-BA 00-BB 00-BC 00-BD 00-BE 00-BF 00-C0 00-C1 00-C2 00-C3 00-C4 00-C5 00-C6 00-C7 00-C8 00-C9 Absolute Relative Address Address Coil Name - Read Only* (decimal) (hex) Digital Output, Channel 1 (J15-P7,8) 00203 00-CA Compressor State - Waiting Digital Output, Channel 2 (J15-P5,6) 00204 00-CB Compressor State - Coasting Digital Output, Channel 3 (J15-P3,4) 00205 00-CC Compressor State - Starting Digital Output, Channel 4 (J15-P1,2) 00206 00-CD Compressor State - Not Ready Digital Output, Channel 5 (J14-P7,8) 00207 00-CE Compressor State - Ready Digital Output, Channel 6 (J14-P5,6) 00208 00-CF Compressor State - Surge Unload Digital Output, Channel 7 (J14-P3,4) 00209 00-D0 Compressor State - Autodual Unload Digital Output, Channel 8 (J14-P1,2) 00210 00-D1 Compressor State - Unloading Digital Output, Channel 9 (J13-P7,8) 00211 00-D2 Compressor State - Unloaded Digital Output, Channel 10 (J13-P5,6) 00212 00-D3 Compressor State - Min load Digital Output, Channel 11 (J13-P3,4) 00213 00-D4 Compressor State - Max load Digital Output, Channel 12 (J13-P1,2) 00214 00-D5 Compressor State - Loading Digital Output, Channel 13 (J12-P7,8) 00215 00-D6 Compressor State - Loaded Digital Output, Channel 14 (J12-P5,6) 00216 00-D7 Compressor State - Full Load Digital Output, Channel 15 (J12-P3,4) 00217 00-D8 Compressor State - Analog Input Failed Digital Output, Channel 16 (J12-P1,2) 00218 00-D9 Any Compressor Trip 00219 00-DA Any Compressor Alarm NOTE: (J15-P7,8) is interpreted as Connector J15, Pins 7 and 8 on the Base Control Module. * IMPORTANT: These coils are defined as read only. If you decide to write to these coils, unexpected results could occur. Coil Name - Read Only* Example: Reading a Single Coil After reviewing the Electrical Schematic for your compressor, you determine that the digital output for the prelube pump is located on J12-P7,8 (Channel 13). From the table above, the Absolute Address is decimal 00199 (Relative Address is hexadecimal 00C6) for the output in question. Therefore, to read the state of the prelube pump output the following command is issued (the following data are presented in hexadecimal format): Device Address 01 Function Code 01 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Address Hi Lo 00 C6 Number of Coils Hi Lo 00 01 CRC Lo 1D Hi F7 98 CMC TECHNICAL REFERENCE MANUAL The response from this command is: Device Address 01 Function Code 01 Byte Count 01 CRC Data 01 Lo 90 Hi 48 The data (01) means that the discrete output is on, or the prelube pump is running. Example: Reading Multiple Coils To read all sixteen digital (discrete) outputs, the following command is sent: Device Address 01 Function Code 01 Address Hi Lo 00 BA Number of Coils Hi Lo 00 10 CRC Lo 1C Hi 23 where relative address 00-BA is for digital (discrete) output for Channel 1. The response from this command is: Device Address 01 Function Code 01 Byte Count 02 CRC Data 04-10 Lo BA Hi F0 To determine the state of each output, review the Electrical Schematic for your compressor. For this example, you determine that the digital output for the prelube pump is located on J12-P7,8 (Channel 13) and the digital output for the remote trouble contact is J15-P3,4 (Channel 3). The first hexadecimal data byte 04 (0000 0100 binary), represents the states of the first eight digital (discrete) outputs (8-1). Therefore, for this example 04 means that Channels 8, 7, 6, 5, 4, 2 and 1 are off and Channel 3 (compressor is in an alarm or trip condition) is on. For the next eight channels (16-9) the hexadecimal data byte 10 (0001 0000 binary) means that Channels 16, 15, 14, 12, 11, 10 and 9 are off and Channel 13 (prelube pump is running) is on. The following table graphically depicts this example: Response Byte 1 Address 8 0 C1 7 0 C0 6 0 BF 5 0 BE 4 0 BD 3 1 BC 2 0 BB 1 0 BA Response Byte 2 Address 16 0 C9 15 0 C8 14 0 C7 13 1 C6 12 0 C5 11 0 C4 10 0 C3 9 0 C2 A bit response of 1 means that the output is on and a response of 0 means that the output is off. Function 02 - Read Input Status This function reads the state of one or more discrete inputs (MODBUS 1x references) in the slave (CMC Base Control Module). For the CMC, these inputs represent the Discrete (Digital) Inputs. If the function returns a 1, the input is on. If the function returns a 0, the input is off. Broadcast is not supported. Refer to the table on the next page for MODBUS Absolute Addresses for each discrete input supported by the CMC-MODBUS Interface. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 99 CMC TECHNICAL REFERENCE MANUAL Absolute Address Relative Address Input Name - Read Only* (decimal) (hex) 10171 00-AA Digital Input, Channel 1 (J4-P2) 10172 00-AB Digital Input, Channel 2 (J4-P3) 10173 00-AC Digital Input, Channel 3 (J4-P4) 10174 00-AD Digital Input, Channel 4 (J4-P5) 10175 00-AE Digital Input, Channel 5 (J4-P6) 10176 00-AF Digital Input, Channel 6 (J4-P7) 10177 00-B0 Digital Input, Channel 7 (J4-P8) 10178 00-B1 Digital Input, Channel 8 (J4-P9) 10179 00-B2 Digital Input, Channel 9 (J5-P2) 10180 00-B3 Digital Input, Channel 10 (J5-P3) 10181 00-B4 Digital Input, Channel 11 (J5-P4) 10182 00-B5 Digital Input, Channel 12 (J5-P5) 10183 00-B6 Digital Input, Channel 13 (J5-P6) 10184 00-B7 Digital Input, Channel 14 (J5-P7) 10185 00-B8 Digital Input, Channel 15 (J5-P8) 10186 00-B9 Digital Input, Channel 16 (J5-P9) NOTE: (J4-P2) is interpreted as Connector J4, Pin 2 on the Base Control Module. * IMPORTANT: These Digital Inputs are defined as read only. If you decide to write to these Inputs, unexpected results could occur. Example: Read Single Discrete Input After reviewing the Electrical Schematic for your compressor, you determine that the digital input for emergency stop push button is located on J4-P5 (Channel 4). From the table above, the Absolute Address is decimal 10174 (Relative Address is hexadecimal 00AD) for the input in question. Therefore, to read the state of the emergency stop push button the following command is issued (the following data are presented in hexadecimal format): Device Address 01 Function Code 02 Address Hi Lo 00 AD Number of Digital Inputs Hi Lo 00 01 CRC Lo 28 Hi 2B The response from this command is: Device Address 01 Function Code 02 Byte Count 01 CRC Data 01 Lo 60 Hi 48 The data (01) means that the input is on, or the emergency stop push button is pressed. Example: Read Multiple Discrete Inputs The method for reading multiple Discrete Inputs is the same as reading multiple coils. See the example for “Reading Multiple Coils”. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 100 CMC TECHNICAL REFERENCE MANUAL Function 03 - Read Holding Registers Reads the binary content of holding registers (MODBUS 4x references) in the slave (CMC Base Control Module). For the CMC, these holding registers contain the Analog Output values and Analog Alarm and Trip Setpoint values for all CMC inputs and outputs. Broadcast is not supported. The CMC is primarily a 32-bit floating-point microprocessor controller. And, since MODBUS is designed to be a 16-bit system, the CMC supports two methods for determining the value for each holding register (This also applies to Input Registers.) NOTE Since MODBUS is a 16-bit system, the programmer must get two 16-bit numbers and combine them into one 32-bit floating-point number. The first method uses two 16-bit integers to represent the integer and fraction part of the value. The second method uses one 32-bit IEEE floating point number. (NOTE: For those who would like to only get the 16-bit integer value, this will work well for most inputs; however, the CMC has some inputs, like vibration, that are typically less than one. Since the CMC has programmable analog and discrete inputs and outputs, the programmer must use the electrical schematic supplied with the contract to determine which function name and units of measure are associated with each input and output. Refer to the table below for MODBUS Absolute Addresses for each Holding Register supported by the CMC-MODBUS Interface. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 101 CMC TECHNICAL REFERENCE MANUAL Holding Register Name - Read/Write Analog Output, Channel 1 (J3-P1,3) Analog Output, Channel 2 (J3-P4,6) Analog Output, Channel 3 (J3-P7,9) Analog Output, Channel 4 (J3-P10,12) Analog Input, Channel 1 (J2-P1,3) - High Trip Setpoint Analog Input, Channel 1 (J2-P1,3) - High Alarm Setpoint Analog Input, Channel 1 (J2-P1,3) - Low Alarm Setpoint Analog Input, Channel 1 (J2-P1,3) - Low Trip Setpoint Analog Input, Channel 2 (J2-P5,7) - High Trip Setpoint Analog Input, Channel 2 (J2-P5,7) - High Alarm Setpoint Analog Input, Channel 2 (J2-P5,7) - Low Alarm Setpoint Analog Input, Channel 2 (J2-P5,7) - Low Trip Setpoint Analog Input, Channel 3 (J1-P1) - High Trip Setpoint Analog Input, Channel 3 (J1-P1) - High Alarm Setpoint Analog Input, Channel 3 (J1-P1) - Low Alarm Setpoint Analog Input, Channel 3 (J1-P1) - Low Trip Setpoint Analog Input, Channel 4 (J1-P4) - High Trip Setpoint Analog Input, Channel 4 (J1-P4) - High Alarm Setpoint Analog Input, Channel 4 (J1-P4) - Low Alarm Setpoint Analog Input, Channel 4 (J1-P4) - Low Trip Setpoint Analog Input, Channel 5 (J1-P5) - High Trip Setpoint Analog Input, Channel 5 (J1-P5) - High Alarm Setpoint Analog Input, Channel 5 (J1-P5) - Low Alarm Setpoint Analog Input, Channel 5 (J1-P5) - Low Trip Setpoint Analog Input, Channel 6 (J1-P8) - High Trip Setpoint Analog Input, Channel 6 (J1-P8) - High Alarm Setpoint Analog Input, Channel 6 (J1-P8) - Low Alarm Setpoint Analog Input, Channel 6 (J1-P8) - Low Trip Setpoint Analog Input, Channel 7 (J1-P9) - High Trip Setpoint Analog Input, Channel 7 (J1-P9) - High Alarm Setpoint Analog Input, Channel 7 (J1-P9) - Low Alarm Setpoint Analog Input, Channel 7 (J1-P9) - Low Trip Setpoint Analog Input, Channel 8 (J1-P12) - High Trip Setpoint Analog Input, Channel 8 (J1-P12) - High Alarm Setpoint Analog Input, Channel 8 (J1-P12) - Low Alarm Setpoint Analog Input, Channel 8 (J1-P12) - Low Trip Setpoint Analog Input, Channel 9 (J1-P13) - High Trip Setpoint Analog Input, Channel 9 (J1-P13) - High Alarm Setpoint Analog Input, Channel 9 (J1-P13) - Low Alarm Setpoint Analog Input, Channel 9 (J1-P13) - Low Trip Setpoint Analog Input, Channel 10 (J1-P16) - High Trip Setpoint Analog Input, Channel 10 (J1-P16) - High Alarm Setpoint Analog Input, Channel 10 (J1-P16) - Low Alarm Setpoint Analog Input, Channel 10 (J1-P16) - Low Trip Setpoint Analog Input, Channel 11 (J1-P17) - High Trip Setpoint Analog Input, Channel 11 (J1-P17) - High Alarm Setpoint Analog Input, Channel 11 (J1-P17) - Low Alarm Setpoint Analog Input, Channel 11 (J1-P17) - Low Trip Setpoint Analog Input, Channel 12 (J1-P20) - High Trip Setpoint Analog Input, Channel 12 (J1-P20) - High Alarm Setpoint Analog Input, Channel 12 (J1-P20) - Low Alarm Setpoint Analog Input, Channel 12 (J1-P20) - Low Trip Setpoint Analog Input, Channel 13 (J1-P21) - High Trip Setpoint Analog Input, Channel 13 (J1-P21) - High Alarm Setpoint Analog Input, Channel 13 (J1-P21) - Low Alarm Setpoint Analog Input, Channel 13 (J1-P21) - Low Trip Setpoint 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Signed 16 Bit Exponent Absolute Relative Address Address (Decimal) (hex) 40053 00-34 40055 00-36 40057 00-38 40059 00-3A 40061 00-3C 40063 00-3E 40065 00-40 40067 00-42 40069 00-44 40071 00-46 40073 00-48 40075 00-4A 40077 00-4C 40079 00-4E 40081 00-50 40083 00-52 40085 00-54 40087 00-56 40089 00-58 40091 00-5A 40093 00-5C 40095 00-5E 40097 00-60 40099 00-62 40101 00-64 40103 00-66 40105 00-68 40107 00-6A 40109 00-6C 40111 00-6E 40113 00-70 40115 00-72 40117 00-74 40119 00-76 40121 00-78 40123 00-7A 40125 00-7C 40127 00-7E 40129 00-80 40131 00-82 40133 00-84 40135 00-86 40137 00-88 40139 00-8A 40141 00-8C 40143 00-8E 40145 00-90 40147 00-92 40149 00-94 40151 00-96 40153 00-98 40155 00-9A 40157 00-9C 40159 00-9E 40161 00-A0 40163 00-A2 Unsigned 16 Bit Fraction Absolute Relative Address Address (Decimal) (hex) 40054 00-35 40056 00-37 40058 00-39 40060 00-3B 40062 00-3D 40064 00-3F 40066 00-41 40068 00-43 40070 00-45 40072 00-47 40074 00-49 40076 00-4B 40078 00-4D 40080 00-4F 40082 00-51 40084 00-53 40086 00-55 40088 00-57 40090 00-59 40092 00-5B 40094 00-5D 40096 00-5F 40098 00-61 40100 00-63 40102 00-65 40104 00-67 40106 00-69 40108 00-6B 40110 00-6D 40112 00-6F 40114 00-71 40116 00-73 40118 00-75 40120 00-77 40122 00-79 40124 00-7B 40126 00-7D 40128 00-7F 40130 00-81 40132 00-83 40134 00-85 40136 00-87 40138 00-89 40140 00-8B 40142 00-8D 40144 00-8F 40146 00-91 40148 00-93 40150 00-95 40152 00-97 40154 00-99 40156 00-9B 40158 00-9D 40160 00-9F 40162 00-A1 40164 00-A3 Signed IEEE 32-Bit Float Absolute Relative Address Address (Decimal) (hex) 43053 0B-EC 43055 0B-EE 43057 0B-F0 43059 0B-F2 43061 0B-F4 43063 0B-F6 43065 0B-F8 43067 0B-FA 43069 0B-FC 43071 0B-FE 43073 0C-00 43075 0C-02 43077 0C-04 43079 0C-06 43081 0C-08 43083 0C-0A 43085 0C-0C 43087 0C-0E 43089 0C-10 43091 0C-12 43093 0C-14 43095 0C-16 43097 0C-18 43099 0C-1A 43101 0C-1C 43103 0C-1E 43105 0C-20 43107 0C-22 43109 0C-24 43111 0C-26 43113 0C-28 43115 0C-2A 43117 0C-2C 43119 0C-2E 43121 0C-30 43123 0C-32 43125 0C-34 43127 0C-36 43129 0C-38 43131 0C-3A 43133 0C-3C 43135 0C-3E 43137 0C-40 43139 0C-42 43141 0C-44 43143 0C-46 43145 0C-48 43147 0C-4A 43149 0C-4C 43151 0C-4E 43153 0C-50 43155 0C-52 43157 0C-54 43159 0C-56 43161 0C-58 43163 0C-5A 102 CMC TECHNICAL REFERENCE MANUAL Holding Register Name - Read/Write Analog Input, Channel 14 (J1-P24) - High Trip Setpoint Analog Input, Channel 14 (J1-P24) - High Alarm Setpoint Analog Input, Channel 14 (J1-P24) - Low Alarm Setpoint Analog Input, Channel 14 (J1-P24) - Low Trip Setpoint Analog Input, Channel 15 (J1-P25) - High Trip Setpoint Analog Input, Channel 15 (J1-P25) - High Alarm Setpoint Analog Input, Channel 15 (J1-P25) - Low Alarm Setpoint Analog Input, Channel 15 (J1-P25) - Low Trip Setpoint Analog Input, Channel 16 (J1-P28) - High Trip Setpoint Analog Input, Channel 16 (J1-P28) - High Alarm Setpoint Analog Input, Channel 16 (J1-P28) - Low Alarm Setpoint Analog Input, Channel 16 (J1-P28) - Low Trip Setpoint Analog Input, Channel 17 (J1-P29) - High Trip Setpoint Analog Input, Channel 17 (J1-P29) - High Alarm Setpoint Analog Input, Channel 17 (J1-P29) - Low Alarm Setpoint Analog Input, Channel 17 (J1-P29) - Low Trip Setpoint Analog Input, Channel 18 (J1-P32) - High Trip Setpoint Analog Input, Channel 18 (J1-P32) - High Alarm Setpoint Analog Input, Channel 18 (J1-P32) - Low Alarm Setpoint Analog Input, Channel 18 (J1-P32) - Low Trip Setpoint Analog Input, Channel 19 (J1-P33) - High Trip Setpoint Analog Input, Channel 19 (J1-P33) - High Alarm Setpoint Analog Input, Channel 19 (J1-P33) - Low Alarm Setpoint Analog Input, Channel 19 (J1-P33) - Low Trip Setpoint Analog Input, Channel 20 (J1-P36) - High Trip Setpoint Analog Input, Channel 20 (J1-P36) - High Alarm Setpoint Analog Input, Channel 20 (J1-P36) - Low Alarm Setpoint Analog Input, Channel 20 (J1-P36) - Low Trip Setpoint Analog Input, Channel 21 (J1-P37) - High Trip Setpoint Analog Input, Channel 21 (J1-P37) - High Alarm Setpoint Analog Input, Channel 21 (J1-P37) - Low Alarm Setpoint Analog Input, Channel 21 (J1-P37) - Low Trip Setpoint Analog Input, Channel 22 (J1-P40) - High Trip Setpoint Analog Input, Channel 22 (J1-P40) - High Alarm Setpoint Analog Input, Channel 22 (J1-P40) - Low Alarm Setpoint Analog Input, Channel 22 (J1-P40) - Low Trip Setpoint Analog Input, Channel 23 (J1-P41) - High Trip Setpoint Analog Input, Channel 23 (J1-P41) - High Alarm Setpoint Analog Input, Channel 23 (J1-P41) - Low Alarm Setpoint Analog Input, Channel 23 (J1-P41) - Low Trip Setpoint Motor Current User Pressure Setpoint MinLoad (Throttle Limit, TL) MaxLoad (High Load Limit, HLL) Autodual Reload Percent Autodual Unload Point Autodual Unload Timer Pressure Setpoint Ramp Rate Inlet Valve Unload Position Start Timer CT Ratio Power On Hours Running Hours Loaded Hours Number of Starts Signed 16 Bit Exponent Absolute Relative Address Address (Decimal) (hex) 40165 00-A4 40167 00-A6 40169 00-A8 40171 00-AA 40173 00-AC 40175 00-AE 40177 00-B0 40179 00-B2 40181 00-B4 40183 00-B6 40185 00-B8 40187 00-BA 40189 00-BC 40191 00-BE 40193 00-C0 40195 00-C2 40197 00-C4 40199 00-C6 40201 00-C8 40203 00-CA 40205 00-CC 40207 00-CE 40209 00-D0 40211 00-D2 40213 00-D4 40215 00-D6 40217 00-D8 40219 00-DA 40221 00-DC 40223 00-DE 40225 00-E0 40227 00-E2 40229 00-E4 40231 00-E6 40233 00-E8 40235 00-EA 40237 00-EC 40239 00-EE 40241 00-F0 40243 00-F2 40267 01-0A 40269 01-0C 40271 01-0E 40273 01-10 40275 01-12 40277 01-14 40279 01-16 40281 01-18 40283 01-1A 40285 01-1C 40287 01-1E 40297 01-28 40299 01-2A 40301 01-2C 40303 01-2E Unsigned 16 Bit Fraction Absolute Relative Address Address (Decimal) (hex) 40166 00-A5 40168 00-A7 40170 00-A9 40172 00-AB 40174 00-AD 40176 00-AF 40178 00-B1 40180 00-B3 40182 00-B5 40184 00-B7 40186 00-B9 40188 00-BB 40190 00-BD 40192 00-BF 40194 00-C1 40196 00-C3 40198 00-C5 40200 00-C7 40202 00-C9 40204 00-CB 40206 00-CD 40208 00-CF 40210 00-D1 40212 00-D3 40214 00-D5 40216 00-D7 40218 00-D9 40220 00-DB 40222 00-DD 40224 00-DF 40226 00-E1 40228 00-E3 40230 00-E5 40232 00-E7 40234 00-E9 40236 00-EB 40238 00-ED 40240 00-EF 40242 00-F1 40244 00-F3 40268 01-0B 40270 01-0D 40272 01-0F 40274 01-11 40276 01-13 40278 01-15 40280 01-17 40282 01-19 40284 01-1B 40286 01-1D 40288 01-1F 40298 01-29 40300 01-2B 40302 01-2D 40304 01-2F Signed IEEE 32-Bit Float Absolute Relative Address Address (Decimal) (hex) 43165 0C-5C 43167 0C-5E 43169 0C-60 43171 0C-62 43173 0C-64 43175 0C-66 43177 0C-68 43179 0C-6A 43181 0C-6C 43183 0C-6E 43185 0C-70 43187 0C-72 43189 0C-74 43191 0C-76 43193 0C-78 43195 0C-7A 43197 0C-7C 43199 0C-7E 43201 0C-80 43203 0C-82 43205 0C-84 43207 0C-86 43209 0C-88 43211 0C-8A 43213 0C-8C 43215 0C-8E 43217 0C-90 43219 0C-92 43221 0C-94 43223 0C-96 43225 0C-98 43227 0C-9A 43229 0C-9C 43231 0C-9E 43233 0C-A0 43235 0C-A2 43237 0C-A4 43239 0C-A6 43241 0C-A8 43243 0C-AA 43267 0C-C2 43269 0C-C4 43271 0C-C6 43273 0C-C8 43275 0C-CA 43277 0C-CC 43279 0C-CE 43281 0C-D0 43283 0C-D2 43285 0C-D4 43287 0C-D6 43297 0C-E0 43299 0C-E2 43301 0C-E4 43303 0C-E6 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 103 CMC TECHNICAL REFERENCE MANUAL Signed 16 Bit Exponent Absolute Relative Holding Register Name - Read/Write Address Address (Decimal) (hex) Inlet Valve, MaxLoad, Proportional Constant 40313 01-38 Inlet Valve, MaxLoad, Integral Constant 40315 01-3A Inlet Valve, MaxLoad, Derivative Constant 40317 01-3C Inlet Valve, MinLoad, Proportional Constant 40319 01-3E Inlet Valve, MinLoad, Integral Constant 40321 01-40 Inlet Valve, MinLoad, Derivative Constant 40323 01-42 Inlet Valve, Pressure, Proportional Constant 40325 01-44 Inlet Valve, Pressure, Integral Constant 40327 01-46 Inlet Valve, Pressure, Derivative Constant 40329 01-48 Bypass Valve, Pressure, Proportional Constant 40331 01-4A Bypass Valve, Pressure, Integral Constant 40333 01-4C Bypass Valve, Pressure, Derivative Constant 40335 01-4E Compressor Control Mode; 1=Modulate, 2=Autodual 40339 01-52 NOTE: (J1-P1) is interpreted as Connector J1, Pin 1 on the Base Control Module. Unsigned 16 Bit Fraction Absolute Relative Address Address (Decimal) (hex) 40314 01-39 40316 01-3B 40318 01-3D 40320 01-3F 40322 01-41 40324 01-43 40326 01-45 40328 01-47 40330 01-49 40332 01-4B 40334 01-4D 40336 01-4F 40340 01-53 Signed IEEE 32-Bit Float Absolute Relative Address Address (Decimal) (hex) 43313 0C-F0 43315 0C-F2 43317 0C-F4 43319 0C-F6 43321 0C-F8 43323 0C-FA 43325 0C-FC 43327 0C-FE 43329 0D-00 43331 0D-02 43333 0D-04 43335 0D-06 43339 0D-0A Example: See example for Function 04. Function 04 - Read Input Registers Reads the binary content of input registers (MODBUS 3x references) in the slave (CMC Base Control Module). For the CMC, these input registers refer to the Analog Input values. Broadcast is not supported. The CMC is primarily a 32-bit floating-point microprocessor controller. And, since MODBUS is designed to be a 16-bit system, the CMC supports two methods for determining the value for each holding register. (This also applies to Input Registers.) The first method uses two 16-bit integers to represent the integer and fraction part of the value. The second method uses one 32-bit IEEE floating point number. NOTE Since MODBUS is a 16-bit system, the programmer must get two 16-bit numbers and combine them into one 32-bit floating-point number. For those who would like to only get the 16-bit integer value, this will work well for most inputs; however, the CMC has some inputs, like vibration, that are typically less than one. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 104 CMC TECHNICAL REFERENCE MANUAL Signed Unsigned Signed 16-Bit Integer 16-Bit Fraction IEEE 32-Bit Float Absolute Relative Absolute Relative Absolute Relative Input Register Name - Read Only* Address Address Address Address Address Address (Decimal) (hex) (Decimal) (hex) (Decimal) (hex) Analog Input, Channel 1 (J2-P1,3) 30003 00-02 30004 00-03 33003 0B-BA Analog Input, Channel 2 (J2-P5,7) 30005 00-04 30006 00-05 33005 0B-BC Analog Input, Channel 3 (J1-P1) 30007 00-06 30008 00-07 33007 0B-BE Analog Input, Channel 4 (J1-P4) 30009 00-08 30010 00-09 33009 0B-C0 Analog Input, Channel 5 (J1-P5) 30011 00-0A 30012 00-0B 33011 0B-C2 Analog Input, Channel 6 (J1-P8) 30013 00-0C 30014 00-0D 33013 0B-C4 Analog Input, Channel 7 (J1-P9) 30015 00-0E 30016 00-0F 33015 0B-C6 Analog Input, Channel 8 (J1-P12) 30017 00-10 30018 00-11 33017 0B-C8 Analog Input, Channel 9 (J1-P13) 30019 00-12 30020 00-13 33019 0B-CA Analog Input, Channel 10 (J1-P16) 30021 00-14 30022 00-15 33021 0B-CC Analog Input, Channel 11 (J1-P17) 30023 00-16 30024 00-17 33023 0B-CE Analog Input, Channel 12 (J1-P20) 30025 00-18 30026 00-19 33025 0B-D0 Analog Input, Channel 13 (J1-P21) 30027 00-1A 30028 00-1B 33027 0B-D2 Analog Input, Channel 14 (J1-P24) 30029 00-1C 30030 00-1D 33029 0B-D4 Analog Input, Channel 15 (J1-P25) 30031 00-1E 30032 00-1F 33031 0B-D6 Analog Input, Channel 16 (J1-P28) 30033 00-20 30034 00-21 33033 0B-D8 Analog Input, Channel 17 (J1-P29) 30035 00-22 30036 00-23 33035 0B-DA Analog Input, Channel 18 (J1-P32) 30037 00-24 30038 00-25 33037 0B-DC Analog Input, Channel 19 (J1-P33) 30039 00-26 30040 00-27 33039 0B-DE Analog Input, Channel 20 (J1-P36) 30041 00-28 30042 00-29 33041 0B-E0 Analog Input, Channel 21 (J1-P37) 30043 00-2A 30044 00-2B 33043 0B-E2 Analog Input, Channel 22 (J1-P40) 30045 00-2C 30046 00-2D 33045 0B-E4 Analog Input, Channel 23 (J1-P41) 30047 00-2E 30048 00-2F 33047 0B-E6 CT Input (J9-P1,2) 30049 00-30 30050 00-31 33049 0B-E8 NOTE: (J1-P1) is interpreted as Connector J1, Pin 1 on the Base Control Module. * IMPORTANT: These Input Registers are defined as read only. If you decide to write to these Input Registers, unexpected results could occur. Example: Read Single Channel 16-Bit Integer and Fraction After reviewing the Electrical Schematic for your compressor, you determine that the analog input for System Pressure is located on J1-P1 (Channel 3). From the table above, the Absolute Address is decimal 30007 (Relative Address is hexadecimal 0006) for the input in question. Therefore, to read the 16 Bit Integer and 16 Bit Fraction for System Pressure the following command is issued (the following data are presented in hexadecimal format): Device Address 01 Function Code 04 Number of Registers Hi Lo 00 02 Address Hi Lo 00 06 CRC Lo 91 Hi CA The response from this command is: Data Device Address 01 Function Code 04 Byte Count 04 Reg-1 Hi 00 Reg-2 Lo 64 Hi 13 CRC Lo 4E Lo 37 Hi 5F Register 1 is the Integer portion of the System Pressure or (0064h, 100 decimal). Register 2 is the Fraction portion of the System Pressure or (134Eh, 4942 decimal). Each fraction has a range between 0 and 9999. So the System Pressure, expressed as a floating point number is 100.4942 psi. Example: Read Single Channel IEEE 32-Bit Floating Point Number To continue with the example, when you decide to get the System Pressure as an IEEE 32 Bit floating point number you must issue the following command: 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 105 CMC TECHNICAL REFERENCE MANUAL Device Address 01 Function Code 04 Number of Registers Hi Lo 00 02 Address Hi Lo 0B BE CRC Lo 13 Hi CB The response from this command is: Data Device Address 01 Function Code 04 Byte Count 04 Reg-1 Hi 42 Reg-2 Lo DC Hi D4 CRC Lo C6 Lo F1 Hi 54 So the System Pressure, expressed as a floating point number is 110.4155731201 psi. IEEE floating-point numbers are represented in 32 bits as shown below. 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 exponent 9 8 7 6 5 4 3 2 1 0 mantissa sign Convert hexadecimal registers 1 and 2 (Reg-1, Reg-2) into decimal values ... Register 1 1 2 2 Byte Hi Lo Hi Lo Symbol R1HB R1LB R2HB R2LB Hex 42 DC D4 C6 Decimal 66 220 212 198 Determine the sign (positive = 0 or negative = 1) ... Sign = (R1HB And 128) / 128, where And is defined as a bit-wise And Sign = (66 And 128) / 128 = 0 Determine the exponent ... Exponent = ((R1HB And 127) ∗ 2) + INT(R1LB / 128), where INT is defined as INTEGER Exponent = ((66 And 127) ∗ 2) + INT(220/128) = 133 Determine the mantissa... Mantissa = ((((R1LB And 127) ∗ 256) + R2HB) ∗ 256) + R2LB Mantissa = ((((220 And 127) ∗ 256) + 212) ∗ 256) + 198 = 6083782 Putting the 32 bit IEEE value together... Value = (-1sign) ∗ (2(exponent - 127)) ∗ ((Mantissa ∗ 2-23) + 1) Value = (-10) ∗ (2(133- 127)) ∗ ((6083782 ∗ 2-23) + 1) = 110.4155731201 NOTE When Sign = Exponent = Mantissa = 0, Value = 0. This is a special case for the above equation. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 106 CMC TECHNICAL REFERENCE MANUAL Example: Read Multiple Channels The procedure for reading multiple channels is the same as reading a single channel with the exception of requesting more data. NOTE: You must read a contiguous group of registers (channels) for a single command. Function 05 - Force Single Coil Forces a single coil (MODBUS 0x references) to either ON or OFF. When broadcast, the function forces the same coil reference in all attached slaves. Refer to the table below for MODBUS Absolute Addresses for each coil supported by the CMC-MODBUS Interface. NOTE The Force Single Coil command will override the CMC’s current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the CMC logic. CAUTION For all of the following Remote Coils, the compressor’s REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch must be in the ENABLED position for these commands to execute. When DISABLED, the CMC ignores (there is no exception response) these coils being forced ON or OFF. Absolute Address (decimal) 00221 00222 00223 00224 00225 00226 Relative Address (hex) 00-DC 00-DD 00-DE 00-DF 00-E0 00-E1 Coil Name - Write Only Remote Horn Silence (Acknowledge) Remote Reset Remote Load Remote Unload Remote Start Remote Stop Example: Forcing a Coil For all MODBUS devices, a value of FF 00 hex requests the coil to be ON. A value of 00 00 requests it to be OFF. All other values are illegal and will not affect the coil. NOTE: For the CMC, forcing the above listed coils OFF is not meaningful because the default state of each of the above coils is OFF. When using these commands, they should be sent once (momentary) and the CMC will execute the commands. To remotely reset the compressor, the following command is issued: Device Address 01 Function Code 05 Address Hi Lo 00 DD Forced Data Hi FF CRC Lo 00 Lo 1C Hi 00 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 107 CMC TECHNICAL REFERENCE MANUAL The response from this command is identical to the command sent: Device Address 01 Function Code 05 Address Hi Lo 00 DD Number of Registers Hi Lo FF 00 CRC Lo 1C Hi 00 Function 06 - Preset Single Register Presets a value into a single holding register (MODBUS 4x reference). When broadcast, the function presets the same register reference in all attached slaves. Refer to the table for the Holding Register list for the MODBUS Absolute Addresses supported by the CMCMODBUS Interface. NOTE The Preset Single Register command will override the CMC’s current state. The preset value will remain valid in the register until the CMC logic next solves the register contents. The register's value will remain if it is not programmed in the controller's logic. CAUTION This function can only set a single 16-bit holding register. Since the CMC operates with 32-bit values, you must use Function 16 (10 Hex) - Preset Multiple Registers for setting the 32-bit IEEE register values. Also, you may not set the 16-bit fraction without its 16-bit integer. Therefore, you must use the Preset Multiple Registers function to send this 32-bit pair. See the examples that follow for Function 16. CAUTION The position of the REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor’s Control Panel. Example: Presetting a Single Register (16-bit) Integer To change the integer value for the User Pressure Setpoint (absolute address 40269, relative address 01-0C) to 100 (00-64 hex) psi, send the following command... 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 108 CMC TECHNICAL REFERENCE MANUAL Device Address 01 Function Code 06 Address Hi Lo 01 0C Register Value Hi Lo 00 64 CRC Lo 49 Hi DE The response from this command is identical to the command sent: Device Address 01 Function Code 06 Address Hi Lo 01 0C Register Value Hi Lo 00 64 CRC Lo 49 Hi DE Function 15 (0F Hex) - Force Multiple Coils Forces each coil (MODBUS 0x reference) in a series of contiguous coils to either ON or OFF. When broadcast, the function forces the same coil references in all attached slaves (CMC Base Control Modules). Refer to the table for the Coil list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface. NOTE The Force Multiple Coils command will override the CMC’s current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic. CAUTION The position of the REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor’s Control Panel. Example: Forcing Multiple Coils To force a reset (absolute address 00222, relative address DD) and start (absolute address 00225, relative address E0) of the compressor the following command is sent... Device Address 01 Function Code 0F Address Hi Lo 00 DD Number of Coils Hi Lo 00 04 Number of Data Bytes 01 Coil Data Lo 09 CRC Lo 12 Hi 83 The number of contiguous coils is four (00225, 00224, 00223 and 00222). The number of data bytes is one because we can set up to eight coils in a single byte. The coil data is nine 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 109 CMC TECHNICAL REFERENCE MANUAL because we want to set the first bit and fourth bit in the byte (0000-1001, the bytes are numbered right to left). All bits not used are padded with zero. The response from this command is similar to the command sent except that the number of data bytes and the coil data themselves are not echoed: Device Address 01 Function Code 0F Address Hi Lo 00 DD Number of Coils Hi Lo 00 04 CRC Lo Hi C4 32 Function 16 (10 Hex) - Preset Multiple Registers Presets values into a sequence of contiguous holding registers (MODBUS 4x references). When broadcast, the function presets the same register references in all attached slaves (CMC Base Control Modules). Refer to the table for the Input Register list for the MODBUS Absolute Addresses supported by the CMC-MODBUS Interface. NOTE The Preset Multiple Registers command will override the CMC’s current state. The forced state will remain valid until the CMC next solves the register. The register will remain forced if it is not programmed in the controller's logic. CAUTION The position of the REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor’s Control Panel. Example: Presetting Holding Registers for 32-bit Values The difficulty in setting 32-bit values is determining the four data bytes for the number you want to send. The process required is... 1. Determine the sign (positive = 0 or negative = 1). This is the first bit. 2. Divide the decimal value by 2 until the result is less than 2, but greater than 1. Count the number of iterations required. Add 127 to the number of iterations. This result is the exponent. Convert this result to binary. These are the next eight bits. 3. From the result obtained from step 2, subtract 1. Then, multiply this result by 2. If the result is less than 1, then the value of the first mantissa bit is 0. Otherwise, the mantissa bit is 1. If the result is greater than or equal to 1, then subtract 1 from the result and proceed with step 3 until the result is 0 or you have gone through this process 23 times. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 110 CMC TECHNICAL REFERENCE MANUAL 4. Combine all 32 bits from the steps above and convert this value to hexadecimal. These 32 bits are the 4 hexadecimal data bytes needed for the command. As an example, we will start with the decimal value of 105.4. 1. Since this is a positive number, the first bit is 0. 2. Determine the exponent bits by ... It took us six iterations to get the result to a number that is less than two and greater than or equal to one. Now, we must add 127 for an exponent of 133. Converting this to binary, the next eight bits are represented as 10000101. Iteration 1 2 3 4 5 6 Iteration 3. Determine the mantissa bits by From the table at right, 0100101100110011001100 represent the next 23 bits. 4. Combining the bits in sign, exponent and then mantissa order ... 0100-0010-1101-0010-1100-1100-1100-1100 This converts to 42-D2-CC-CC in hexadecimal. To change the holding registers for user pressure setpoint (for 32 bit IEEE floating point numbers the absolute address is 43269, relative address 0C-C4) to 105.4, issue the following command... Device Address 01 Function Code 10 Address Hi Lo 0C C4 Number of Registers Hi Lo 00 02 Number of Data Bytes 04 Decimal 105.40000 52.70000 26.35000 13.17500 6.58750 3.29375 Data Bytes for Register #1 Hi Lo 42 D2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Decimal 1.646875 1.29375 0.5875 1.175 0.35 0.7 1.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 Data Bytes for Register #2 Hi Lo CC CC / / / / / / 2 2 2 2 2 2 Operatio n -1*2= -1*2= *2= -1*2= *2= *2= -1*2= *2= -1*2= -1*2= *2= *2= -1*2= -1*2= *2= *2= -1*2= -1*2= *2= *2= -1*2= -1*2= *2= Result 52.700000 26.350000 13.175000 6.587500 3.293750 1.646875 = = = = = = Result Bit 1.29375 0.5875 1.175 0.35 0.7 1.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1 0 1 0 0 1 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 CRC Lo 4A Hi 18 The response from this command is similar to the command sent except that the number of data bytes and the data bytes themselves are not echoed: Device Address 01 Function Code 10 Address Hi Lo 0C C4 Number of Registers Hi Lo 00 02 CRC Lo 03 Hi 65 NOTE Sending 32 bit values are typically not necessary. Sending the data as a 16 bit integer only or a 16 bit integer and 16 bit fraction will satisfy most requirements. Some systems have 32 bit capability built directly into their products. We have provided this feature for those systems. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 111 CMC TECHNICAL REFERENCE MANUAL CAUTION The position of the REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor’s Control Panel. Example: Presetting a 16-bit Integer and 16-bit Fraction Holding Register Change the integer and fraction value for the user pressure setpoint (absolute address 40269, relative address 01-0C) to 110.5 psi. The integer portion of the number 110 (00-6E hex) is placed at address 40269 and the fraction 0.5 is converted to 5000 (13-88 hex) and is placed at address 40270 (or the second data byte). To change the register, issue the following command... Device Address 01 Function Code 10 Address Hi Lo 01 0C Number of Registers Hi Lo 00 02 Number of Data Bytes 04 Data Bytes for Register #1 Hi Lo 00 6E Data Bytes for Register #2 Hi Lo 13 88 CRC Lo 92 Hi E1 The response from this command is similar to the command sent except that the number of data bytes and the data bytes themselves are not echoed: Device Address 01 Function Code 10 Address Hi Lo 01 0C Number of Registers Hi Lo 00 02 CRC Lo 80 Hi 37 Exception Responses Except for broadcast messages, when a master device sends a query to a slave device it expects a normal response, in all other cases a time out or exception response is returned. The four possible responses to a the master's query are: • If the slave device receives the query without a communication error, and can handle the query normally, it returns a normal response. • If the slave does not receive the query due to a communication error, no response is returned. The master program will eventually process a time-out condition for the query. • If the slave receives the query, but detects a communication error (parity, or CRC), no response is returned. The master program will eventually process a time-out condition for the query. • If the slave receives the query without a communication error, but cannot handle it (for example, if the request is to read a nonexistent coil or register), the slave will return an exception response informing the master of the nature of the error. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 112 CMC TECHNICAL REFERENCE MANUAL The exception response message has two fields that differentiate it from a normal response: Function Code Field For a normal response, the UCM echoes the function code of the original query in the function code field of the response. All function codes have their most significant bits set to zero; therefore, the values are always below 80 hexadecimal. When an exception response occurs, the UCM sets the most significant bit of the function code to 1. This makes the function code value in an exception response exactly 80 hexadecimal higher than the value would be for a normal response. 7 1 Most Significant Bit 6 5 4 0 0 0 3 0 Least Significant Bit 2 1 0 0 0 0 With the function code's most significant bit set, the application program can recognize an exception response and can examine the data field for the exception code. Data Field For a normal response, the UCM will return information in the data field (depending upon the query message sent). For an exception response, the UCM returns an exception code in the data field. This defines the UCM’s condition that caused the exception. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 113 CMC TECHNICAL REFERENCE MANUAL Exception Codes Supported by the CMC Microcontroller Code 01 Name Illegal Function Meaning The function code received in the query is not an allowable action for the slave. This exception code happens when: (1) the function code is other than 1, 2, 3, 4, 5, 6, 15 or 16 (2) a message has the incorrect number of bytes for the function specified 02 Illegal Data Address The data address received in the query is not an allowable address for the slave. This exception code happens when: (1) the address is not programmed into the Base Control Module (BCM) (2) the address is outside of the ranges (a) 00001-00512 for coils (b) 10001-10512 for discrete inputs (c) 30001-31024 for integer and fractional analog inputs (d) 33001-34024 for floating point analog inputs (e) 40001-41024 for integer and fractional input registers (f) 43001-44024 for floating point analog input registers 03 Illegal Data Value A value contained in the query data field is not an allowable value for the slave. This exception code happens when: (1) the number of coils, discrete inputs, registers or analog inputs is equal to zero (2) request for more than the maximum number of parameters (3) the force single coil command, Function 05, is issued and the value is other than FF00 or 0000 (4) the force multiple coil command, Function 15, is issued and the number of bytes does not equal the number of bits to set (5) the preset single register command, Function 6, and preset multiple registers commands, Function 16, is issued and the starting address is not even, the number of registers specified does not correspond to the number of bytes in the message, the integer part of the number is outside the range –32768 to +32767, the fractional part of the number is outside of the range 0-9999, or the value is not a valid 32 bit IEEE floating point number 04 Slave Device Failure An unrecoverable error occurred while the slave was attempting to perform the requested action. This exception code happens when: (1) no response from the Base Control Module (BCM) since 800 milliseconds from the time the message was sent … BCM not wired properly, BCM hardware problem or BCM Module ID not equal to one (2) when there is an unexpected response from the BCM … this is the default exception response Maximum Query / Response Parameters The listing below shows the maximum amount of data that the CMC Microcontroller can return in a single slave response from a valid MODBUS command. Function Dec Hex 01 01 02 02 03 03 04 04 05 05 06 06 15 0F 16 10 Description Read Coil Status Read Input Status Read Holding Registers Read Input Registers Force Single Coil Preset Single Register Force Multiple Coils Preset Multiple Registers Maximum Parameters 512 coils 512 inputs 64 registers 64 registers 1 coil 1 register 512 coils 64 registers CMC Data The CMC Microcontroller supports several data types. They are coil, integer, fraction and floating point. • Coil - 1 bit, 1 means True or Active, 0 means False or Not Active. • Integer - 16 bit signed integer, –32768 to +32767. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 114 CMC TECHNICAL REFERENCE MANUAL • Fraction - 16 bit unsigned integer, 0 – 9999, represents the decimal (fractional) part of the number (1 represents 0.0001, 10 represents 0.0010, 100 represents 0.0100 and 1000 represents 0.1000). • Floating Point - 32 bit IEEE number (requires reading two registers to get full number). For example if the System Pressure input is located on Channel 3 (address 30007) and the value of the pressure is 100.5 then: Address 30007 contains 100 Address 30008 contains 5000 Address 33007 contains the high 16 bits of the IEEE value for 100.5 Address 33008 contains the low 16 bits of IEEE value for 100.5 Additionally, the type of data in a location determines the commands that can be used to access the data. For the previous example of System Pressure addresses 00007, 03007, 10007, 13007, 40007 and 43023 return errors because coil, input status and holding register commands cannot read input register data. Scaling and Units of Measure The MODBUS data are scaled in English engineering units. All pressures are in psi, temperatures in degrees F, vibrations in mils, and current in amps. For example, when the CMC Operator User Interface displays the system pressure as 7.73 kg/cm2, the value for system pressure obtained through MODBUS communications is 110 psi. Communication Parameters Configuration of the communication speed (baud rate), parity, number of data bits and number of stop bits is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 115 The CMC-DF1 Interface Introduction Customers may want to communicate to the CMC control systems for remote compressor control and monitoring through their Allen-Bradley data highway plus (DH+) network. Adding Allen-Bradley DF1 protocol to the UCM module allows our customers to incorporate our compressors into their plant-wide Allen-Bradley PLC control system. This communication capability also provides for flexibility in the customer's compressed air operation through remote start, stop, and data gathering for preventative maintenance. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires. One avenue for communicating with the CMC is via DF1 protocol over a full duplex RS-422 link. This requires an Allen-Bradley interface module 1770-KF2 to link our intelligent RS422A asynchronous device, Universal Communication Module (UCM), to the Allen-Bradley DH+ network. The CMC Microcontroller can communicate with other devices over a variety of communication standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), Modicon’s MODBUS, and Allen-Bradley DF1. The built-in ports of the CMC’s Universal Communication Module access communications. This UCMDF1 Interface defines the message structure that a CMC Microcontroller uses to exist on a DH+ network. This interface will allow the DH+ network to gather information and control the compressor. The information presented in these sections that follow do not include the Allen-Bradley DF1 protocol details. Detailed information can be obtained from “Allen-Bradley Publication 1770-6.5.117 - October 1996” - DF1 Protocol and Command Set Reference Manual and “Data Highway or Data Highway Plus Asynchronous (RS-232-C or RS-422-A) Interface Module (Cat. No. 1770-KF2) User’s Manual”. A DH+ link implements peer-to-peer communication with a token-passing scheme to rotate mastership among the nodes connected to that link. In order to communicate over AllenBradley DH+ network, an Allen-Bradley 1770-KF2 interface module must be used. The 1770-KF2 always acts as one node on the DH+ network, which translates DH+ messages to DF1 format, and passes these messages on to the UCM on the RS-422A asynchronous end, or vice versa. The following is a picture of 1770-KF2: 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 116 CMC TECHNICAL REFERENCE MANUAL Full-Duplex Protocol The UCM-DF1 interface only supports the point-to-point full-duplex DF1 protocol, which is like a two-lane bridge; traffic can travel in both directions at one time. Full-duplex protocol also provides higher performance applications to get the highest possible throughput. DF1 Full-Duplex Protocol Message Frames The following table shows the general format of a DF1 full-duplex message frame. The control symbols DLE STX bytes are sender symbols indicating the start of a message frame. The control symbols DLE ETX BCC (CRC) bytes are sender symbols that terminates a message frame. The bytes comprised in the command data field vary from command to command. DLE STX DST SRC CMD STS TNS Command Data DLE ETX BCC(CRC) NOTE The standard definitions of the control characters used by DF1 full-duplex protocol are listed below: Abbreviation STX ETX ENQ ACK DLE NAK Hexadecimal Value 02 03 05 06 10 0F DF1 Device Address Configuration of the DF1 device address is available through the Ingersoll-Rand UCMWizard Tool and will be configured by a certified Ingersoll-Rand Service Representative. CAUTION The UCM must be configured to have the same node address as 1770-KF2 interface module. Otherwise, the DF1 messages will not be relayed to the IRBUS port of the UCM. Destination (DST) Byte This byte indicates the destination node address for the message. For a command message, it will be the address of the 1770-KF2 module. The UCM must have the same address as the 1770-KF2, which can be configured using the Ingersoll-Rand UCM-wizard software. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 117 CMC TECHNICAL REFERENCE MANUAL Source (SRC) Byte This byte indicates the source node address of the message. If the command is initiated from an Allen-Bradley PLC, the SRC byte will be the address of the processor module. Command (CMD) and Function (FNC) Bytes The CMD byte defines the command type. The FNC byte defines the specific function under that command type. These bytes together define the activity being performed by the command message at the destination node. The message format depends on the CMD and FNC values. CMD Byte Bit: 7 0 6 0:Command msg 1:Reply msg 5 0: normal priority(for DH+) 1: high priority(only applies to DH link) 4 0 3 2 1 0 Command code From the figure above, the CMD byte of a reply message for DH+ network is always 40h ORed with the CMD byte of its original command message. Status (STS) Byte - Status Error Code Bit: 7 6 5 4 Remote Error Nibble 3 2 1 0 Local Error Nibble Bits 7, 6, 5, and 4 are used to report remote errors - errors that occur when the command executor at the destination node tries to execute the command message. Bits 3, 2, 1, and 0 are used to report local errors - errors found by the local source node and code 09h through 0Fh are not used. The UCM-DF1 driver uses mainly the higher nibble to report errors occur in CMC. A special error code with non-zero local error nibble, 3Fh, is used to report errors caused by illegal CMC data table address or count. The maximum number of data table entries allowed to be read or set for CMC is 16 currently. If a read command requests more than 16 data items from CMC, an exception response of 3Fh will be returned. Following is a list of status error code supported by the UCM-DF1 driver: Transaction (TNS) Bytes The two TNS bytes contain a unique 16-bit transaction identifier. Generate this number by maintaining a 16-bit counter. Increment the counter each time your command initiator creates a new message, and store the counter value in the two TNS bytes of the new message. You must use only one TNS counter in a multi-tasking environment. If the command initiator is an Allen-Bradley PLC, the PLC will maintain the counter internally. The reply message should have the same TNS value as the original command message. The UCM-DF1 driver copies the original TNS field of the command message into the TNS field of the corresponding reply message. BCC (Block Check Character) and CRC (Cyclic Redundancy Check) At the end of each DF1 command message, there is a one-byte BCC field, or a two-byte CRC field for error checking. These bytes allow you to verify the accuracy of each message frame transmission. SW-1 of 1770-KF2 module allows you to select BCC or CRC error checking for the command messages sent to CMC. The Ingersoll-Rand UCM-wizard 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 118 CMC TECHNICAL REFERENCE MANUAL software allows you to configure BCC or CRC error checking for the UCM-DF1 driver, which needs to be the same error checking method as 1770-KF2. BCC (One Byte) The BCC field contains the 2’s compliment of the 8-bit sum of all data bytes between DLE STX and DLE ETX BCC control characters. BCC provides a medium level of data security. It cannot detect either the transposition of bytes during transmission nor the insertion or deletion of the value zero within a message frame. Another way to quickly determine a BCC value, add up the hex values of all data bytes between DLE STX and DLE ETX BCC in the message frame. If the total is greater than 100h, drop the most significant digit, and then subtract the result from 100h. This gives you the BCC. CRC (Two Bytes) This provides a higher level of data security than BCC but is more difficult to implement. All the data bytes between DLE STX and DLE ETX CRC plus the ETX byte are used to calculate the CRC value. The following explains how to calculate the CRC value: • Before starting the calculation, a 16-bit register used to store the CRC value is cleared to be zero. • As a byte is fetched from the data buffer, it is XORed (least-significant bit to the right) with the right eight bits of the CRC register. • The result is placed in the right eight bits of the CRC register. • Inserting 0s on the left then shifts the 16-bit CRC Register right eight times. Each time a 1 is shifted out on the right, the CRC register is XORed with a 16-bit constant A0-01h. • As each additional byte is fetched, it is included in the value in the register the same way. • After the ETX byte transmitted is also included in the calculation, the CRC calculation is complete. The 16-bit CRC value is transmitted low byte first then high byte. Comparing the calculated BCC/CRC bytes with the received BCC/CRC bytes always validates the DF1 messages received by UCM. CAUTION To transmit the data value of 10 hex, you must use the data symbol DLE DLE (double-stuffing DLEs). However, only one of these DLE bytes is included in the BCC/CRC calculation. However, if your BCC check sum is 10 hex, send it as DLE and not DLE DLE. The rest of this section explains the meaning of the data bytes between DLE STX and DLE ETX BCC/CRC control characters. Usually, a command message stripping off the control characters has the following format, 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 119 CMC TECHNICAL REFERENCE MANUAL DST SRC CMD STS TNS command specific data packet a reply message to a read command has the format below, SRC DST CMD STS TNS command specific data packet a reply message to a write command has the following format, SRC DST CMD STS TNS The DST and SRC bytes of a reply message are formed by interchanging the DST and SRC bytes of the corresponding command message. The combination of SRC, CMD, and TNS bytes uniquely identifies every message packet. If all fields are the same, the message is considered to be a duplicate. The UCM-DF1 driver does not detect duplicate messages. Scaling and Units of Measure The MODBUS data are scaled in English engineering units. All pressures are in psi, temperatures in degrees F, vibrations in mils, and current in amps. For example, when the CMC Operator User Interface displays the system pressure as 7.73 kg/cm2, the value for system pressure obtained through MODBUS communications is 110 psi. Data Addressing The CMC is primarily a 32-bit floating-point microprocessor controller. We support two methods for determining the analog data value. These methods are two 16-bit integers representing the integer and fraction part of the number and one 32-bit IEEE floating point number. (NOTE: If you use the 16-bit system, you must get two 16-bit numbers and combine them into one 32-bit floating point number.) The UCM-DF1 interface can prepare data as either two 16-bit integers or one 32-bit floating point number with respect to the received DF1 command. The Allen-Bradley PLC floating point format is a subset of IEEE STD 754-1985. Accessing data from the CMC via DF1 interface emulates accessing data from a PLC5 or SLC5/04. In SLC 5/04, each data file can hold up to 256 data elements (element number: 0255) and the file number has to be in the same range (0-255). The UCM-DF1 addressing scheme uses this file/element structure and complies with the SLC5/04’s limits on file number and element number. Please see next section for details. A DF1 command initiator is a device on the DH+ network that initiates the query or set commands to the CMC. It can be an Allen-Bradley PLC or other device that can send/receive a PLC5 Typed Read (Write) or SLC Typed Logical Read (Write) command/response. CMC as PLC5 As to treating CMC as a PLC5, the command initiator can issue a PLC5 Typed Read (Write) command to the CMC. Please see the section on Supported Functions for detailed message format. For a PLC5 Typed Write command, the data can be sent as either two 16-bit integers or one 32-bit floating point. If a PLC5 or SLC5/04 issues the command, the setpoint data type is determined by the local data file type used to store it. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 120 CMC TECHNICAL REFERENCE MANUAL The PLC5 Typed Read commands for requesting data in integer or float format is exactly the same messages. The UCM-DF1 driver cannot tell the requested data type from the command bytes received. Therefore, the returned data type has to be pre-configured in UCM via the Ingersoll-Rand UCM-wizard tool. Default is the integer type. If a PLC5 or SLC5/04 issues the command, the local data file used to store the gathered data should be the same type. Otherwise, you get erroneous data or an error status code due to data type mismatch. CMC as SLC5/04 As to treating a CMC as a SLC5/04, the command initiator can issue a SLC Typed Logical Read (Write) command to the CMC. Please see the section on Supported Functions for detailed message format. If the command initiator is another SLC5/04, you can do either integer or float data type. However, if the command initiator is a PLC5, only integer type is supported for the time being. Data File Addressing for PLC5/SLC504 When RSLogix software is used to program message instructions in PLC for sending read/write commands to the CMC, the target data table address is in the form of either Fxx:yyy or Nxx:yyy, where xx is the file number (10-14) and yyy (0-255) is the corresponding CMC data table address. The target file type (F for float, N for integer) should be consistent with the local file type. NOTE File numbers 10-14 are reserved for address only! The UCM-DF1 interface designates file number 10 for discrete usage (READ ONLY). Each element represents 16 Boolean data bit-packed together in two bytes. File type can be either N (integer) or B (bit) type. The following table shows the address in file 10 for discrete values. PLC File Address B10:10 B10:11 B10:12 B10:13 CMC Data Table Address (decimal) 160-175 176-191 192-207 208-223 15 175 191 207 223 14 174 190 206 222 13 173 189 205 221 12 172 188 204 220 11 171 187 203 219 16 Discretes Packed as Binary Bits in Two Bytes 10 9 8 7 6 5 170 169 168 167 166 165 186 185 184 183 182 181 202 201 200 199 198 197 218 217 216 215 214 213 4 164 180 196 212 3 163 179 195 211 2 162 178 194 210 1 161 177 193 209 0 160 176 192 208 Bit 10-15 of integer element 10 in data file 10 represents digital input channels 1-6 (CMC data table address 170-175). Bit 0-9 of integer element 11 represent digital input channels 7-16 (CMC data table address 176-185). Bit 10-15 of integer element 11 represents digital output channels 1-6 (CMC data table address 186-191). Bit 0-9 of integer element 12 represent digital output channels 7-16 (CMC data table address 192-201). Bit 10-15 of integer element 11 represents digital output channels 1-6 (CMC data table address 186191). Bit 10-15 of integer element 12 and bit 0-10 of integer element 13 represent various compressor states (CMC data table address 202-218). Currently, CMC data table has 512 entries. In order to satisfy the (0-255) limit of elements per data file for SLC5/04, the CMC data table is divided into two segments; each has 256 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 121 entries. File number 11 is designated to the first 256 entries. File number 12 is for the second 256 entries. If the CMC data table gets expanded later, the subsequent file number will be used. According to the above, N11:170 refers to the 170-th item in the CMC data table, which is the digital input channel 1. Similarly, N12:170 will be the 426-th = (170+256) item in the CMC data table. If an invalid file or element number is used, you will get a 3Fh-status error code. See the status error code section for details. The number of bytes per element is 2 for integer type and 4 for float type. The assigned message length in elements for local data file should be a multiple of 2 for integer type. If it is an odd number, only the 2-byte integer (whole) part will be transmitted for the last data item. Since the CMC has programmable analog and discrete inputs and outputs, the programmer must use the electrical schematic supplied with the machine to determine which function name and units of measure are associated with each input and output. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 122 CMC TECHNICAL REFERENCE MANUAL CMC Data Addressing Refer to the table below for data addresses supported by the UCM-DF1 Interface. Data Address (decimal) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Data Address (hex) 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 1D 1E 1F 32 33 34 35 36 37 38 39 40 41 20 21 22 23 24 25 26 27 28 29 Analog Input, Ch 1 (J2-P1,3) Analog Input, Ch 2 (J2-P5,7) Analog Input, Ch 3 (J1-P1) Analog Input, Ch 4 (J1-P4) Analog Input, Ch 5 (J1-P5) Analog Input, Ch 6 (J1-P8) Analog Input, Ch 7 (J1-P9) Analog Input, Ch 8 (J1-P12) Analog Input, Ch 9 (J1-P13) Analog Input, Ch 10 (J1-P16) Analog Input, Ch 11 (J1-P17) Analog Input, Ch 12 (J1-P20) Analog Input, Ch 13 (J1-P21) Analog Input, Ch 14 (J1-P24) Analog Input, Ch 15 (J1-P25) Analog Input, Ch 16 (J1-P28) Analog Input, Ch 17 (J1-P29) Analog Input, Ch 18 (J1-P32) Analog Input, Ch 19 (J1-P33) Analog Input, Ch 20 (J1-P36) Analog Input, Ch 21 (J1-P37) Analog Input, Ch 22 (J1-P40) Analog Input, Ch 23 (J1-P41) CT Input (J9-P1,2) Reserved Analog Output, Ch 1 (J3-P1,3) Analog Output, Ch 2 (J3-P4,6) Analog Output, Ch 3 (J3-P7,9) Analog Output, Ch 4 (J3-P10,12) Analog Input, Ch 1 (J2-P1,3) – Hi Trip Setpoint Analog Input, Ch 1 (J2-P1,3) – Hi Alarm Setpoint Data Address (decimal) 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 Data Address (hex) 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 3F 40 41 42 43 44 45 46 47 48 Analog Input, Ch 4 (J1-P4) – Hi Trip Setpoint Analog Input, Ch 4 (J1-P4) – Hi Alarm Setpoint Analog Input, Ch 4 (J1-P4) - Lo Alarm Setpoint Analog Input, Ch 4 (J1-P4) - Lo Trip Setpoint Analog Input, Ch 5 (J1-P5) - Hi Trip Setpoint Analog Input, Ch 5 (J1-P5) - Hi Alarm Setpoint Analog Input, Ch 5 (J1-P5) - Lo Alarm Setpoint Analog Input, Ch 5 (J1-P5) - Lo Trip Setpoint Analog Input, Ch 6 (J1-P8) - Hi Trip Setpoint Analog Input, Ch 6 (J1-P8) - Hi Alarm Setpoint Analog Input, Ch 6 (J1-P8) - Lo Alarm Setpoint Analog Input, Ch 6 (J1-P8) - Lo Trip Setpoint Analog Input, Ch 7 (J1-P9) - Hi Trip Setpoint Analog Input, Ch 7 (J1-P9) - Hi Alarm Setpoint Analog Input, Ch 7 (J1-P9) - Lo Alarm Setpoint Analog Input, Ch 7 (J1-P9) - Lo Trip Setpoint Analog Input, Ch 8 (J1-P12) - Hi Trip Setpoint Analog Input, Ch 8 (J1-P12) - Hi Alarm Setpoint Analog Input, Ch 8 (J1-P12) - Lo Alarm Setpoint Analog Input, Ch 8 (J1-P12) - Lo Trip Setpoint Analog Input, Ch 9 (J1-P13) - Hi Trip Setpoint Analog Input, Ch 9 (J1-P13) - Hi Alarm Setpoint Analog Input, Ch 9 (J1-P13) - Lo Alarm Setpoint Analog Input, Ch 9 (J1-P13) - Lo Trip Setpoint Analog Input, Ch 10 (J1-P16) - Hi Trip Setpoint Analog Input, Ch 10 (J1-P16) - Hi Alarm Setpoint Analog Input, Ch 10 (J1-P16) - Lo Alarm Setpoint Analog Input, Ch 10 (J1-P16) - Lo Trip Setpoint Analog Input, Ch 11 (J1-P17) - Hi Trip Setpoint Analog Input, Ch 11 (J1-P17) - Hi Alarm Setpoint Analog Input, Ch 11 (J1-P17) - Lo Alarm Setpoint Analog Input, Ch 1 (J2-P1,3) – Lo Alarm Setpoint Analog Input, Ch 1 (J2-P1,3) – Lo Trip Setpoint Analog Input, Ch 2 (J2-P5,7) – Hi Trip Setpoint Analog Input, Ch 2 (J2-P5,7) – Hi Alarm Setpoint Analog Input, Ch 2 (J2-P5,7) – Lo Alarm Setpoint Analog Input, Ch 2 (J2-P5,7) – Lo Trip Setpoint Analog Input, Ch 3 (J1-P1) – Hi Trip Setpoint Analog Input, Ch 3 (J1-P1) – Hi Alarm Setpoint Analog Input, Ch 3 (J1-P1) – Lo Alarm Setpoint Analog Input, Ch 3 (J1-P1) – Lo Trip Setpoint 73 74 75 76 77 78 79 80 81 82 49 4A 4B 4C 4D 4E 4F 50 51 52 Analog Input, Ch 11 (J1-P17) - Lo Trip Setpoint Analog Input, Ch 12 (J1-P20) - Hi Trip Setpoint Analog Input, Ch 12 (J1-P20) - Hi Alarm Setpoint Analog Input, Ch 12 (J1-P20) - Lo Alarm Setpoint Analog Input, Ch 12 (J1-P20) - Lo Trip Setpoint Analog Input, Ch 13 (J1-P21) - Hi Trip Setpoint Analog Input, Ch 13 (J1-P21) - Hi Alarm Setpoint Analog Input, Ch 13 (J1-P21) - Lo Alarm Setpoint Analog Input, Ch 13 (J1-P21) - Lo Trip Setpoint Analog Input, Ch 14 (J1-P24) - Hi Trip Setpoint Description Description 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 123 CMC TECHNICAL REFERENCE MANUAL Data Address (decimal) 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 Data Address (hex) 53 54 55 56 57 58 59 5A 5B 5C 5D 5E 5F 60 61 62 63 64 65 66 67 68 69 6A 6B 6C 6D 6E 6F 70 71 72 73 74 75 76 77 78 79 7A 7B 7C 7D 7E 7F 80 81 82 83 84 85 86 87 88 89 8A 8B 8C 8D Description Analog Input, Ch 14 (J1-P24) - Hi Alarm Setpoint Analog Input, Ch 14 (J1-P24) - Lo Alarm Setpoint Analog Input, Ch 14 (J1-P24) - Lo Trip Setpoint Analog Input, Ch 15 (J1-P25) - Hi Trip Setpoint Analog Input, Ch 15 (J1-P25) - Hi Alarm Setpoint Analog Input, Ch 15 (J1-P25) - Lo Alarm Setpoint Analog Input, Ch 15 (J1-P25) - Lo Trip Setpoint Analog Input, Ch 16 (J1-P28) - Hi Trip Setpoint Analog Input, Ch 16 (J1-P28) - Hi Alarm Setpoint Analog Input, Ch 16 (J1-P28) - Lo Alarm Setpoint Analog Input, Ch 16 (J1-P28) - Lo Trip Setpoint Analog Input, Ch 17 (J1-P29) - Hi Trip Setpoint Analog Input, Ch 17 (J1-P29) - Hi Alarm Setpoint Analog Input, Ch 17 (J1-P29) - Lo Alarm Setpoint Analog Input, Ch 17 (J1-P29) - Lo Trip Setpoint Analog Input, Ch 18 (J1-P32) - Hi Trip Setpoint Analog Input, Ch 18 (J1-P32) - Hi Alarm Setpoint Analog Input, Ch 18 (J1-P32) - Lo Alarm Setpoint Analog Input, Ch 18 (J1-P32) - Lo Trip Setpoint Analog Input, Ch 19 (J1-P33) - Hi Trip Setpoint Analog Input, Ch 19 (J1-P33) - Hi Alarm Setpoint Analog Input, Ch 19 (J1-P33) - Lo Alarm Setpoint Analog Input, Ch 19 (J1-P33) - Lo Trip Setpoint Analog Input, Ch 20 (J1-P36) - Hi Trip Setpoint Analog Input, Ch 20 (J1-P36) - Hi Alarm Setpoint Analog Input, Ch 20 (J1-P36) - Lo Alarm Setpoint Analog Input, Ch 20 (J1-P36) - Lo Trip Setpoint Analog Input, Ch 21 (J1-P37) - Hi Trip Setpoint Analog Input, Ch 21 (J1-P37) - Hi Alarm Setpoint Analog Input, Ch 21 (J1-P37) - Lo Alarm Setpoint Analog Input, Ch 21 (J1-P37) - Lo Trip Setpoint Analog Input, Ch 22 (J1-P40) - Hi Trip Setpoint Analog Input, Ch 22 (J1-P40) - Hi Alarm Setpoint Analog Input, Ch 22 (J1-P40) - Lo Alarm Setpoint Analog Input, Ch 22 (J1-P40) - Lo Trip Setpoint Analog Input, Ch 23 (J1-P41) - Hi Trip Setpoint Analog Input, Ch 23 (J1-P41) - Hi Alarm Setpoint Analog Input, Ch 23 (J1-P41) - Lo Alarm Setpoint Analog Input, Ch 23 (J1-P41) - Lo Trip Setpoint Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Surge Pressure Rate Surge Current Rate Motor Current User Pressure Setpoint MinLoad (Throttle Limit, TL) MaxLoad (High Load Limit, HLL) Autodual Reload Percent Autodual Unload Point Autodual Unload Timer Pressure Setpoint Ramp Rate Inlet Valve Unload Position 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Data Address (decimal) 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 Data Address (hex) 8E 8F 90 91 92 93 94 95 96 97 98 99 9A 9B 9C 9D 9E 9F A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 AA AB AC AD AE AF B0 B1 B2 B3 B4 B5 B6 B7 B8 B9 BA BB BC BD BE BF C0 C1 C2 C3 C4 C5 C6 C7 C8 Description Start Timer CT Ratio Reserved Reserved Reserved Reserved Power on hours Running Hours Loaded Hours Number of starts Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Inlet Valve Proportional Constant Inlet Valve Integral Constant Reserved Bypass Valve Proportional Constant Bypass Valve Integral Constant Reserved Reserved Compressor Control Mode Digital Input, Ch 1 (J4-P2) Digital Input, Ch 2 (J4-P3) Digital Input, Ch 3 (J4-P4) Digital Input, Ch 4 (J4-P5) Digital Input, Ch 5 (J4-P6) Digital Input, Ch 6 (J4-P7) Digital Input, Ch 7 (J4-P8) Digital Input, Ch 8 (J4-P9) Digital Input, Ch 9 (J5-P2) Digital Input, Ch 10 (J5-P3) Digital Input, Ch 11 (J5-P4) Digital Input, Ch 12 (J5-P5) Digital Input, Ch 13 (J5-P6) Digital Input, Ch 14 (J5-P7) Digital Input, Ch 15 (J5-P8) Digital Input, Ch 16 (J5-P9) Digital Output, Ch 1 (J15-P7,8) Digital Output, Ch 2 (J15-P5,6) Digital Output, Ch 3 (J15-P3,4) Digital Output, Ch 4 (J15-P1,2) Digital Output, Ch 5 (J14-P7,8) Digital Output, Ch 6 (J14-P5,6) Digital Output, Ch 7 (J14-P3,4) Digital Output, Ch 8 (J14-P1,2) Digital Output, Ch 9 (J13-P7,8) Digital Output, Ch 10 (J13-P5,6) Digital Output, Ch 11 (J13-P3,4) Digital Output, Ch 12 (J13-P1,2) Digital Output, Ch 13 (J12-P7,8) Digital Output, Ch 14 (J12-P5,6) Digital Output, Ch 15 (J12-P3,4) 124 CMC TECHNICAL REFERENCE MANUAL Data Address (decimal) 201 202 203 204 205 206 207 208 209 210 211 212 Data Address (hex) C9 CA CB CC CD CE CF D0 D1 D2 D3 D4 Data Address (decimal) 213 214 215 216 217 218 220 221 222 223 224 225 Description Digital Output, Ch 16 (J12-P1,2) Compressor State - Waiting Compressor State - Coasting Compressor State – Starting Compressor State - Not Ready Compressor State - Ready Compressor State - Surge Unload Compressor State - Autodual Unload Compressor State - Unloading Compressor State - Unloaded Compressor State - Min load Compressor State - Max load Data Address (hex) D5 D6 D7 D8 D9 DA DC DD DE DF E0 E1 Description Compressor State - Loading Compressor State - Loaded Compressor State - Full Load Compressor State - Analog Input Failed Any Compressor Trip Any Compressor Alarm Remote Acknowledge Remote Reset Remote Load Remote Unload Remote Start Remote Stop Supported Functions The listing below shows the DF1 commands supported by the CMC Microcontroller. Command Code (hex) 0F 0F 0F 0F Function Code (hex) 68 67 A2 AA Function Name PLC5 Typed Read PLC5 Typed Write SLC Typed Logical Read SLC Typed Logical Write Command 0F/Function 68 - PLC5 Typed Read The CMC is treated as a PLC5 when this command is issued. This command reads a block of data from CMC starting at a specified data table address. As to the format of floating point number, Allen-Bradley DF1 protocol always put low byte first then high byte, low word first then high word, which is different from the UCMMODBUS protocol. The byte format for a floating point value, 105.4, is differentiated between the two interfaces as below (Byte 1 to 4 is in the order of transmission): Protocol UCM-MODBUS UCM-DF1 Floating Point Byte Representation Byte 1 Byte 2 Byte 3 Byte 4 42 D2 CC CD CD CC D2 42 Example: Reading an Analog Input After reviewing the Electrical Schematic for your compressor, you determine that the analog input for system pressure is located on J1-P1 (Channel 3). From the CMC data table above, the address is 03h. The UCM should be configured to represent data type as desired. Following is a table illustrating how the PLC5 system address is mapped to the CMC data table address. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 125 CMC TECHNICAL REFERENCE MANUAL CMC Data Address 3 254 255 256 259 PLC5 Target Data Table Address N11:3 N11:254 N11:255 N12:0 N12:3 07 07 07 07 07 00 00 00 00 00 PLC5 System Address Element File Number 0B 03 0B FE 0B FF FF 0C 00 0C 03 00 As 16-Bit Integer and Fraction To get the reading of system pressure as 16-bit integer and 16-bit fraction, the following command is issued (data are presented in hexadecimal format): DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS 21 FNC BD 68 Packet Offset 00 00 Total Trans 02 00 PLC5 System Address 07 00 0B 03 Size 02 DLE ETX BCC 00 10 03 74 DLE 10 ETX 03 BCC 03 The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 21 BD A 99 09 B 05 42 64 00 5C 09 In the response above, the first two bytes (low byte first then high byte) in field B is the integer portion of the system pressure (00-64h, 100 decimal). The second two bytes in field B are the fraction portion of the system pressure (09-5Ch, 2396 decimal). Each fraction has a range between 0 and 9999. So the system pressure, expressed as a floating-point number, is 100.2396 PSIG. The following table contains a list of data types and the ID value of each supported by Allen-Bradley DF1 protocol: Data Type ID 1 2 3 4 5 6 7 8 9 15 16 Data Type bit bit string byte (or character) string integer Allen-Bradley timer Allen-Bradley counter Allen-Bradley general control structure IEEE floating point array of similar elements address data binary-coded decimal (BCD) The first byte, 99h, in field A of the above response message is a flag byte, which has the format below: Bit: 7 1 Data Type ID 6 5 0 0 4 1 3 1 Data Type Size 2 1 0 0 0 1 If the data type ID is greater than 7, set bit 7 of this flag byte to 1 and insert the number of bytes to follow that contains the data type ID value in bits 4, 5, and 6. These additional ID bytes follow directly after the flag byte. In the above response message, the additional one byte is 09h, which means array of similar elements. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 126 CMC TECHNICAL REFERENCE MANUAL If the data type defined uses more than 7 bytes for each data element, enter 1 in bit 3 of the flag byte and enter the number of bytes to follow that contains the number of bytes used for each data element. These additional size bytes follow the flag byte and any ID bytes. The individual bytes in field A and B of the above response message is explained in the following table: Field Byte (hex) 99 09 05 42 A Definition flag byte data type ID byte: array of similar elements number of bytes to follow descriptor byte 4: type ID for integer 2: two bytes per element 64 00 5C 09 B 4 data bytes As IEEE 32-Bit Floating Point Number If the UCM is configured to read data as floating point, the following command is sent: DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS 21 FNC BD 68 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0B Size 03 01 00 DLE ETX 10 03 BCC The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 21 BD 99 09 A 06 B 94 08 C6 D4 DC DLE 10 42 ETX 03 BCC The individual bytes in field A and B of the above response message is explained in the table below: Field A B Byte (hex) 99 09 06 94 08 C6 D4 DC 42 means flag byte data type ID byte: array of similar elements number of bytes to follow descriptor byte 9: one byte to follow 4: four bytes per element type ID for floating point 4 data bytes After the proper byte swapping, the system pressure (42-DC-D4-C6), expressed as a floating point number is 110.4155731201 PSIG. IEEE floating-point numbers are represented in 32 bits as shown below. 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 exponent 9 8 7 6 5 4 3 2 1 0 mantissa sign Convert hexadecimal words 1 and 2 (W1, W2) into decimal values ... 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 127 CMC TECHNICAL REFERENCE MANUAL Word Lo 1 Lo 1 Hi 2 Hi 2 Byte Lo Hi Lo Hi Symbol W1LB W1HB W2LB W2HB Hex C6 D4 DC 42 Decimal 198 212 220 66 Determine the sign (positive = 0 or negative = 1) ... Sign = (W2HB And 128) / 128, where And is defined as a bit-wise And Sign = (66 And 128) / 128 = 0 Determine the exponent ... Exponent = ((W2HB And 127) * 2) + INT (W2LB / 128), where INT is defined as INTEGER Exponent = ((66 And 127) * 2) + INT (220/128) = 133 Determine the mantissa... Mantissa = ((((W2LB And 127) * 256) + W1HB) * 256) + W1LB Mantissa = ((((220 And 127) * 256) + 212) * 256) + 198 = 6083782 Putting the 32 bit IEEE value together... Value = (-1sign) * (2(exponent - 127)) * ((Mantissa * 2-23) + 1) Value = (-10) * (2(133- 127)) * ((6083782 * 2-23) + 1) = 110.4155731201 NOTE When Sign = Exponent = Mantissa = 0, Value = 0. This is a special case for the above equation. Example: Read Multiple Analog Channels The procedure for reading multiple channels is the same as reading a single channel with the exception of requesting more data. The message length in elements should be set as desired but no more than 16 data at a time, because IRBUS can handle at most 16 data in one query for the time being. NOTE A contiguous group of data (channels) must be read for a single command. Example: Reading a Discrete Value Reading discrete values from file number 11 or higher is the same as reading analog data. To read a digital output (Channel 3, 188h) as a two-byte integer, the following command is sent: DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS A1 C2 FNC 68 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0B BC Size 01 00 DLE ETX BCC 10 03 38 128 CMC TECHNICAL REFERENCE MANUAL The response to this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS A1 C2 A 99 09 B 03 42 01 DLE 10 00 ETX 03 BCC 48 Example: Reading Multiple Discrete Values To read digital output channels 1-6 as integers, the following command is sent: DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS 41 FNC 17 Packet Offset 00 00 68 Total Trans 0C 00 PLC5 System Address 07 00 0B BA Size 0C 00 DLE ETX BCC 10 03 2F The response to this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 41 17 A 99 09 B 19 42 00 00 00 00 B 00 00 00 00 00 00 00 00 00 00 00 00 DLE 10 00 00 00 ETX 03 00 01 00 00 00 BCC 3D Example: Reading Bit-Packed Discrete Data Reading discrete values from file number 10 is to read the 16 bit-packed discrete values in a two-byte integer format. When the following command is sent, DLE STX DST SRC 10 02 0D 11 CMD STS 0F 00 TNS 61 C4 FNC 68 Packet Offset 00 00 Total Trans 01 00 PLC5 System Address 07 00 0A Size 0B 01 00 DLE ETX BCC 10 03 28 the response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 61 C4 A 99 09 03 42 28 B 10 10 DLE 10 ETX 03 BCC 4F NOTE The data value 10h in field B is transmitted as 10h 10h to be distinguished from the control character DLE. Please see the DF1 Full-Duplex Protocol Message Frames section for more details. In the above example, the local data file type can be either bit or integer types. Local data element B10:11 covers CMC data table address 176-191. Bit 10-15 is for digital output channels 1-6. You can determine the remote trouble contact (Channel 3, J15-P3,4) by bit 12 in the returned integer. The table below graphically depicts the individual bit value for the returned two-byte integer. Response (hex) Byte 1 Bit CMC Data Address 28 Bit CMC Data Address Byte 2 10 7 183 0 15 191 0 6 182 0 14 190 0 5 181 1 13 189 0 4 180 0 12 188 1 3 179 1 11 187 0 2 178 0 10 186 0 1 177 0 9 185 0 0 176 0 8 184 0 A bit response of 1 means that the output is ON and a response of 0 means that the output is OFF. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 129 CMC TECHNICAL REFERENCE MANUAL Command 0F/Function 67 - PLC5 Typed Write CAUTION The position of the REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is NOT considered when forcing coils or writing registers to the CMC. Reads and Writes are always enabled. Repeatedly writing a value to a register or forcing a coil without regard to the position of the switch can effectively disable a local write. Please use caution when writing registers or forcing coils. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor’s Control Panel. The CMC is treated as a PLC5 when this command is issued. This command writes data to the CMC starting at the specified data table address. You can write to a setpoint with either an integer or floating point number. Example: Presetting Analog Setpoints for 32-bit Values To write 105.4 PSIG as a floating point number to the user pressure setpoint (CMC data table address, 86h), issue the following command: DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 81 CE 67 A 06 94 08 CD CC 99 09 TNS FNC Packet Offset 00 00 B D2 42 Total Trans 01 00 DLE 10 ETX 03 PLC5 System Address 07 00 0B 86 BCC 93 The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 81 CE DLE 10 ETX 03 BCC 44 The difficulty in setting 32-bit values is determining the four data bytes for the number you want to send. The process required is ... 1. Determine the sign (positive = 0 or negative = 1). This is the first bit. 2. Divide the decimal value by 2 until the result is less than 2, but greater than 1. Count the number of iterations required. Add 127 to the number of iterations. This result is the exponent. Convert this result to binary. These are the next eight bits. 3. From the result obtained from step 2, subtract 1. Then, multiply this result by 2. If the result is less than 1, then the value of the first mantissa bit is 0. Otherwise, the mantissa bit is 1. If the result is greater than or equal to 1, then subtract 1 from the result and proceed with step 3 until the result is 0 or you have gone through this process 23 times. 4. Combine all 32 bits from the steps above and convert this value to hexadecimal. These 32 bits are the 4 hexadecimal data bytes needed for the command. As an example, we will start with the decimal value of 105.4. 1. Since this is a positive number, the first bit is 0. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 130 CMC TECHNICAL REFERENCE MANUAL 2. Determine the exponent bits by ... Iteration 1 2 3 4 5 6 Decimal 105.40000 52.70000 26.35000 13.17500 6.58750 3.29375 / / / / / / 2 2 2 2 2 2 = = = = = = Result 52.700000 26.350000 13.175000 6.587500 3.293750 1.646875 It took us six iterations to get the result to a number that is less than two and greater than or equal to one. Now, we must add 127 for an exponent of 133. Converting this to binary, the next eight bits are represented as 10000101. 3. Determine the mantissa bits by ... Iteration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Decimal 1.646875 1.29375 0.5875 1.175 0.35 0.7 1.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 0.8 1.6 1.2 0.4 Operation Result - 1 * 2 = 1.29375 -1*2= 0.5875 *2= 1.175 -1*2= 0.35 *2= 0.7 *2= 1.4 -1*2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 *2= 1.6 -1*2= 1.2 -1*2= 0.4 *2= 0.8 Bit 1 0 1 0 0 1 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 From the table above, 10100101100110011001100 represent the next 23 bits. 4. Combining the bits in sign, exponent and then mantissa order ... 0100-0010-1101-0010-1100-1100-1100-1100 This converts to 42-D2-CC-CC in hexadecimal. To conform to DF1 floating point format, the bytes are swapped as CC-CC-D2-42. Example: Presetting a 16-bit Integer and 16-bit Fraction Analog Setpoint To change the integer and fraction value for the user pressure setpoint to 105.4 PSIG, issue the command below. The integer portion of the number 105 (00-69h) and the fraction 0.4 is converted to 4000 (0F-A0h). These four bytes are placed in field B in the order of (6900-A0-0F). 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 131 CMC TECHNICAL REFERENCE MANUAL DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS 41 FNC D0 67 A 99 09 Packet Offset 00 00 B 05 42 69 00 A0 0F Total Trans 02 00 DLE 10 ETX 03 PLC5 System Address 07 00 0B 86 BCC C0 The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 41 D0 DLE 10 ETX 03 BCC 82 Example: Forcing a Coil Forcing a single coil to either ON or OFF. Refer to the table below for each coil supported by the UCM-DF1 interface. An integer value of one or greater forces the coil to be ON. An integer value of zero forces the coil to be OFF. CMC Data Table Address (decimal) 220 221 222 223 224 225 CMC Data Table Address (hex) DC DD DE DF E0 E1 Coil Name (Write only) Remote Acknowledge Remote Reset Remote Load Remote Unload Remote Start Remote Stop NOTE For the CMC, forcing the above listed coils OFF is not meaningful because the default state of each of the above coils is OFF. When using these commands, they should be sent once (momentary) and the CMC will execute the commands. NOTE The Forcing Coil command will override the CMC’s current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 132 CMC TECHNICAL REFERENCE MANUAL CAUTION For all of the Remote Coils, the compressor’s REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch must be in the ENABLED position for these commands to execute. When DISABLED, the CMC ignores these coils being forced ON. The REMOTE COMMUNICATIONS DISABLED/ENABLED selector switch is typically located on the front door of the Compressor’s Control Panel. To remotely acknowledge the compressor’s alarm or trip condition, the following command is issued: DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS E1 FNC F8 67 A 99 09 Packet Offset 00 00 B 03 42 01 Total Trans 01 00 DLE 10 ETX 03 BCC BC TNS E1 F8 DLE 10 ETX 03 00 PLC5 System Address 07 00 0B DC The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 BCC BA The following command works the same: DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS 41 FNC E3 67 A 99 09 Packet Offset 00 00 B 05 42 01 00 00 00 Total Trans 02 00 DLE 10 ETX 03 PLC5 System Address 07 00 0B DC BCC 6E The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 41 E3 DLE 10 ETX 03 BCC 6F Example: Forcing Multiple Coils Forces each coil in a series of contiguous coils to either ON or OFF. Refer to the data table above for a coil list supported by the UCM-DF1 Interface. NOTE The Forcing Multiple Coils command will override the CMC’s current state. The forced state will remain valid until the CMC next solves the coil. The coil will remain forced if it is not programmed in the controller's logic. To force a reset (CMC data table address, DDh) and start (CMC data table address, E0h) of the compressor the following command is sent: 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 133 CMC TECHNICAL REFERENCE MANUAL DLE STX DST SRC CMD STS 10 02 0D 11 0F 00 TNS 21 FNC 0C Packet Offset 00 00 67 A 99 09 11 42 01 00 00 00 01 00 00 Total Trans 08 00 B 01 00 PLC5 System Address 07 00 00 00 00 DLE 10 ETX 03 BCC 66 0B 01 DD 00 00 00 DLE ETX 10 03 The response from this command is: DLE 10 STX 02 DST 11 SRC 0D CMD 4F STS 00 TNS 21 0C The number of contiguous coils is four (DD, DE, DF, and E0h). The message length of integer elements is 8 and the number of data bytes in field B is 16. Command 0F/Function A2 - SLC Typed Logical Read The CMC is treated as an SLC5/04 when this command is issued. This function reads a block of data from CMC starting at a specified data table address. Example: Reading an Analog Value To read the pressure setpoint (CMC data table address 86h) as a floating point number, the following command is issued: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS D4 19 FNC Byte Size A2 04 File No. 0B File Type 8A Ele No. 86 S/Ele No. 00 DLE ETX 10 03 BCC 2B The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS D4 19 CD CC Data D2 42 DLE 10 ETX 03 BCC FF The important command bytes are explained below: Field Byte Size File Number Description The number of data bytes to be read. Address files 0-255 only. For CMC, file 10 is designated for discrete only. File (11+N) is for the (N+1) th 256 entries in the CMC data table. 85h: bit 89h: integer 8Ah: float Address elements 0-255 only. The address byte format is the same as PLC5 for CMC. 254: (FE) 255: (FF-FF-00) Not used, always 00h. File Type Element Number Sub-Element Number The four bytes in data field of the response message are converted to a floating point number, 105.4 PSIG. To read the pressure setpoint value as integer, the following command is sent: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS D4 The response from this command is: 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 27 FNC Byte Size A2 04 File No. 0B File Type 89 Ele No. 86 S/Ele No. 00 DLE ETX 10 03 BCC 1E BCC 4F 134 CMC TECHNICAL REFERENCE MANUAL DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS D4 27 69 00 Data A0 DLE 10 0F ETX 03 BCC 86 The first two bytes in data field represent the integer portion, 106 (00-69h), of the setpoint. The second two bytes represent the fraction portion, 4000 (0F-A0h), of the setpoint. Example: Reading Multiple Analog Values The following command reads analog inputs channels 3-9 as integer: DLE STX DST 10 02 0D SRC CMD STS 0B 00 0F TNS D5 A9 FNC Byte Size 1C A2 File File No. Type 0B 89 Ele No. 03 21 00 0A S/Ele No. 00 DLE ETX 10 03 BCC 06 The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 00 00 TNS D5 A9 FF 63 0B 00 5C Data 00 66 2E 14 09 BC 00 0F 83 Data 20 00 DLE 10 1E D6 ETX 03 00 62 00 E7 0B BCC C0 Example: Reading Single Discrete Data After reviewing the Electrical Schematic for your compressor, you determine that the digital input for emergency stop push button is located on J4-P5 (Channel 4). The CMC data table address is ADh for the input in question. Therefore, to read the state of the emergency stop push button as a two byte integer, the following command is issued: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS D6 79 FNC Byte Size 02 A2 File File No. Type 0B 89 TNS D6 79 Data 01 00 Ele No. AD S/Ele No. 00 DLE ETX 10 03 BCC A5 The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 DLE 10 ETX 03 BCC 49 The data response (01) means that the input is ON, or the emergency stop push button is pressed. Example: Reading 16 Bit-Packed Discrete Data To read 16 bit-packed discrete values for digital outputs as a two-byte integer, the following command is sent: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS E1 41 FNC Byte Size 02 A2 File File No. Type 0A 85 Ele No. 0B S/Ele No. 00 DLE ETX 10 03 BCC 79 Note that the file number must be 10. The local data file used to store the returned data can be either bit (85h) or integer (89h) type. The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 41 28 Data 10 10 DLE 10 ETX 03 BCC 3F Please refer to the PLC5 Typed Read command section for the method to interpret the 16bit discrete values. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 135 CMC TECHNICAL REFERENCE MANUAL Command 0F/Function AA - SLC Typed Logical Write The CMC is treated as a SLC5/04 when this command is issued. This command writes a block of data to CMC starting at a specified data table address. You can write to a setpoint with either an integer or floating point number. Example: Presetting Analog Setpoint for 32-bit Value To write 105.4 PSIG as a floating point number to the user pressure setpoint (CMC data table address, 86h), issue the following command: DLE STX DST 10 02 0D SRC CMD STS 0B 0F TNS 00 E1 FNC Byte Size 04 AA 70 File File No. Type 0B 8A Ele No. 86 S/Ele No. 00 Data CD CC D2 DLE 42 10 ETX BCC 03 12 The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 70 DLE 10 ETX 03 BCC 48 Example: Presetting a 16-bit Integer and 16-bit Fraction Analog Setpoint To change the integer and fraction value for the user pressure setpoint to 105.4 PSIG, issue the command below. The integer portion of the number 105 (00-69h) and the fraction 0.4 is converted to 4000 (0F-A0h). These four bytes are placed in field B in the order of (6900-A0-0Fh). DLE STX DST 10 02 0D SRC CMD STS 0B 0F TNS 00 E1 FNC Byte Size 04 AA 82 File File No. Type 0B 89 Ele No. 86 S/Ele No. 00 Data 69 00 A0 DLE 0F 10 ETX BCC 03 96 The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 82 DLE 10 ETX 03 BCC 36 Example: Forcing a Coil Forces a single coil to either ON or OFF. Refer to the CMC data table for each coil supported by the UCM-DF1 interface. See the same example in the PLC5 Typed Write command section for more details. To remotely acknowledge the compressor’s alarm or trip condition, the following command is issued: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS E1 FNC Byte Size AA 04 A3 File No. 0B File Type 89 Ele No. DC S/Ele No. 00 Data 01 00 00 DLE 00 10 ETX BCC 03 36 The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 A3 DLE 10 ETX 03 BCC 15 To remotely acknowledge the compressor’s alarm or trip condition, the following command works the same: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS E1 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 AD FNC Byte Size AA 02 File No. 0B File Type 89 Ele No. DC S/Ele No. 00 Data 01 00 DLE 10 ETX BCC 03 2E 136 CMC TECHNICAL REFERENCE MANUAL The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E1 AD DLE 10 ETX 03 BCC 0B Example: Forcing Multiple Coils Forces each coil in a series of contiguous coils to either ON or OFF. Refer to the CMC data table for a list of coils supported by the UCM-DF1 interface. To force a reset (CMC data table address, DDh) and start (E0h) of the compressor, the following command is sent: DLE STX DST 10 02 0D SRC CMD STS 0B 0F 00 TNS E2 FNC 3A AA Byte Size 10 10 File No. 0B File Type 89 Ele No. DD Data 01 00 00 00 01 00 00 00 S/Ele No. 00 DLE 10 ETX 03 Data 01 00 00 00 01 00 00 00 BCC 8E NOTE The byte size value 10h is transmitted as 10h 10h to be distinguished from the control character DLE. The response from this command is: DLE 10 STX 02 DST 0B SRC 0D CMD 4F STS 00 TNS E2 3A DLE 10 ETX 03 BCC 7D The number of contiguous coils is four (DD, DE, DF, and E0h). The assigned local message buffer length is 8 integer elements, which is 16-byte long. Allen-Bradley SLC 504 Example Data Files RSLogix 500 Ladder Diagram The following ladder logic example is the fastest and most reliable method for gathering data from a CMC. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 137 CMC TECHNICAL REFERENCE MANUAL First Pass S2:1 N7:0 U 15 0000 15 MSG Read/Write Message Peer-To-Peer Type Read Read/Write 500CPU Target Device Local Local/Remote N7:0 Control Block 14 Control Block Length Setup Screen 0001 N7:0 N7:0 12 10 EN DN ER N7:0 U 15 0002 MSG Read/Write Message Peer-To-Peer Type Read Read/Write 500CPU Target Device Local Local/Remote N7:20 Control Block 14 Control Block Length Setup Screen N7:0 0003 13 N7:20 N7:20 12 10 N7:20 N7:0 N7:20 13 13 10 EN DN ER N7:20 U 15 0004 N7:0 U 15 0005 0006 END UCM STS Error Codes STS Code (hex) 00 10 30 3F D0 E0 Definition Success - no error Illegal command or function Remote node host is missing, disconnected, or shutdown Illegal CMC data address or count Illegal data type Cannot form CMC data table query/set list NOTE The UCM-DF1 driver does not support EXT STS. According to Allen-Bradley DF1 protocol convention, EXT STS is part of the message only if STS = F0h. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 138 CMC TECHNICAL REFERENCE MANUAL When the CMC receives a DF1 command without any communication error and the command is executed successfully, a normal response with status code 00h is returned. If the UCM does not receive the command due to a communication error, no response is returned and the command initiator will eventually time out. If the UCM does receive the command, but detects error (invalid BCC/CRC...), control characters DLE NAK is returned to the command initiator, which in turns retransmits the command message and restarts a time out to wait for the response. This can be repeated a few times depending on the limit preset for retransmission. Once the limit is exceeded, the command initiator is informed of the failure and proceeds to the next command. If the time out expired before a response is received, the command initiator sends out DLE ENQ control characters to request a retransmission of the last response. It restarts a time out and wait for the response. There is a limit on the number of inquiries allowed per command message. When this limit is exceeded, the command initiator proceeds to the next command. When UCM receives DLE ENQ or DLE NAK message, it resends the last response to the command initiator. When DLE ACK message is received by the UCM, no response is returned. When the UCM receives a command without any communication error, but cannot handle it, the UCM will return an exception response with the appropriate status code informing the command initiator of the nature of failure. NOTE The table below explains the meanings of different control symbols for DF1 protocol: Control Symbol DLE ACK DLE NAK DLE ENQ Definition a message frame has been successfully received a message frame was not received successfully request retransmission of a response from the destination node Communication Parameters Configuration of the UCM RS-422 port’s communication speed (baud rate), parity, number of data bits, number of stop bits... is available through the Ingersoll-Rand Service Tool for the UCM and will be configured by a certified Ingersoll-Rand Service Representative. The settings should be the same as the 1770-KF2 interface module. Network Setup The network diagram that follows depicts the communication interface between AllenBradley DF1 network and Ingersoll-Rand CMC Microcontroller. The 1770-KF2 always acts as a slave. The slave cannot initiate a command; i.e., the UCM cannot initiate a command over DH+ network. It only returns response messages to queries that are addressed to them individually. Broadcast is not supported over the DF1 network. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 139 CMC TECHNICAL REFERENCE MANUAL CMC Panel CENTAC Microcontroller RS-232 Network for Operator User Interface, Twisted Pair Wires with Common (3 Wires) IRBUS (RS-485) Network for Base Control Modules and Universal Communication Modules, Twisted Pair Wires with Ground (3 Wires) Base Control Module (BCM) IRBUS Address: 1 Serial Port (COM1) INGERSOLL-RAND Service Tool 470 ohm IRBUS IN (For IR Use) IRBUS OUT (For IR Use) Base Control Module (BCM) Service Tool Plug on Panel Door Universal Communication Module (UCM) IRBUS Address 4 Network Card Comm Port on Server IRBUS Address: 2 INGERSOLL-RAND Air System Controller (ASC) Universal Comm. Module (UCM) IRBUS Address 5 Universal Comm. Module (UCM) IRBUS Address 6 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Next CMC Panel(s) for use in ASC Modbus Network #1 Full or Half Duplex RS-422 or RS-485 DF1 Network Full Duplex RS-422A Cat5 Cable Ethernet to Modbus Bridge To DH+ Network Allen-Bradley 1770-KF2 Interface Module 140 CMC TECHNICAL REFERENCE MANUAL 1770-KF2 Setup A 1770-KF2 module links asynchronous devices (RS-422A or RS-232C) to an AllenBradley Data Highway or Data Highway Plus network. The 1770-KF2 module has 8 switch assemblies that let you select various communication options. The switch assemblies are shown in the diagram below: Switch Assembly SW-1 SW-2, SW-3, SW-4 SW-5 SW-6 SW-7 SW-8 Communication Option Asynchronous link features Node number Network link communication rate Asynchronous link communication rate DH/DH+ network link section RS-232C/RS-422A selection CAUTION The 1770-KF2 module reads the status of these communication option switches only at power up, so you need to change switch settings with 1770-KF2 powered off. SW-1 (Asynchronous Link Features) The following table shows the different combinations available for setting the asynchronous link with the 5 dipswitches of SW-1. Protocol Error Check Parity Embedded Response 1 2 Full Duplex Full Duplex Full Duplex Full Duplex Full Duplex BCC BCC BCC BCC CRC None Even None Even None No No Yes Yes Yes OFF ON OFF ON OFF OFF OFF ON ON ON SW-1 Settings 3 (Duplicate Message) ON: ignore OFF: accept OFF OFF OFF OFF OFF 4 (Hand Shake) 5 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON CAUTION Only the UCM-DF1 driver supports the full duplex options. Half duplex is not supported. SW-2, SW-3, SW-4 (Node Address) These three switch assemblies are used to set the network node number of the 1770-KF2 module. Set both switches in SW-2 OFF for DH+ link because the node number should be 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 141 CMC TECHNICAL REFERENCE MANUAL a 2-digit octal number that identifies the 1770-KF2 as a unique node on DH+. Valid node numbers for 1770-KF2 in DH+ network are 00 to 77 octal. First digit (SW-2) should always be set to zero. SW-2 Setting 1 2 OFF OFF OFF ON ON OFF ON ON Digit 0 1 2 3 Second and third digits: 1 OFF OFF OFF OFF ON ON ON ON SW-3, SW-4 Setting 2 OFF OFF ON ON OFF OFF ON ON 3 OFF ON OFF ON OFF ON OFF ON Digit 0 1 2 3 4 5 6 7 SW-5 (Network Link Communication Rate) Switch assembly SW-5 lets you select the communication rate for the 1770-KF2 module’s network link (DH+). Set both switches ON for a network communication rate of 57,600 bits per second. Be sure to set all modules on the same DH+ network for this communication rate. SW-6 (Asynchronous Link Communication Rate and Diagnostic Commands) Switches #1, #2, #3 of SW-6 let you select the communication rate for the 1770-KF2 module’s asynchronous port. Meanwhile, switch #4 determines how 1770-KF2 module treats diagnostic commands sent by a remote DH+ node. It is recommended to set at 9600 baud or higher, and execute received diagnostic commands. Execute received diagnostic commands Pass any received diagnostic commands to the attached asynchronous device SW-6 Setting 4 ON OFF The available baud rate settings are shown below: Baud Rate (Bits per second) 110 300 600 1200 2400 4800 9600 19200 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 1 OFF ON OFF ON OFF ON OFF ON SW-6 Setting 2 OFF OFF ON ON OFF OFF ON ON 3 OFF OFF OFF OFF ON ON ON ON 142 CMC TECHNICAL REFERENCE MANUAL SW-7 (Network Link Selection) UCM only supports DH+ network. SW-7 should always select DH+. Network Mode DH DH+ SW-7 Setting 1 2 OFF OFF ON OFF SW-8 (RS-232C/RS-422A Selection) The UCM-DF1 interface uses RS-422 communication. SW-8 should select RS422. Communication Type RS-232C RS-422A SW-8 Setting 1 2 OFF ON ON OFF Wiring Diagram for RS-422A 1770 KF2 Module RS-422 1 14 25 16 18 UCM RS-422 GND TX+ TXRX+ RX- Cable not to exceed 4000 feet RX+ RXTX+ TX- 4 5 6 8 20 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 143 Documentation An Electrical Schematic drawing is provided as standard after order placement. Control Panel Outline drawings are optional. Logic diagrams are considered proprietary and are not available. System Information Status Codes The following table lists the status codes for the Base Control Module (BCM) only. These codes indicate every operating condition, both normal and abnormal, for the system. A code always exists for the system; for example, Status 05h indicates that the system is running properly. These codes, except Status 00h and 05h, are shown on a blank screen in the upper left hand corner of the Operator User Interface (OUI). Since Status 00h and 05h are normal operating conditions, these codes are not displayed. When a code is displayed, contact your local Ingersoll-Rand Service Representative. Status Code 00h Definition Booting 01h Stay In Boot 02h ROM CRC Failed 03h Commanded To Boot 04h Invalid Application 05h 06h Application Running Fatal Exit 07h System Error 08h Incompatible Software Versions A-D System Error D-A System Error Digital I/O System Error Logic Engine System or Loop Task Error Comparator System Error Operator User Interface Error 09h 0Ah 0Bh 0Ch 0Dh 0Eh 0Fh Data Logging System Error 10h Low Power Comments The BCM is in the boot process. This is a normal process during BCM power up. This state will not be displayed. The BCM is held in boot mode by the hardware configuration. This condition exists only when the boot jumper (hardware device) is plugged into the display (OUI) port. This hardware jumper is only required when doing system level reprogramming of the module. The BCM software is not valid. This condition occurs when the CRC (Cyclic Redundancy Check) calculated by the module does not equal the CRC value written to the module when programmed. This would typically occur when the programming process is aborted (halted). The module must be reprogrammed. The BCM is currently in the process of being programmed. If this message does not disappear after programming is completed, power cycle the unit. The BCM software has failed to operate properly. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Normal operating condition. This state will not be displayed. Operating system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Operating system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. The BCM application software and tables are not compatible. The module must be reprogrammed. Analog input system error. A hardware malfunction has occurred. Analog output system error. A hardware malfunction has occurred. Digital input and output system error. A hardware malfunction has occurred. Ladder logic processing system or loop task error. The module must be reprogrammed. Comparator system error. The module must be reprogrammed. Operator User Interface system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Data logging system error. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. Power supply voltage (+24 VDC) dropped below minimum operating level. Check power supply. Cycle power when voltage is within proper operating limits. Once restarted, the program will operate properly until the same condition reoccurs. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 144 CMC TECHNICAL REFERENCE MANUAL Status Code 11h Definition Task Overrun 12h Watchdog Failure 13h Intermodule Data Error 14h Calculation Block Error 15h Interpolation System Error 16h Calibration System Error Comments System processing capabilities do not meet requirements for operation. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. The internal backup system monitor is not operational. BCM hardware should be replaced. Cycling the power on the module will restart the system. Once restarted, the program will operate properly until the same condition reoccurs. An error has occurred while generating a message to be sent from one BCM to the other BCM in a multi-module configuration. The module must be reprogrammed. A stack underflow or overflow has occurred in a calculation block. The module must be reprogrammed. An error has occurred in the interpolation block. The module must be reprogrammed. Occurs during initialization of the EEPROM block. The module must be reprogrammed. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 145 CMC TECHNICAL REFERENCE MANUAL Base Control Module (BCM) Module Layout J15-Digital Outputs, Channels 4-1 J14-Digital Outputs, Channels 8-5 J13-Digital Outputs, Channels 12-9 J12-Digital Outputs, Channels 16-13 Pin 1 J10-Power Input (24 VDC) Pin 1 Pin 1 F102-Fuse for AnalogI/O (J1, J2 and J3) Pin 1 J9-Current Transformer Input (0-5 Amps) Pin 1 F101-Fuse for Operator User Interface (Display) F103-Fuse for Digital Inputs (J4 and J5) F100-Fuse for Base Module CPU Card J8-Speed Sensor Input (1-150 Hz) Pin 1 J7-RS485 Serial Data Link (IRBUS) Pin 4 All Fuses are 5x20mm, GMA 1.5 amp, Fast Blow J7-RS232 Serial Data Link (Display), Pin 1 J6-RS232 Serial Data Link (Display), Female DB9 J5-Digital (Discrete) Inputs (24 VDC), Channels 9-16 Pin 1 J4-Digital (Discrete) Inputs (24 VDC), Channels 1-8 Pin 1 J3-Analog Outputs (4-20mA) Channels 1-4 Pin 25 Pin 7 Pin 1 Pin 5 Pin 1 Pin 1 J1-Grounded Analog Inputs, (4-20mA) Channels 3-23 J2-Floating Analog Inputs, (4-20mA) Channels 1-2 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 146 CMC TECHNICAL REFERENCE MANUAL Connector Description Tag Type Channel Module Connector Mating Connector J1 Grounded Analog Inputs, 4-20 mA 3-23 (2) Phoenix MDST 2, 5/24-3T-5, 08 J2 Floating Analog Inputs, 4-20 mA 1-2 J3 Analog Outputs, 4-20 mA 1-4 J4 J5 J6 Digital (Discrete) Inputs, 24 VDC 1-8 9-16 na (12) Phoenix MDSTB 2, 5/2-G-5, 08 (2) Phoenix MDSTB 2, 5/2-G-5, 08 (3) Phoenix MDSTB 2, 5/2-G-5, 08 Phoenix MSTBA 2, 5/10-G-5, 08 9 Position “D” Sub Miniature (Female) Phoenix MSTBA 2, 5/9-G-5, 08 Phoenix MSTBA 2, 5/3-G-5, 08 Terminal Strip Phoenix MSTBA2, 5/5-G-5, 08 (4) Phoenix MSTBA 2, 5/8-G-5, 08 J7 J8 J9 J10 J12 J13 J14 J15 RS232 Serial Data Link (Operator User Interface) RS232 Serial Data Link (OUI) RS485 (IRBUS) Serial Data Link Speed Sensor Input, Variable Reluctance Current Transformer Input Power Digital Outputs na na na 13-16 9-12 5-8 1-4 (2) Phoenix MDST 2, 5/4-3T-5, 08 (2) Phoenix MDST 2, 5/6-3T-5, 08 Phoenix MSTB 2, 5/10-ST-5, 08 9 Position “D” Sub Miniature (Male) Phoenix MSTB 2, 5/5-ST-5, 08 Phoenix MSTB 2, 5/3-ST-5, 08 Wire Lugs Phoenix MSTB 2, 5/5-ST-5, 08 (4) Phoenix MSTB 2, 5/8-ST-5, 08 NOTES: 1. BCM Weight: 1775 ± 177g [3.92 ± .39 lb.] 2. BCM Size: Length=355.6 mm [14.0 in] x Width=247 mm [9.7 in] x Depth=45 mm [1.8 in] 3. To ensure chassis ground, install 12-gauge ground strap between this module and the NEMA enclosure. Place external tooth lock washer between this module and the ground strap. 4. “na” is defined as “not applicable”. 5. All Phoenix connectors may be replaced with an equal supplier. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 147 CMC TECHNICAL REFERENCE MANUAL Connector Input and Output (I/O) Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 J1-Grounded Analog Inputs Analog Input Channel 3 Power 24 VDC, Channels 3 & 4 Shield, Channels 3 & 4 Analog Input Channel 4 Analog Input Channel 5 Power 24 VDC, Channels 5 & 6 Shield, Channels 5 & 6 Analog Input Channel 6 Analog Input Channel 7 Power 24 VDC, Channels 7 & 8 Shield, Channels 7 & 8 Analog Input Channel 8 Analog Input Channel 9 Power 24 VDC, Channels 9 & 10 Shield, Channels 9 & 10 Analog Input Channel 10 Analog Input Channel 11 Power 24 VDC, Channels 11 & 12 Shield, Channels 11 & 12 Analog Input Channel 12 Analog Input Channel 13 Power 24 VDC, Channels 13 & 14 Shield, Channels 13 & 14 Analog Input Channel 14 Analog Input Channel 15 Power 24 VDC, Channels 15 & 16 Shield, Channels 15 & 16 Analog Input Channel 16 Analog Input Channel 17 Power 24 VDC, Channels 17 & 18 Shield, Channels 17 & 18 Analog Input Channel 18 Analog Input Channel 19 Power 24 VDC, Channels 19 & 20 Shield, Channels 19 & 20 Analog Input Channel 20 Analog Input Channel 21 Power 24 VDC, Channels 21 & 22 Shield, Channels 21 & 22 Analog Input Channel 22 Analog Input Channel 23 Power 24 VDC, Channel 23 Shield, Channel 23 Spare Spare Power 24 VDC, Spare Shield, Spare Spare Pin 1 2 3 4 5 6 7 8 J2-Floating Analog Inputs Analog Input Channel 1+ Power 24 VDC, Channel 1 Analog Input Channel 1Shield, Channel 1 Analog Input Channel 2+ Power 24 VDC, Channel 2 Analog Input Channel 2Shield, Channel 2 Pin 1 2 3 4 5 6 7 8 9 10 11 12 J3-Analog Outputs Analog Output Channel 1+ Power 24 VDC, Channels 1 & 2 Analog Output Channel 1Analog Output Channel 2+ Shields, Channels 1 & 2 Analog Output Channel 2Analog Output Channel 3+ Power 24 VDC, Channels 3 & 4 Analog Output Channel 3Analog Output Channel 4+ Shields, Channels 3 & 4 Analog Output Channel 4- Pin 1 2 3 4 5 6 7 8 9 10 J4-Digital Inputs Power 24 VDC, Channels 1-8 Digital Input Channel 1 Digital Input Channel 2 Digital Input Channel 3 Digital Input Channel 4 Digital Input Channel 5 Digital Input Channel 6 Digital Input Channel 7 Digital Input Channel 8 Ground, Channels 1-8 Pin 1 2 3 4 5 6 7 8 9 10 J5-Digital Inputs Power 24 VDC, Channels 9-16 Digital Input Channel 9 Digital Input Channel 10 Digital Input Channel 11 Digital Input Channel 12 Digital Input Channel 13 Digital Input Channel 14 Digital Input Channel 15 Digital Input Channel 16 Ground, Channels 9-16 Pin 1 2 3 4 5 6 7 8 9 J6-RS232 (Display) Not Used Receive Data (RxD) Transmit Data (TxD) Not Used Signal Ground Not Used Not Used Not Used Not Used Pin 1 2 3 4 5 6 7 8 9 J7-RS232 (Display) / RS485 (IRBUS) Receive Data (RxD) (Display) Transmit Data (TxD) (Display) Signal Ground (Display) Data Link 1+ (IRBUS) Data Link 1(IRBUS) Data Link Ground (IRBUS) Data Link 1+ (IRBUS) Data Link 1(IRBUS) Data Link Ground (IRBUS) 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Pin 1 2 3 J8-Speed Sensor SS+ SSSS Ground Pin 1 2 J9-Current Transformer CT+ CT- Pin 1 2 3 4 5 J10-Power Power +24V DC Power Ground Chassis Ground Display Power +24VDC Display Power Ground Pin 1 2 3 4 5 6 7 8 J12-Digital Outputs Digital Output Channel 16 Digital Output Channel 16 Digital Output Channel 15 Digital Output Channel 15 Digital Output Channel 14 Digital Output Channel 14 Digital Output Channel 13 Digital Output Channel 13 Pin 1 2 3 4 5 6 7 8 J13-Digital Outputs Digital Output Channel 12 Digital Output Channel 12 Digital Output Channel 11 Digital Output Channel 11 Digital Output Channel 10 Digital Output Channel 10 Digital Output Channel 9 Digital Output Channel 9 Pin 1 2 3 4 5 6 7 8 J14-Digital Outputs Digital Output Channel 8 Digital Output Channel 8 Digital Output Channel 7 Digital Output Channel 7 Digital Output Channel 6 Digital Output Channel 6 Digital Output Channel 5 Digital Output Channel 5 Pin 1 2 3 4 5 6 7 8 J15-Digital Outputs Digital Output Channel 4 Digital Output Channel 4 Digital Output Channel 3 Digital Output Channel 3 Digital Output Channel 2 Digital Output Channel 2 Digital Output Channel 1 Digital Output Channel 1 148 CMC TECHNICAL REFERENCE MANUAL Operator User Interface Module (OUI) Module Layout Side View J1-RS232 Port Pin 1 J3-RS232 Port Pin 1 Pin 1 J2-Input Power Connector Description Tag Type J1 RS232 Port J2 Input Power J3 RS232 Port Module Connector Mating Connector 9 Position “D” Sub Miniature (Female) Phoenix MSTBA2, 5/2-G-5, 08 Phoenix MC 1.5/5G-3.81 9 Position “D” Sub Miniature (Male) Phoenix MSTW2, 5/2-ST-5, 08 Phoenix MC 1.5/5ST-3.81 NOTES: 1. OUI Weight: 410 g [0.90 lb.] 2. OUI Size: Length=267 mm [10.5 in] x Width=175 mm [6.9 in] x Depth=60 mm [2.4 in] 3. All Phoenix connectors may be replaced with an equal supplier. Connector Input and Output (I/O) Pin 1 J1-RS232 Port No Connection Pin 1 2 3 4 5 6 7 8 9 Transmit (TX) Receive (RX) No Connection Signal Common No Connection No Connection No Connection No Connection 2 J2-Input Power +12 To +24 VDC (VPOWER) Ground (GND) Pin 1 J3-RS232 Port RS232 Data Link Tx 2 3 4 5 RS232 Data Link Rx Common (Com) IRBUS RS485 Data Link (DL+) IRBUS RS485 Data Link (DL-) 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 149 CMC TECHNICAL REFERENCE MANUAL OUI PCB Assembly (Cover Removed) Showing replaceable fuse J1 9 Position "D" Sub Connector Fast-Acting, SMF, .75A, 125V Littlefuse 0451.750 or 0453.750 or Equivalent J3 5 Pin Connector F2 J2 2 Pin Connector CMC User Interface/Bezel Cleaning Instructions The following procedure is recommended to clean the CMC User Interface vinyl overlay material and/or the User Interface bezel. 1. Stop the compressor and depress the maintained ‘Emergency Stop’ push-button, this will prevent an inadvertent start up or trip of the compressor during the cleaning process. 2. Dampen a soft cloth or paper towel with water and wipe any dust, dirt or liquids from the surface of the User Interface, do not use an abrasive pad or brush to clean the surface of the User Interface vinyl overlay or bezel. 3. If more aggressive measures are required to clean the User Interface and/or bezel surface use a mild non-abrasive household cleaner (such as Formula 409, Fantastik, etc.) sprayed or wiped directly onto the surface to be cleaned. Dampen a soft cloth or paper towel with water and wipe any remaining cleaner from the surfaces. Ingersoll-Rand Company recommends the following for cleaning the OUI and bezel: Cleaners: Water or mild household cleaner, no petroleum or acetone based fluids. Cleaning wipes: Soft cotton clothe or paper towels. Backlight Replacement Procedure Tools Needed: 1. Flat blade screwdriver with a small tip (1/8 inch) 2. Number 1 Phillips Screwdriver 3. Electrostatic Discharge Strap Connected to Earth Ground 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 150 CMC TECHNICAL REFERENCE MANUAL Step 1 J1 User Terminal J3 User Terminal Tx Rx COM DL+ DL- Lift cover to remove J2 Loo s + en scr ew s, s l ide righ Step 2 Remove cabling Unplug connector and remove nylon cable retainer screws Display Power t Step 3 Step 4 Remove screws from the lower printed circuit board, then use a screwdriver to gently pry the backlight panel loose. Use circular stand-offs to rest screwdriver shaft against while prying backlight panel out. The backlight is part of a larger panel that is removed as an assembly. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 151 CMC TECHNICAL REFERENCE MANUAL Step 5 Step 6 Backlight panel is inserted into display between the circuit board and the LCD glass with the white plastic backing sheet and wires facing toward the circuit boards. Slide the backlight panel in place and align the screw holes so the screws may be inserted and tightened. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Insert screws being careful not to over tighten. Route wiring, replace nylon cable retainers, insert backlight plug, replace main cover and connect power and communication cable to complete installation. 152 CMC TECHNICAL REFERENCE MANUAL Universal Communication Module (UCM) Optional Module Layout Side View J2-Service/Modem (RS232) Port J1-Microcontroller/Network (RS422/RS485) Port Pin 1 J3-Input Power Pin 1 Pin 1 Top View RS232 Activity Indicator IRBUS RS485 Activity Indicator RS422/485 Activity Indicator 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 153 CMC TECHNICAL REFERENCE MANUAL Connector Description Tag Type Module Connector Mating Connector J1 Microcontroller/Network (RS422/485) Port Phoenix MSTBA2, 5/8-G-5, 08 Phoenix MSTBW2, 5/24-ST-5, 08 J2 Service/Modem (RS232) Port 9 Position “D” Sub Miniature (Female) 9 Position “D” Sub Miniature (Male) J3 Input Power Phoenix MSTBA2, 5/2-G-5, 08 Phoenix MSTW2, 5/2-ST-5, 08 NOTES: 1. UCM Weight: 410 g [0.90 lb.] 2. UCM Size: Length=136 mm [5.4 in] x Width=143 mm [5.6 in] x Depth=31 mm [1.2 in] 3. All Phoenix connectors may be replaced with an equal supplier. Connector Input and Output (I/O) Pin 1 2 3 4 5 6 7 8 J1-Microcontroller/Network Port IRBUS RS485 Datalink + (DL+) IRBUS RS485 Datalink - (DL-) Ground (GND) RS422/485 Transmit + (TX+) RS422/485 Transmit - (TX-) RS422/485 Receive + (RX+) RS422/485 Receive - (RX-) Ground (GND) Pin 1 2 3 4 5 6 7 8 9 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 J2-Service/Modem Port No Connection Transmit (TX) Receive (RX) No Connection Signal Common No Connection No Connection No Connection No Connection Pin 1 2 J3-Input Power +12 To +24 VDC (VPOWER) Ground (GND) 154 CMC TECHNICAL REFERENCE MANUAL UCM Port Activity LEDs The UCM has three light emitting diodes (LEDs) to indicate the activity of the RS232, RS422/485 and the IRBUS RS485 ports. The following table indicates the different states of these ports. RS232 off on RS422 RS485 off off IRBUS RS485 off off on on blinking blinking on on on on on blinking blinking on on on blinking blinking blinking on blinking blinking blinking UCM State No power (24 VDC) Boot mode, check A1 switch for being non-zero (cycle power to exit boot mode) Running, but no communication on any port Multi-module job with inter-module communication Service Tool in use Service Tool in use, but no response from BCM … check connection between BCM and UCM MODBUS communication in use RS-422 port in use, but no response from BCM … check connection between BCM and UCM or Modbus and DF1 address All blinking together imply a continuous reboot or application problem UCM Communications Parameters The UCM has three communication ports, RS232, RS422/485 and IRBUS RS485. Each of these ports has its own communication parameters that it supports. Service Tool RS-232 50 feet (15.2 meters) 9600 Modbus/DF1 IRBUS Parameter RS-422/485 RS-485 Distance 4000 feet (1218.3 Meters) 100 feet (30.4 Meters) Baud Rate 300, 600, 1200, 2400, 9600 9600, 19200, 38400 Parity None None, Even, Odd None Data Bits 8 8 8 Stop Bits 1 1, 1.5, 2 1 Configurable No Yes* No * A certified Ingersoll-Rand Service Representative will provide this configuration. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 155 CMC TECHNICAL REFERENCE MANUAL RS422/485 Network Wiring Diagram - Full Duplex SERVER (Modbus Master) Compressor Panel #n Modbus Address - nn IRBUS Address - any 120 VAC To Server's Network Card Ethernet Switch Ethernet Cable Cat5 or Better Compressor Panel #6 Modbus Address - 06 IRBUS Address - any Compressor Panel #5 A terminating resistor is not required at the end of the network. Modbus Address - 05 IRBUS Address - any Rx- Rx+ Tx+ Tx- Ethernet / Modbus Bridge The maximum distance of a MODBUS Network is 4000 electrical feet; i.e., the length of the wire from the Ethernet Bridge (Location A) to the last compressor's Universal Communication Module (Location B). The maximum number of devices (nodes) on a MODBUS Network is 30. 3 Com 120 VAC B Compressor Panel #4 RS-422 2 Twisted Pair Wires with Ground (5 Wires) Modbus Address - 04 IRBUS Address - any 174 CEV 300 Compressor Panel #3 24VDC + Fused - Modbus Address - 03 IRBUS Address - any RS-422 2 Twisted Pair Wires Plus Gnd. (5 Wires) Connect Ground One End Only To Power Supply 24+ Gnd Power To Power Supply To BCM DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485 RS-232 DB-9 Universal Communication Module (UCM) Modbus Address - 01 (Set through software) Compressor Panel #1 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 RS-422 2 Twisted Pair Wires with Ground (5 Wires) 24+ Gnd Power To BCM DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485 RS-232 DB-9 Universal Communication Module (UCM) Modbus Address - 02 (Set through software) Compressor Panel #2 156 CMC TECHNICAL REFERENCE MANUAL RS422 Network Wiring Diagram - Half Duplex SERVER (Modbus Master) Compressor Panel #n Modbus Address - nn IRBUS Address - any 120 VAC To Server's Network Card Ethernet Switch Ethernet Cable Cat5 or Better Compressor Panel #6 The maximum distance of a MODBUS Network is 4000 electrical feet; i.e., the length of the wire from the Ethernet Bridge (Location A) to the last compressor's Universal Communication Module (Location B). The maximum number of devices (nodes) on a MODBUS Network is 30. 3 Com Modbus Address - 06 IRBUS Address - any 120 VAC B Compressor Panel #5 A terminating resistor is not required at the end of the network. Modbus Address - 05 IRBUS Address - any Rx- Rx+ Tx+ Tx- Compressor Panel #4 Ethernet / Modbus Bridge RS-422 Twisted Pair Wires with Ground (3 Wires) Modbus Address - 04 IRBUS Address - any 174 CEV 300 24VDC + Fused - Compressor Panel #3 A Modbus Address - 03 IRBUS Address - any RS-422 Twisted Pair Wires With Ground (3 Wires) Connect Ground One End Only To Power Supply 24+ Gnd Power To BCM DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485 RS-232 DB-9 Universal Communication Module (UCM) Modbus Address - 01 (Set through software) Compressor Panel #1 RS-422 Twisted Pair Wires with Ground (3 Wires) To Power Supply 24+ Gnd Power To BCM DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485 RS-232 DB-9 Universal Communication Module (UCM) Modbus Address - 02 (Set through software) Compressor Panel #2 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL 157 Terminating Resistor – Modbus Network The RS422/485 circuitry built into each UCM supports Alternate-Fail-safe AC Termination. This termination circuitry enhances the UCM's ability to operation in harsher (electrically noisier) environments. Since this circuitry is built into the product, no external terminating resistor is required. For a thorough discussion of the various termination techniques, please refer to "A Comparison of Differential Termination Techniques", National Semiconductor Application Note 903 (AN-903), August 1993. This application note can be obtained from the Internet at "www.national.com". Terminating Resistor – IRBUS Network Due to the data rate the RS485 IRBUS is provided with termination resistors mounted inside the panel. The value of each resistor is 470 ohms. The purpose of the termination is to prevent reflections. Reflections occur when a signal encounters different impedance and is reflected back towards the source. This can corrupt the intended data transmission. Where IRBUS is networked with other panels two termination resistors are required, one at each end of the network. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 158 CMC TECHNICAL REFERENCE MANUAL Typical System Layout Operator User Interface (OUI) CENTAC Microcontroller 24 VDC Power RS232 Base Control Module (BCM) #1 470 ohm IRBUS OUT IRBUS IN IRBUS (RS485) IRBUS (RS485) 24 VDC 120/240 VAC Power Universal Communications Module (UCM) Base Control Module (BCM) #2 Power Supply 24 VDC Service Tool Port Not Shown 24 VDC Optional Equipment 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 159 CMC TECHNICAL REFERENCE MANUAL Network Diagram CMC Panel CENTAC Microcontroller RS-232 Network for Operator User Interface, Twisted Pair Wires with Common (3 Wires) IRBUS (RS-485) Network for Base Control Modules and Universal Communication Modules, Twisted Pair Wires with Ground (3 Wires) Base Control Module (BCM) IRBUS Address: 1 Serial Port (COM1) INGERSOLL-RAND Service Tool 470 ohm IRBUS IN (For IR Use) IRBUS OUT (For IR Use) Base Control Module (BCM) Service Tool Plug on Panel Door Universal Communication Module (UCM) IRBUS Address 4 Network Card Comm Port on Server IRBUS Address: 2 INGERSOLL-RAND Air System Controller (ASC) Universal Comm. Module (UCM) IRBUS Address 5 Universal Comm. Module (UCM) IRBUS Address 6 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Next CMC Panel(s) for use in ASC Modbus Network #1 Full or Half Duplex RS-422 or RS-485 Modbus Network #2 Full or Half Duplex RS-422 or RS-485 Cat5 Cable Ethernet to Modbus Bridge To next CMC Panel or any other Modbus compliant product 160 CMC TECHNICAL REFERENCE MANUAL Technical Specification DESCRIPTION OF STANDARD Switches, Lights and Push Buttons Control Power On/Off switch... activates panel power and prelube pump Compressor trouble light (red) Emergency stop pushbutton Microprocessor OUI 240x128 pixel LCD graphic display window Tabbed folders for ease of navigation Status Bar with compressor state Eighteen screens of compressor information and setup data Left/Right/Up/Down/Return push buttons Acknowledge/Reset push buttons Start/Stop push buttons Load/Unload push buttons Contrast Button Event Log Most recent 224 events with name, time, date and value Logged events Alarms Trips Command key press (local and remote) E-Stop pressed Module control power up and down MinLoad reset Analog input failed Setpoint change (local and remote) Automatic start and stop (when Auto Hot Start purchased) Surge Unload Compressor Started Driver Failed to Start Loss of Motor Power Language and Units of Measure Language and Units of Measure Sets Two Language and Units of Measure sets are select-able from the display. NOTE: The English language and psia, degF, mils are standard for all units. English and kPA, degC, microns are the default alternate language unless otherwise specified. Other Units of Measure are available upon request. Languages Arabic Bulgarian Chinese Croatian Czech Danish Dutch French Finnish German Greek Hungarian Italian Norwegian Polish Portuguese Romanian Russian Slovakian Slovenian Spanish Swedish Turkish Units of Measure Available upon request. Control Functions Modulate or Autodual Manual Valve control for compressor setup High motor load limit (controls maximum opening of inlet valve) MinLoad (controls minimum opening of inlet valve) Partial Unload on Surge Moves inlet valve to minimum load setting and bumps the bypass valve open to exit the surge condition Minimizes duration and magnitude of pressure drop from surge Surge Indexing Actual/Alarm/Trip Functions Low oil pressure High/low oil temperature High air temperature into last compression stage High stage shaft vibrations, single plane Alarm Function Surge Trip Function Low seal air (interlocked w/ prelube pump operation) PHYSICAL DATA Panel Construction NEMA 12 enclosure Formed and welded 11-gauge carbon steel cabinet, 14 gauge door Door gasket with butt type hinges Back panel for component mounting Dimensions Panel1 Panel2 Height 54 in (137.2 cm) 54 in (137.2 cm) Width 32 in (81.3 cm) 35 in (88.9 cm) Depth 12 in (30.5 cm) 14 in (35.6 cm) 1 - No Starter or size 5 starter panels 2 - with size 5DP or size 6 starter panels Controller Board 14.0 in (35.5 cm) 9.7 in (24.6 cm) 1.0 in (2.5 cm) Weight Without starter 300 lb. (136.1 kg) With size 5 starter 350 lb. (158.8 kg) With size 6 starter 375 lb. (170.1 kg) Component Data Canadian Standard Association (CSA) Underwriters Laboratories (UL) approved components Control Wiring High voltage and low voltage wiring segregation TEW wire with PVC insulation (meets NEMA VM-1 for Flame Retardant 105 degC temperature rise on insulation 600 V rating, 18 gauge for instrumentation and signal, 16 gauge for control Heat shrink wire markers for harness Clip-on wire markers internal to panel Wire Ferules Terminal Blocks 300 VAC design for #22 through #10 wire size Tubular clamp contacts and tang clamping collar, DIN Rail mounted Push Buttons/Selector Switches/Indicating Lights Corrosion resistant, Oil-tight Designed and manufactured to NEMA 4/12/13 Pilot lights are 120 VAC full voltage type Control Interposing Relays Two normally open and Two normally closed contacts rated: 1/3HP 10AMP 120VAC 1/2HP 10AMP 240VAC 10AMP 28VDC Coil rated 120 VAC Contacts Normally Open, 5 amps at 120 VAC Pressure Transducers Ranges 0-50 PSIG, 0-200 PSIG, 0-500 PSIG, 4-20 mA Output Channel 7/16-20 SAE or 1/4" NPT pressure port fitting Hirschmann GSA3000N connection head fitting for machine mounted model Temperature Transducers 0-500 degF operating range, 4-20 mA transmitter 100 ohm platinum, TCR=0.00385 Four compression type terminals NEMA 4 rating Vibration Transmitters Eddy current probe Vibration range 0-4 mils, Frequency range 5-3000 Hz Output Channel 4-20 mA and 200 mV/Mil, Supply voltage 18-50 VDC Barrier type screw terminals, DIN rail mountable Hardened against 150 MHz and 440 MHz radio interference Wiring Harness One wiring harness per device NEMA 4 rated Display Functions (Read Only) Motor current System air pressure Copper Ground Bar 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 161 CMC TECHNICAL REFERENCE MANUAL OPTIONS Analog Inputs (Monitor, Alarm and Trip) Any Temperature Any Pressure Any Vibration Any 4-20 mA signal Digital (Discrete) Inputs (Monitor and Alarm or Trip) Low water flow Dirty inlet filter (switch supplied loose) Dirty oil filter Low oil level High condensate level (common for all traps) High motor temperature Any Discrete Input Panel Enclosures Cooing Fan with Filter 110/115 VAC, 50/60 Hz, 0.24 Amps, 20 Watts Air flow with filter 36 CFM (61 M3/Hr) NEMA 4 Enclosure Space Heater, Vortex Tube Cooler NEMA 4X Enclosure Space Heater, Vortex Tube Cooler Stainless steel or epoxy coated carbon steel Space Heater 120 VAC, 120 Watts, finned strip heater Bimetallic baseboard type thermostat set at 45 degF (7 degC) Vortex Tube Cooler 25 SCFM (42 NM3/Hr) at 100 PSIG (7 BarG) of compressed air 1500 BTU/Hr (378 kCal/Hr), Thermostat set at 90 degF (32 degC) Solenoid operated valve, Air Filter Type Z Purge Select-able quick and normal flow rates with meters Differential pressure switch set at 0.2 inches (5 mm) of water Loss of purge indication, Relief valve, Warning label Fused Control Power Disconnect Rotary handle through door, 30 amp fuse Ground Fault Protector for UL Panels 120 Vac circuits protected against ground fault currents. Control Electrical Package (Standard on CV) Prelube Pump Motor Starter Two horsepower and less Available voltages 380, 460, 575 VAC Maximum voltage rating 600 VAC, 10 Amp rating, 120 VAC coils IEC Style Heater Contactor IEC Style, Adjustable ambient compensated overloads Available voltages 380, 460, 575 VAC Maximum voltage rating 600 VAC, 10 Amp rating, 120 VAC coils Control Power Transformer Machine tool type, 230, 460, 575 VAC to 120/95 VAC 500 VA or optional 1000 and 1500 VA, 50 or 60 Hz Transient Voltage Surge Suppressor UL 1449 Listed Tested to ANSI / IEEE C62.41 category A and B environments. Stage Data Package (Standard on CV) Interstage Air Pressure and Temperature each stage Alarm Horn 80-95 dBA, 2900 Hz Running Unloaded Shutdown Timer Timing range and mode select-able through CMC Water Solenoid Post Run Timer Timing range and mode select-able through CMC Inlet Valve Tight Closure Keeps inlet valve closed until motor reaches full speed 0-30 second timer range settable by IR Service Tech Diesel Engine Driven Compressor Control Steam and Gas Turbine Driven Compressor Control Main Motor Starter (Wye-Delta) NEMA Size 5 or 6 Open transition type, Ambient compensated overloads Available voltages 380, 460, 575 VAC, 120 VAC coils Power Regulating Transformer 120 VAC, 60 Hz, 250 VA -65% Input Channel line variation, Output Channel +5-10% NEMA Specification ±15% Input Channel line variation, Output Channel ±3% 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Automatic Starting Automatic Hot Start REMOTE FUNCTIONS DISABLED/ENABLED Selector Switch Solenoid Valves for Intercoolers CMC settable start up pressure setpoint Post Run Water Flow Timer Automatic Cold Start CONTROL POWER LOCAL/OFF/ COLD Selector Switch Strobe Light Solenoid Valves for Intercoolers and Instrument Air Line CMC settable start up pressure setpoint Post Run Water Flow Timer Start Timer Lube Oil Alarm Bypass Timer COMMUNICATIONS OPTIONS Communications Card(s) Up to three cards per module RS-422/485 Local/Network Selector Switch Direct CMC Communication with RS422/RS-485 Requires programming application by customer Utilizes standard MODBUS protocol or Allen-Bradley DF1 protocol for PLC2, PLC5 and SLC500 devices Hard Wired Communication REMOTE FUNCTIONS DISABLED/ENABLED Selector Switch Contacts for Remote Start/Stop, Load/Unload, Acknowledge/Reset Trouble Indication Contacts (Alarm and Trip, Alarm Only or Trip Only) Remote 4-20 for Pressure Setpoint Running Unloaded Contact Air System Controller (ASC) Features Sequencing, load sharing and energy management for eight (8) compressors (more depending on network design and hardware) A CMC Communication Adapter mounted in each CMC panel Max distance from last compressor to Communication Adapter is 4000 feet (1218 meters) Modbus to Ethernet Bridge Ethernet Switch ASC Personal Computer (running Server Software) Pentium IV processor (Minimum 1.4GHz microprocessor) 256 MB RAM (512 Recommended) 144 MB 3.5 inch diskette drive Network Interface card Recordabel/Rewriteable CD ROM Drive 144 MB 3.5 inch diskette drive Minimum 40.0 GB hard drive CUSTOMER RESPONSIBILITIES Three phase power Clean, dry control air 80-150 PSIG (5.62-10.55 kg/cm2) Control air tubing from control air header, 1/4 in (0.635 cm) FNPT connection Mount and wire external switches and field wired devices Tuning control parameters for system Current transformer – instrument grade 0-5 amp Better than 1% accuracy CONTROLLER OPERATING ENVIRONMENT Electrical Operation 115 VAC ±5% 24 VDC Instruments except three wire RTDs 32 VA of AC power requirement 50/60 Hz AC supply frequency Temperatures Operating temperature 32 to 140 degF (0 to 60 degC) Storage temperature -4 to 158 degF (-20 to 70 degC) Relative Humidity 95% (maximum) non-condensing DOCUMENTATION Instruction book Electrical schematic Panel Outline drawing (Optional) CMC TECHNICAL REFERENCE MANUAL Glossary The following glossary is generic; therefore, some terms do not apply to all CMC systems. AB — See Allen-Bradley. Absolute Address — For Modbus compliant devices, the specific memory location for a coil, discrete input, register or analog input. The address is a five-digit number. Accelerometer — An instrument used to measure acceleration. These instruments are typically used for bearing analysis. Actuator — The device on a control valve that provides the power to move the valve to a position. Typically, this power is supplied through control air to open (for the inlet valve) and close (for the bypass valve). For “fail-safe” operation, a spring is used to drive the valve in the opposite direction. Address — This term is used by PLC manufacturers to indicate a specific memory location within the unit. These locations typically reference the value for data items like analog inputs, analog outputs, digital inputs, digital outputs, coils and intermediate computational states. Through these memory locations, the current system pressure, first stage vibration and discharge air temperature can be determined. Alarm — The term used to indicate that an abnormal condition exists that should be addressed by an operator. This condition has not reached a level that would shut down the compressor. Alert — See Alarm. Allen-Bradley — A manufacturer of control products, most notably PLCs. These PLCs are used for various industrial applications including controlling compressors. American Wire Gage (AWG) — The measurement system used to indicate the diameter of the wire. The gage number increases as the wire diameter decreases. Ambient Control — See Polytropic Head. Analog Input — An electrical device, which represents a specific real world pressure, temperature, vibration or current. As these items fluctuate, the electrical signal to and from the microprocessor board also fluctuates proportionally to the amount of change. The electrical signal is typically in the form of a current that ranges from 4 to 20 milli-amps in magnitude. Analog Output — An electrical signal, which typically represents the inlet and bypass valve position. As these valves fluctuate, the electrical signal to and from the microprocessor board also fluctuates proportionally to the amount of change. The electrical signal is typically in the form of a current that ranges from 4 to 20 milli-amps in magnitude. Auto-Cold Start — A control mode that automatically energizes the panel power, opens cooling water flow valve to the coolers, turns on seal air, starts and loads the compressor on a low pressure condition. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Auto-Dual — The control mode that automatically unloads a modulating compressor when the bypass valve position reaches a specified value or the check valve closes. Once unloaded, this control mode will automatically reload the compressor when the system pressure drops below a specified value. Auto-Dual Unload Timer The time delay, in seconds, at which the machine will be unloaded after the bypass valve has passed and stayed below the unload point when Autodual is active. Auto-Hot Start — A control mode that automatically starts and loads the compressor on a low-pressure condition. Auto-Reload — The portion of Auto-Dual control mode that automatically reloads the compressor when the pressure drops below a specified value. Auto-Start Pressure The system pressure, in pressure setpoint units, at which the machine will start when either auto hot or cold start is active. Axial Position — The position of the rotating assembly with respect to the horizontal axis of the pinion. Baud Rate — Unit of signaling speed for data communications. The speed in baud is the number of line changes (in frequency, amplitude, etc.) or events per second. At low speeds each event represents only one bit and baud rate equals bits per second. As speed increases, each event represents more than one bit, and baud rate does not truly equal bits per second. BCM — Base Control Module. The device of the CMC that receives all of the compressor inputs and outputs and makes decisions about how the compressor is to operate. Binary Signal — The type of signal used in communications. Binary refers to the smallest size of data being transmitted, a bit. Blow-off Valve — Also know as a bypass valve or antisurge valve. This valve protects the compressor from surge by bypassing a percentage of the compressed air to the atmosphere, which results in keeping the compressor loaded above the surge point. BPS — Bits per second. Unit of signaling speed for data communications. Bridge — A device which forwards traffic between network segments based on data link layer information. These segments would have a common network layer address. Bypass Valve — See blow-off valve. CAT 5 — Category 5. A classification of cable used in twisted-pair networks. CE Mark — The CE Mark is a combination of various individual European standards into one set of standards for the entire European community. The Mark is a self declaration and self marking process. Once you have proven that the particular equipment meets the requirements of CE 1 2 Mark and have the data to back it up, you may mark the product with the CE Mark. Citect — One of many SCADA software packages that can be used for air system integration. Choke — Also know as stonewall. This is the maximum flow that can be compressed by a given machine’s hardware configuration. Circuit Breaker — An automatic switch that stops the flow of electric current in a suddenly overloaded or abnormally stressed electric circuit. CMC — Centac MicroController. CMC System — Any combination of CMC control components which when combined create a control system. The typical CMC system consists of a Base Control Module (BCM), Operator User Interface (OUI), and Power Supply (PS). A common variation on the typical system is the addition of a Universal Communications Module (UCM). Coast Timer — The time interval, in seconds, between a compressor stop or trip and the motor coming to a complete stop. The timer is used to inhibit restarting. Compressor Load, Load — The power consumption of the compressor. It is typically indicated in amps, kilowatts, SCFM, etc. COM Port — See Serial Port. Control Transformer — The transformer that is used to reduce the incoming voltage (for the prelube pump motor and oil heater) to approximately 120 volts for controlling the CMC electrical devices (relays, power supply, etc.). Control Valve — The inlet or bypass valve used to control pressure or current. Control Variable, Process Variable — The variable being regulated. When at MinLoad the control variable is load for the inlet valve and System Pressure for the bypass valve. When at MaxLoad the control variable is load and when loaded the control variable is System Pressure. CSA Approval — Canadian Standards Association approval is required for all electrical devices shipped into Canada. This association is similar to UL for the United States and CE for Europe. CT — Current Transformer. CT Input Channel — The current transformer input channel. CT Ratio — Current Transformer Ratio. The current transformer ratio used in displaying the motor current; e.g. 600:5 = 120. Current Transformer — The electrical device used to measure the amps of the main drive motor. For our standard application, we only measure the current from one of the three phases. Daisy Chain — A method of wiring a communication network. This method starts with the “master” and it is wired directly to compressor #1. Compressor #2 is wired to compressor #1, then compressor #3 is wired to compressor #2. CMC TECHNICAL REFERENCE MANUAL Data Link — A direct serial data communications path between two devices without intermediate switching nodes. Data Highway Plus — A communication protocol used by Allen-Bradley PLC 5 and SLC500 PLCs. DCS — See Distributed Control System. degC — Degrees Celsius, Centigrade. degF — Degrees Fahrenheit. DH+ — See Data Highway Plus. Derivative Mode — Provides a change in the control variable (through the inlet or bypass valve) based on the rate of change of the error (setpoint pressure minus system pressure). Derivative Constant — Also know as the rate time, in units of seconds. Design Point — The pressure and capacity required at maximum ambient conditions. Digital Device — A device, which is either on or off; e.g., the N.C. contact on the seal air switch. Discrete Device — See Digital Device. Discharge Pressure — The gas pressure between the last stage of compression and the check valve. Distributed Control System — A system that attempts to control an entire plant or process with multiple independent local controllers by networking these local controllers to a central computer through digital communications. These central computers can be a PC, PLCs or other larger systems. Some manufacturers of these DCS products are Bailey, Honeywell, Allen-Bradley, Siemens, and others. Drain Wire — An insulated wire in contact with a shield throughout its length, and used for terminating the shield. Dry Contacts — A set of contacts that require a power source supplied by others (customer). This is the normal type of contacts that we provide. Electro-pneumatic — A term used to indicate a combination of electronics and pneumatics. In the past, we provided electro-pneumatic panels as standard equipment. With the advent of digital computers, most all control panels are electronic. ERAM — Erasable Random Access Memory. Event — The control transfer or “rule(s)” as used in State Logic to transfer from one state to another. FactoryLink — One of many SCADA software packages that can be used for air system integration. FLA — Motor Full Load Amps. The motor amperage at full load, this value is found on the motor nameplate. Flexible Conduit — Small diameter hose, made of plastic coated aluminum, which is used to enclose wire from the control panel to machine mounted instruments. Fused Disconnect — As a safety precaution, this option removes power from the panel before the door is opened. By turning the rotary door handle, the panel power is terminated. The disconnect would have to be mounted 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL external to the panel enclosure. The short circuit capacity, maximum ground fault, motor full load amps, motor locked rotor amps and motor voltage must be known to size the disconnect properly. Ground — A connection to earth or to some extended conducting body that serves instead of the earth. Ground Loop — An unwanted, continuous ground current flowing back and forth between two devices that are at different ground potentials. Grounded System — An electrical system in which at least one point (usually a wire) is intentionally grounded. Head — See Polytropic Head. High Load Limit — See HLL HLL — High Load Limit. The load that the controller maintains when at MaxLoad. I/O — See Input/Output. IBV — Inlet Butterfly Valve. See Inlet Valve. IEC — International ElectroTechnical Commission is the governing body of Europe for electrical equipment and codes. IGV — Inlet Guide Vanes. See Inlet Valve. Inlet Unload Position — The position of the inlet valve when in the unloaded state. Inlet Valve — The device used on the inlet pipe to the compressor that restricts the amount of airflow to the compressor. This valve can be a butterfly valve or a valve with inlet guide vanes. Input/Output —The hardware interface between the compressor and the control system. This term generically applies to the entire interface circuit including sensor, wiring, and junction points. Instrument Air — The air supply to the panel that is directed to the power air system for the inlet and bypass valves and the compressor seals. Integral Mode — Provides a change in the control variable (through the inlet or bypass valve) based on the time history of the error (setpoint pressure minus system pressure). Integral Time Constant—This value is expressed in repeats per second and represents the number of times per second the integral mode acts. Intellution — One of many SCADA software packages that can be used for air system integration. Interface — The hardware or software device used to communicate between products. Interlock — An electrical function that prevents the compressor from starting in the event that the function has not been satisfied. For example, the seal air interlock prevents the compressor from starting until the seal air pressure is adequate. IRBUS — The proprietary communication protocol used to communicate to and from one or many Base Control Modules 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 (BCM), Universal Communication Modules (UCM) and Operator User Interfaces (OUI). Loopback — A diagnostic test in which a transmitted communication signal is returned to the sending device after passing through all or part of the communication network. This test compares the transmitted signal to the received signal. The test passes if the signals are identical. MA, mA — Milliampere Maintained Contact — A contact closure that remains closed. MaxLoad — The message displayed on the OUI Status Bar when the machine is running at MaxLoad. MinLoad — The message displayed on the OUI Status Bar when the machine is running at MinLoad. MMI — Man Machine Interface. The term used to indicate the device or method used for a human to interface with a machine. Typically these interfaces are LCD displays or computer screens. For the CMC, the MMI is the Operator User Interface (OUI). Modbus — A sixteen-bit communication protocol originally developed for Modicon PLCs. This protocol has become a defacto standard for industrial equipment. Modicon — A PLC brand name manufactured by Schneider Automation. Modulate — The control mode that opens and closes (modulates) the inlet or bypass valve to maintain a constant discharge pressure. This is the primary control mode for centrifugal compressors. Momentary Contact — A contact closure that closes and then opens. N.C. — Normally Closed. Used to indicate the state of a contact when no power is applied. N.O. — Normally Open. Used to indicate the state of a contact when no power is applied. Natural Curve — The set of pressure and capacity points that define the operating characteristic of the centrifugal compressor. Natural Surge — The point on the natural curve that is represented by the maximum pressure and minimum capacity. NEMA — National Electrical Manufacturers Association. Network — A series of points, nodes or devices connected by some type of communication medium. On-Line/Off-Line — Control mode that allows the system discharge pressure to fluctuate between two pressure setpoints. The compressor will load when the actual pressure is below the lower setpoint pressure and will unload when it reaches the higher setpoint pressure. This type of control mode is normally used on reciprocating and rotary compressors. 3 4 CMC TECHNICAL REFERENCE MANUAL OUI — Operator User Interface. The device on the CMC that gathers user inputs and provides compressor operating status. Parity — The addition of non-information bits to make up a data transmission block that ensures the total number of 1s is either even (even parity) or odd (odd parity). This is used to detect errors in communication transmission. Partial Unload — See Surge Absorber. Password — The four digit parameter used to determine when the user can modify setpoints. The range of this password is 0000 to 9999. PID — Proportional, Integral, Derivative. The parameters used to adjust the behavior of PID control loops. PLC — Programmable Logic Controller. This hardware device is configurable such that many types of analog and digital inputs and outputs can be utilized to control various industrial products. PLC 5 — Type of Allen-Bradley PLC used for large applications. Pneumatic — Run by or using compressed air. Polytropic Head — The energy in foot-pounds to transfer one pound of given gas from one pressure level to another. (ft-lb/lb) Positioner — The device on a control valve that instructs the actuator how much (to what position) to move the valve. PROM — Programmable Read Only Memory. Proportional Mode — Provides a change in the control variable (through the inlet or bypass valve) proportional to the error (setpoint pressure minus system pressure). Proportional Band Constant — The percent change in system air pressure that causes a percent change in the valve position. This value is dimensionless. Protocol — A formal set of conventions governing the formatting and relative timing of message exchange between two communication systems. RAM — Random Access Memory. Relative Address — For Modbus compliant devices, the fourdigit address within the range of 0-9999. The relative address can be determined from the absolute address by deleting the type (the ten-thousandth place) and subtracting one. Reload Percent — The reload pressure, in percent of user pressure set point, at which the machine will load when Autodual is active. Rigid Conduit — Small diameter pipe, made of carbon steel with welded connections, which is used to enclose wire from the control panel to machine mounted instruments. This conduit is typically used in hazardous area classifications. Rise To Surge — The amount of pressure from the operating pressure to the natural surge pressure. This amount is usually expressed in percent. RS-232 — Electronic Industries Association interface standard between data terminal equipment and data communication equipment, using serial binary data interchange. This is the most common standard used by industry. RS-232 to RS-422/485 Converter — A hardware device that electrically converts an RS-232 signal into an RS-422 or RS485 signal. RS-422 — Electronic Industries Association interface standard that specifies electrical characteristics for balanced circuits and extends transmission speed and distances beyond RS-232. This standard is a balanced voltage system with a high level of noise immunity. RS-485 — Electronic Industries Association balanced interface standard similar to RS-422, but uses a tri-state driver for multi-drop applications. RTD — Resistance Temperature Detector. An instrument that measures temperature by detecting the voltage across the RTD material (mostly platinum). The temperature is determined because as the temperature increases the resistance increases. RTU — Remote Terminal Unit. A device typically used for data acquisition to gather data. By using this definition, the Base Control Module is an RTU. SCADA — Supervisor Control and Data Acquisition. The generic classification for software that gathers data for control of industrial products. Sequencer — A hardware or software device that controls the order in which compressors starts, stops, loads and unloads. Some sequencers also control loading and unloading through incremental pressure setpoints among the compressors. For example, in a three-compressor application the setpoints may be 101 psi for compressor #1, 100 psi for compressor #2 and 99 psi for compressor #3. Assuming the pressure transducers were calibrated within one psi of each other and the machines were running unloaded, this configuration would drive compressor #1 to load first when the pressure dropped to 101 psi. Serial Device — A Personal Computer (PC), Programmable Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit, receive and interpret an RS422/485 formatted signal. Serial Port — The RS-232 connection on the back of a PC to communicate with other equipment. This connection is typically referred to as COM1. A single PC can have more than one serial port. Service Tool — The software used on the PC to configure, tune, record and log data from the CMC. Service Tool Plug — A port on Panel door to provide access to IRBUS Network. Requires Laptop and external UCM. Setpoint Ramp Rate — The gradual increase of the system pressure set point during a loading operation of the compressor. The ramping of the system pressure set point helps to smooth the transition and prevents a pressure overshoot in the air system upon initial compressor loading. Shielded Wire — Wire that has a sheet, screen or braid of metal, usually copper, aluminum, or other conducting 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 CMC TECHNICAL REFERENCE MANUAL material placed around or between electric circuits or cables or their components, to contain any unwanted radiation, or to keep out any unwanted interference. SLC500 — Type of Allen-Bradley PLC used for relatively small applications and is lower in cost than an equivalent PLC 5. Start Timer — The time interval, in seconds, between pressing the Start button and the compressor is running at full speed. The timer is used to transition wye delta starters, inhibit loading, de-energize the prelube pump, and disable the alternate alarm and trip setpoints. State — A task that is currently being executed in State Logic. Only one state is active at one time. State Logic — State Logic is an alternative to traditional control languages used for machines, systems, and processes. State Transition — The movement from one state to another based on one or more events. Status Bar — The Status Bar provides four distinct types of information (Compressor Operating State, Compressor Status, Compressor Control Location and Page Number). This region is always visible from any folder and page combination. Stonewall — See Choke. Surge Absorber — The reaction of the control system to a surge that pops the bypass valve open by a small percentage to get the compressor out of the surge condition. This feature is initiated by surge detection. Surge Anticipation — The ability of a control system to prevent surge by predicting that a surge is about to happen. Surge Detection — The ability of a control system to indicate that a surge has happened. This feature is important because a persistent surge condition can damage the compressor. Once detected, the control system can respond to the event by taking a corrective action; i.e., by opening the bypass valve. Surge Indexing — A method of automatically increasing the setting of TL upon a surge. Surge Indexing TL — The setpoint at which the inlet valve controls to MinLoad. Surge Line — A series of points that represent natural surge for various inlet pressure conditions. Surge PTX — Surge Pressure Transducer. Surge PTX is mounted between the last compression stage and the check valve. Surge Sensitivity — A setpoint that is used to indicate the magnitude of pressure and current changes that occur during a surge condition. This setpoint determines when the control system detects a surge. Surge Unload — The reaction of the control system to a surge that unloads the compressor to exit the surge condition. This feature is initiated by surge detection. Switch, Ethernet — A device connected to several other devices. Transfers messages across the network. System Pressure — The pressure at the location of the system pressure transducer. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003 Terminal Block — A device that is used to connect to wires. Typically, these blocks are provided for customer field wiring to the panel and when one wire is to be connected to multiple devices. Terminating Resistor — A resistor placed at the end of a communication network for absorbing or sufficiently attenuating signals incident on it so that they are not reflected back into the transmission line at amplitudes where they would cause distortion of the data signal. Typically, a resistor is placed at each end of the network to help eliminate noise. Thermocouple — A device used to measure temperatures accurately and consists of two dissimilar metals joined so that a voltage is generated between to the contacts of the two metals as the temperature changes. Throttle Limit — See TL. Throttled Surge — The condition created by closing the inlet valve past the surge point to maintain constant pressure. Tight Closure — A term used to describe the inlet valve position when the compressor is not running and starting. The inlet valve ideally is closed tightly when stopped to prevent reverse rotation of the compressor if the check valve fails. Also, to reduce the load on the compressor during starting, the inlet valve can be held closed for a short period of time (less than thirty seconds) after the start button is pushed. This is most typically done on compressors at high altitude, most notably snow making applications. Bearing analysis must be done prior to using this option. TL — Throttle Limit. Establishes the minimum flow through the machine when loaded, it is the maximum point of inlet valve throttling. If system demand is below this throttle point, the compressor must bypass air to maintain pressure setpoint or unload. TL increment value — When Surge Indexing is enabled, the TL increment value is the amount added to the Surge Indexing TL upon a surge. The Surge Indexing TL will stop being incremented when and if the value reaches MaxLoad. Transducer — An electrical device that provides a usable output (4-20 mA, 0-5 vDC, etc.) in response to a measured property (pressure, temperature, etc.). Transformer — An electrical device that transfers energy from one circuit to another by electromagnetic induction. Transient Voltage Surge Suppressor — An electrical device that prevents temporary over-voltages of short duration (typically associated with lightning strikes and ground faults on an ungrounded system) from damaging other electrical equipment. Transmitter — An electrical device that sends the digital representation of a real measured value (e.g., pressure, temperature), to the BCM in the control panel for analysis and display. Turndown — The amount of capacity that can be decreased from full load (maximum load) at a constant pressure before 5 6 CMC TECHNICAL REFERENCE MANUAL the bypass valve begins to open to avoid surge. This amount is usually expressed as a percent of full load capacity. TVSS — See Transient Voltage Surge Suppressor. Twisted Pair Wire — Paired cables allow balanced signal transmission, which results in signals with low noise. Due to the improved noise immunity of twisted pairs, data speeds are usually higher than those of multi-conductor cables. UCM — Universal Communications Module. The device that allows outside systems to communicate with the CMC. UL — Underwriter’s Laboratory. Ungrounded System — An electrical system, without an intentional connection to ground. Unload — The operating mode that passes a small amount of air through the compressor and bypasses it to the atmosphere. In this mode, the inlet valve is cracked open a small amount and the bypass valve is fully open. This mode is used when starting the compressor before loading, stopping the compressor and during periods of no demand. Unload Point — The bypass valve position, in percent open, at which the Autodual unload timer will start timing to unload the compressor when Autodual is active. User Pressure Set Point — The local control pressure set point. Valve Stroking — The process of calibrating the valves to align the fully open position to 100 percent and the fully closed position to 0 percent of output signal. VDC — Volts Direct Current Voltage Regulator — An electrical device that maintains voltage to a predefined level. Wait Timer — The delay interval, in seconds, between power up and the ready state. Wire Gage — See American Wire Gage. Wonderware — One of many SCADA software packages that can be used for air system integration. Z-Purge — Required when the customer environment is Division 2. A Type Z Purge reduces the classification within an enclosure from Division 2 too non-hazardous. When provided, a NEMA 4 or NEMA 4X enclosure is required. Hand valve selectable quick and slow purges, with flow meters are provided to regulate the amount of gas entering the panel. A differential pressure switch is wired to a light on the front of the panel to indicate if there is a loss of purge gas. A relief valve is installed to prevent over-pressurization and a warning label, text below, is affixed to the front of the panel. 22204796 Rev. B, Version 3.10 1996-2003 Ingersoll-Rand Company Date of Issue: March 24, 2003
