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Neuron II Manual

Index
1.0
2.0
3.0
4.0
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.4
4.4.1
4.4.2
4.4.3
4.5
5.0
5.1
5.2
6.0
7.0
8.0

Technical Features
Controller terminal configuration
Main Menu Screen
Menu Structure
View
Operator
Fault Report
Day Report
Service Time
Cumulative Time
VFD
Operator
Machine
Schedule
Maintenance
Language
Change Password
Service
Calibration
Relay
Change Password
Maintenance
Clock
Self Test
Change Password
Factory menu
Machine
Change Password
Integrator Dryer
Customer care
Data Interface
Analog output
DCS Port
Construction & Dimension Drawing
Controller Identification
Revision Details
APPENDIX A: Mimic LED Table
APPENDIX B: Short Cut Key Functions
APPENDIX C
APPENDIX-D
21.0

23.0
24.0
25.0
26.0
26.0
26.1
26.1
26.2
26.2
26.3
26.3
26.4
26.5
26.7
26.7
26.8
26.8
26.9
26.9
26.10
26.10
26.10
26.11
26.11
26.11
26.12
26.13
26.14
26.14
26.14
27.0
27.0
27.0
28.0
29.0
29.0
30.0
31.0
32.0
33.0

21.1

Technical Features

8 nos of Optically Isolated Digital Inputs of 24VDC


01
02
03
04
05
06
07
08

=
=
=
=
=
=
=
=

Emergency Stop
Differential Pressure Oil Filter - DPOF
Reverse Rotation
Differential Pressure Air Filter - DPAF
Remote Start/Stop
High Sump Pressure
Cooler
Main Motor Overload

8 nos of Output Relay (SPDT 250V AC 10A, 1,00,000 cycle electric life)
01
02
03
04
05
06
07

=
=
=
=
=
=
=

08

Main contactor
Star contactor
Delta contactor
Load Valve
Fan
Auto Drain Valve
Dryer (if Dryer is Connected- else Programmable -Load,
Service, Standby, Warn, Trip, Remote, Ready)
Programmable [Load, Service, Standby, Warn, Trip, Remote,
Ready]

22.0

Technical Features
4 nos of Analog Input Channels
1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure
1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature
1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure
1 no of RTD (Pt-100) channel, -50 to +90 degree C for Drier Dew Point or
Ambient Temperature
2 nos of Analog Output Channels
1 to 5 VDC, One for Discharge Pressure and One Programmable (Sump
Pressure, Discharge temp, Dew point/Ambient)
9 nos of Function keys
Up, Down, Left, Right, Enter, Escape, Start, Stop and Reset.
1 no of Display
128X64 White Backlight Graphical LCD
9 nos of LEDs for Visualization Alarm & Machine Status
Auto
Air Filter
Main Motor Overload
Reverse Rotation
Cooler
Pressure
Temperature
Differential Pressure Oil Filter
Differential Pressure Separator Element
1 no. of Dual LED for Start/Stop Indication
Green for start and Red for stop
1 no. of Non Volatile Memory
For storage of 30 Days reports & 99 Fault Reports
1 no. of Real Time Clock
With Battery life of about 10 years

22.1

Technical Features
4 nos of Communication Port (RS485, 2 wire)
Serial Port 1: MODBUS-RTU or SCADA Port
Serial Port 2: Dedicated FPD Port (For future use)
Serial Port 3: Add-On I/O Interface Port (expansion possibility)
Serial Port 4: VFD Interface Port
1 no. of In System Programming (ISP) Port For program / Data down loading
and data uploading
Power Supply Input: 24VAC +/- 25%, 50Hz / 60Hz, 1A (In built Protection
present for Surge, Over Current)

22.2

Controller Terminals Configuration


X01: Power supply
Connector type: 3 pole combicon
Pin
1
2
3

Function
24V AC Phase
Earth
24V AC Neutral

Id
24 VAC P
Earth
24 VAC N

Active state
-

X02: Relays
Connector type: 10 pole combicon
Pin
1
2

Function
Common - Load Relay
Load Relay

Id
Common
L / UL

3
4
5
6
7
8
9
10

Common - Fan Relay


Fan Relay
Common - Auto Drain Valve Relay
Auto Drain Valve Relay
Common Dryer Relay
Dryer Relay/ programmable relay
Common - Programmable Relay
Programmable Relay

Common
Fan
Common
ADV
Common
Dryer / Pr2
Common
Pr1

Active state
Load when
Energised
Energised
Energised
Energised
Energised

X03: Main Motor Relays


Connector type: 4 pole combicon
Pin

Function

Id

Active state

Common for Main, Star and Delta


contactors

Common

Main Contactor

Main

Energised

Star Contactor

Star

Energised

Delta Contactor

Delta

Energised

23.0

Controller Terminals Configuration


X04: Digital Inputs
Connector type: 11 pole combicon
Pin
1
2
3
4
5
6

Function
Digital Inputs Common 24VDC
Emergency Stop
Differential Pressure Oil Filter
Reverse Rotation
Differential Pressure Air Filter
Remote Start Stop Control

Id
24VDC
Emergency
DPOF
Rev. Rot
DPAF
Remote

7
8
9
10

High Sump Pressure


Cooler Fault Input
Main Motor Overload
24V Supply Ground

HSP
Cooler
MMOL
-24V DC

No Connection

voltage)
-

11

Active state
Fault if open
Fault if open
Fault if closed
Fault if open
Stop if open/
start on Closure
Fault if open
Fault if open
Fault if open
(provision for
check DI
-

X05: Analog Inputs


Connector type: 8 pole combicon
Pin
1
2
3
4
5
6
7
8

Function
Discharge pressure
15 to 24VDC
Discharge Temperature
Discharge Temperature
Sump Pressure
15 to 24VDC
Dryer or Ambient
temperature
Dryer or Ambient
temperature

23.1

Id
Type
Dis. Pr
4-20 ma
18V
Dis. Tr + KTY10
Dis. Tr Sump Pr 4-20 ma
18V
Pt100 + Pt100
Pt100 -

Range
0 to 16 bar
0 to 150C
0 to 16 bar
-50 to +90C

Controller Terminals Configuration


X06: Analog Outputs and VFD
Connector type: 5 pole combicon
Pin
1
2
3
4

Function
VFD Interface
VFD Interface
Supply Ground For 5V
Dis. Pressure Output

Id
VFD A
VFD B
0VDC
AO1

Type
Protocol/Range
RS485A
FC Protocol
RS485 B
Voltage(1-5V)
0 to 16 bar

Programmable Analog
Output

AO2

Voltage
(1-5V)

0 to 160C /
0 to 16 bar /65 to 95C

X07: Communication
Connector type: 6 pole combicon
Pin

Id

Type

Protocol/Range

DCS Interface-Modbus
RTU

DCS A

RS485 A

Modbus-RTU

DCS Interface Modbus RTU

DCS B

RS485 B

FPD Interface

FPD A

RS485 A

FPD Interface

FPD B

RS485 B

Add On Interface

Add-On A

RS485 A

Add On Interface

Add-On B

RS485 B

1
2

Function

23.2

ASCII
Modbus

Main Menu Screen


Dis. Pr
Dis. Tr
Message 1
Message 2
Warning
HH:MM:SS 1

:
:

6.0 bar
32C

2 DD/MM

Message 1: Based on the short cut keys pressed (refer APPENDIX B)


Message 2: Compressor Status or fault message
1 - Pressure schedule
- If Blank Pressure schedule is disabled
- If PS Pressure schedule is enabled
- If PS blinking Waiting for pressure schedule acknowledgement
2 - Control Mode (*/$)
- *L Local, ON/OFF control from local keypad
- *R Remote, ON/OFF control from remote input
- *D DCS, Control is from DCS System
- $M Manual, Start command given after power failure
- $A Auto, Compressor will automatically restart after power failure

24.0

Main Menu Screen


Message 2 - Compressor Status or Fault message
Status
Ready
Star
Run
Run load
Run unload
Stop busy
Idle
Emergency stop
Start inhibit xx.x

Description
Ready for start
Motor running in Star
Motor running in Delta
Compressor in load
Compressor in unload
Stop sequence in progress
When the controller is in idle, User interface will not
function during this period for 5 seconds
Emergency Stop Push Switch is ON
During the start, if sump pressure is higher than the
set sump pressure value for starting, this message is
displayed XX.X denotes the live sump pressure value.
The compressor starts only if the pump pressure value
is below the set value.

Start inhibit
seconds

If the sump pressure is not used (Disabled) then the


controller will ensure a minimum of 60 seconds
delay between the stop and the start. Count stops if
STOP key is pressed

Auto restart
seconds

If the compressor is in Auto Mode, the controller


will ensure a minimum delay (user set, e.g. 90 sec)
between the stop and the start operations. Count stops
if STOP key is pressed
This message is displayed when the compressor waits
for user acknowledgement, after fault clearance. By
pressing START key user can acknowledge

Start ack wait

24.1

Main Menu Screen


Status
Pr. Probe failure
Tp. Probe failure
Sump Pr. probe
HSP (A)

HSP (D)
Cooler
Main motor
Rev Rot / Ph fail
Trip temperature
Sump pressure
not developing

Power failure
Low voltage

Description
Discharge pressure sensor probe failure
Temperature sensor probe failure
Sump pressure sensor probe failure
Failure
Case 1: Sump pressure is enabled when the sump
pressure exceeds the set high sump pressure value.
Case 2: Sump pressure is disabled when the discharge
pressure exceeds the set high sump pressure value.
HSP digital input opens due to high sump
pressure
Cooler digital input opens due to cooler fault
MMOL digital input opens due to main motor
overload overload.
If the Rev Rot input closes, when the motor is running,
due to motor reverse rotation or phase failure.
Discharge temperature exceeds the set trip
temperature value
This function is displayed when the sump pr sensor is
activated. After the Start, the sump pressure should
be at least 1.0 bar in 10 seconds. If this is
not achieved fault may occurs.
Mains supply is interrupted for more than 30 msec
Mains supply voltage is less than the 67% of rated
voltage, compressor is tripped and the controller
operation is stopped until the Mains supply returns to
normal (at least 75% of the rated)

24.2

Menu Structure
From the default screen, press shortcut keys to view the following (Refer
Appendix B)
S
Set load, unload, start sump & maximum differential pressure values
T
Current day report
W
Warning messages (All warning messages can be viewed)
X
Current sump pressure, diff pressure & ambient temperature or dew point
Press Enter Key to display main menu
Main Menu
Dis. Pr
: 6.0 bar
Dis. Tr
: 32C Status
X View
Operator
Service
Factory
Customer Care
Scroll up or down by using up and down keys to select the menu. Then press
Enter to enter the selected menu.

View

Operator

Fault
Report

Day
Report

Service
Time

Cumulative
Time

VFD

4.1 View
No password required.
On view parameters, the preset parameters like mode, pressure values,
temperature values, timer settings, DCS parameters, last 99 fault reports, last
30days report, remaining service hrs due, cumulative time details and VFD
parameters can be viewed. The values cannot be altered through this menu.

25.0

Menu Structure
4.1.1 Operator
LEVEL 1

LEVEL 2

View

Operator

LEVEL 3
Mode

Pressure

Delay

DCS port

Temperature

LEVEL 4
Control mode
Unload mode
Auto restart
Pressure unit
Temperature unit
Unload pressure

Local / Remote / DCS


Enable / Disable
ON/ OFF
PSI / Bar
Fahren / Centi
X X . X b or p (bar or
psi)
Load pressure
X X . X b or p
Pr. schedule
ON/ OFF
Start sump pressure X X . X b or p
Max .diff pressure X X . X b or p
Warn RST delay
X X X s(second)
Star delay
XXs
DTR delay
XXs
RTS delay
XXs
Standby time
Sby X X m minute)
St/Sp PH X X
Type
Modbus / SCADA
Compr. ID
XX
Baud rate
9600/19200
Parity
None / Even
Length
8/7
Stop bit
2/1
Trip temperature X X X C or F
Warn temperature X X X C or F
Fan temperature X X X C or F
Low dew Pt
X X C or F
High dew Pt
X X C or F

4.1.2 Fault Report


Use S ,T to select the Fault record number (1 to 99).
LEVEL 1
View

LEVEL 2
Fault report

LEVEL 3
Fault code: XX, Message
Time:

25.1

HH:MM:SS

Date:

DD/MM/YY

Dis.Pr:

X X .X

Dis.Tr:

XXX

Status:

Load/ UnLoad /OFF

Menu Structure
Fault Code:
01 & 09 Reserved
02-Main motor overload, 03-Cooler, 04-HSP(Analog), 05Trip temperature, 06Reverse rotation, 07-Pressure probe failure, 08-Temperature
probe failure, 0A-HSP(Digital), 0B-Power failure( Short Power Interrupt), 0CSump pressure not developing , 0D-Sump pressure probe failure.
On the fault report, parameters such as line pressure, discharge temperature and
status of compressor will be displayed. This will help to troubleshoot the failure.
4.1.3 Day Report
Use S ,T to select the Record number (1 to 30).
LEVEL 1

LEVEL 2

View

LEVEL 3

Day report

Date:

DD/MM/YY

L:

X X Hours

St:

X X Hours

UL:

X X Hours

F:

X X Hours

R:

X X Hours

Sby:

X X Hours

STC: X X X

LDC: X X X X X

L- Load, St Stop, UL Unload, F- Fault, R- Run, Sby- Standby,


STC Start Count, LDC Load Count
On the fault report, parameters such as line pressure, discharge temperature
and status of compressor will be displayed. This will help to troubleshoot the
failure.

4.1.4 Service Time


LEVEL 1

LEVEL 2

View

Service time

LEVEL 3
Remaining AFCT:

X X X X X X hours

Remaining OFCT:

X X X X X X hours

Remaining OSCT:

X X X X X X hours

Remaining OCT:

X X X X X X hours

Remaining RGT:

X X X X X X hours

The remaining service hours for the consumable parts can be viewed and the
service due is completed. The countdown then will be shown in negative
(- hrs).

25.2

Menu Structure
4.1.5 Cumulative Time
LEVEL 1
View

LEVEL 2
Cumulative time

LEVEL 3
Load

X X X X X X hrs: X X Min

Unload

X X X X X X hrs: X X Min

Run

X X X X X X hrs: X X Min

Stop

X X X X X X hrs: X X Min

Fault

X X X X X X hrs: X X Min

Standby

X X X X X X hrs: X X Min

Start Count

XXXXXX

Load Count

XXXXXXXXX

Utilisation

XX%

On this menu, the cumulative hours including number of start/stops, number of


load/unloads and percentage of utilization can be viewed. With this Cumulative
Time feature, the Emergency stop hours will be accounted in stop hours, and
not under fault hours. This enables the user to view the real fault hours. These
details will further guide for energy savings in compressed air.
4.1.6 VFD
When the VFD is connected to the compressor, user can view the following
parameters of VFD on Neuron II.
1.
Voltage in V
2.
Current in A
3.
Frequency in Hz
4.
Power in KW
5.
Run Hours
6.
Kilowatt Hour (Multiply the value shown by 100 to get the real KWH)
7.
Status of the VFD

25.3

Menu Structure
4.2 Operator
Password protected. The operator has to receive the password from the
compressor commissioning engineer
Operator

Machine

Mode

Schedule

Pressure

Maintenance

Set
Delay

DCS
Port

Language

Auto Drain
Valve

Change
Password

Set Dew
Point

With this menu, the operator parameters can be adjusted to match the
requirement. Minimum and maximum limits are fixed for all the value adjustment
parameters. When the setting exceeds these values, there will be an indication
of out of range.

25.4

Menu Structure
4.2.1 Machine
#
1
2
3
4
5
6

Item
Auto restart
Pr unit
Tr unit
Control mode
Unload mode
Analog output 2

7 Unload
pressure
+0.5
(bar)
8 Load
pressure

Min
-

Max
Option
on / off
bar / psi
cen / fah
loc/rem/dcs
en/dis
Tmp / Sp /
Pt / off
off
Pressure
> load
< max
pressure unload
pressure
according
(bar)
to pr
model)
4.0 (bar) < unload
pressure0.5 (bar)
according
to pr

Default
off
bar
cen
loc
dis

Unit
-

7.5 bar
(Varied

bar/psi

5.5 bar
(Varied

bar/psi

model)
9
10
11
12
13
14

Warn RST
Star
DTR
RTS
Standby
St/Sp per hr

15

Type

16
17
18
19
20

ID
Baud rate
Parity
Length
Stop bit

21
22

Off time
On time

23
24

Low dew point


High dew point

90
6
10
5
1
3
-

Set Delay
300
10
60
30
99
10
DCS Port
-

90
6
10
5
5
5

second
second
second
second
minute
-

Modbus / modbus
SCADA
01
99
01
9600/19200 9600
bps
None /Even None
8/7
8
2/1
2
Auto Drain Valve
1
150
4
minute
1
15
5
Second
Set Dew Point
-6 C
+2 C
-2 C
C/F
6C
12 C
8C
C/F
25.5

Menu Structure
Important Function Keys:
Auto restart ON: Switches On the compressor automatically after a power
failure. The internal timer counts the power Off period and the period when
power resumes. The compressor starts after elapsing the set time by this
function, ensuring the compressor availability immediately after a power failure.
On the screen A will be displayed and the Auto lamp is On, indicating that the
compressor can be automatically started. If it doesnt, M (manual) will be
displayed. This mode indicates that a manual start is required after power failure.
Local: The compressor is switched On/ Off through the start and stop buttons
in the controller.
Remote: The compressor is switched On/Off only through Digital input (Remote),
and cannot be operated through the controller push buttons.
DCS : The compressor is operated only through modbus.
In Remote and DCS modes, the compressor can be stopped through the
Emergency stop. The Auto LED will glow, in both these modes, indicating that
the compressor can be automatically started.
Unload mode: This key verifies the functions of the compressor with out loading.
If this mode is selected, the relay out put (load / unload) will be de energized.
During this mode, the compressor runs continuously in Unload mode. If the
function is disabled, then the compressor operates as per the pressure set in
the controller.
Load pressure & unload pressure: The user can adjust these values within
the limits of the factory. The value is set at a minimum load pressure of 4 bar.
The maximum unload pressure is set as per the indication on the compressor
name plate. The minimum differential is 0.5 bar.

25.6

Menu Structure
4.2.2 Schedule
Enable Pressure Schedule, and use %, % to select the schedule number
(1 to 32).
Then Press Enter to set the following
#
1

Item
Day

2
3
4
5

Action
Time HH
Time MM
Unload
Pressure

Min
-

Max
-

00
23
00
59
> Load
< Max
Pressure Unload
+0.5
Pressure
(bar)
(bar)
Load Pressure 4.0 bar < Unload
Pressure
0.5 (bar)

Option

Default
Unit
Sun to Sat /
-- (means no
schedule)
on / off
Hour
Minute
bar/psi

bar/psi

Once the pressure scheduler is selected, PS blinks on the screen. To


acknowledge this, press START button. When pressed, the compressor starts
and stops as per the pressure scheduler. The start / stop keys are not activated
in this mode, after the user acknowledges it.
The controller is designed to accommodate changes in the schedule in between
periods. It avoids the necessity of marking changes in schedules in an order.
For example, consider the two periods: Monday schedule (1-4) and Tuesday
schedule (5-8). If the user wants to make changes to the Monday schedule, he
can enter the changes in the 9 schedule (that follows after the Tuesday schedule).
4.2.3 Maintenance
#

Item

AF changed

Min

Max

Option

Default

Unit

no/yes

no

OF changed

no/yes

no

OS changed

no/yes

no

Oil changed

no/yes

no

Re Grease

no/yes

no

Once the consumable part is replaced, enter in to the maintenance menu. Type
the changed part as Yes. Set the remaining service hours as per the 100%
service hours.

25.7

Menu Structure
4.2.4 Language
#
1
2
3

Item
English
Hindi
Portuguese

The user language can be selected, Default is in English.


4.2.5 Change Password
Procedure for changing the password
1.
2.

Enter the old password


If old password is correct, next screen is displayed. If wrong, the control
comes out of the change password screen
3.
When the next screen is displayed, enter the new password
4.
Re-enter new password
5.
If new password matches both the entries, the password will be updated.
If mismatch occurs, the control goes back to step 3.
Pressing Esc will bring the control back to the main menu screen

25.8

Menu Structure
4.3 Service
Password protected. Only Elgi Service engineers are authorized to change the
menu.
Service

Calibration

Relay

Fan
Temp

Maintenance

Clock

Self
Test

4.3.1 Calibration
Select the parameter needed for calibration using the %, %keys. Then Press
Enter to calibrate.
Discharge Pressure/ Discharge Temperature/ Sump Pressure Calibration
Run the compressor. Measure the value using a standard and recently calibrated
meter, when the value is stable. Enter the meter reading in the set value field
displayed on the Neuron II. Set Value should not exceed +/- 1 bar and +/- 10 C
the actual value.
Pt 100 Calibration
Measure the value using a standard and recently calibrated meter, when the
dew point/ ambient temperature is stable. Enter the meter reading in the set
value field displayed on the Neuron II. Set Value should not exceed +/- 3 C the
actual value.
Note:
Calibration should be done when the compressor is switched Off , and ensure
the digital outputs (relay terminals) are disconnected from the controller.
Calibration for pressure should be done for the pressure sensor at 8 bar (in bar
only), and at 100 Deg C (in Centigrade only).
(3.3k resistor=100Deg C)
Analog Output 1 & 2
Calibration for analog output is done for two values: one at zero and the other
at 8.0 bar / 80 degree C. These values are set by connecting a Variable Resistor
(TRIM POT) to the analog input channel. Measure the analog output value (can
be viewed in the DCS/VFD / or any master unit where this output is connected).
Enter this value in set pressure:

25.9

Menu Structure
4.3.2 Relay
Select the Programmable Relay 1 or 2 using the S,Tkeys. Then Press Enter
to assign any of the following functions for the relay.
#
1
2
3
4
5
6
7

Item
Warn
Load
Service
Standby
Trip
Remote
Ready

Default:
Relay 1 = Warn
Relay 2 = Trip
Note: If Dryer is enabled, the Programmable Relay
2 is not user programmable. It is used for automatic
dryer control.

4.3.3 Change Password


The fan temperature set point is used to start the fan when set temperature is
reached. Stop the fan when the temperature reaches 10 Deg C or lesser than
the set temperature. This setting is used to control On / Off settings of the fan,
based on the discharge oil temperature.
#

Item

Min

Max

Option

Default

Unit

Fan temperature

60 C

85 C

85 C

C/F

Max

Option

Default

4.3.4 Maintenance
#

Item

Min

Unit

Set AFCT

000000

999999

001500H

Hour

Set OFCT

000000

999999

001000H

Hour

Set OSCT

000000

999999

004000H

Hour

Set OCT

000000

999999

001000H

Hour

Set RGT

000000

999999

001500H

Hour

The maintenance due is fixed by Elgi Service Engineer based on the spare
parts used.

25.10

Menu Structure
4.3.5 Clock
#

Item

Min

Max

Hour

00

23

Minute

00

59

Second

00

59

Date

01

31

Month

01

12

Year

00

99

Day

Sun/Mon/Tue/Wed/Thu/Fri/Sat

The clock setting of the controller is not changed, if used in India. When used
overseas, the time is set according to the local timings, at the time of
commissioning
4.3.6 Self Test
Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output,
Memory & Communication Ports working.
Follow the instructions displayed on the screen.

Warning
Self-Test should be conducted only after disconnecting the compressor from
the controller. (Use connect power supply X01 3 pin connector) DO NOT perform
self-test when the controller is connected to the compressor. Doing so will cause
severe damage to the compressor.
4.3.7 Change Password
1.

Enter the old password

1.
2.

Enter the old password


If old password is correct, next screen is displayed. If wrong, the control
comes out of the change password screen
When the next screen is displayed, enter the new password
Re-enter new password
If new password matches both the entries, the password will be updated. If
mismatch occurs, the control goes back to step 3.
Pressing Esc will bring the control back to the main menu screen

3.
4.
5.

25.11

Menu Structure
4.4 Factory menu
Password protected. Only Elgi authorized persons are allowed to change the
setting.

Factory

Change
Password

Machine

Compressor
Info

DPAF

DPOF

Dryer

Max.
Pressure
Settings

25.12

Temperature
Settings

Menu Structure
4.4.1 Machine
#

Item

Min

Max

Rating

Pressure

Fab no
(10 digit)

Alpha:A
num:0

Alpha:Z
num:9

DPAF

DPOF

Max UL
Pressure

> Unload <13.5bar


Pressure

High sump
pressure

> Max
< Max
Unload Unload
pressure pressure
+0.5
+3

Sump
pressure

Option

Default

Unit

11 to 315

22

KW

LP/ 7.0to12.5

LP

bar

AAAA
000000

on/off

off

on/off
Max. Pressure Settings

off

7.5 bar

bar
/psi

10.5 bar

bar
/psi

enable/
disable

disable

Start sump
pressure

0.0 bar

16.0 bar

1.0 bar

bar
/psi

10 Max.
differential
pressure

0.0 bar

2.0 bar

1.5 bar

bar
/psi

Temperature Settings
11 Trip
temperature

80 C

120 C

110 C

C/F

12 Warn
temperature

70 C

110 C

105 C

C/F

If the sump pressure sensor is enabled, the Star sump pressure and the
maximum differential pressure values will function. In this mode, the high
sump pressure is activated based on the sump pressure in the Air oil
sump.

25.13

Menu Structure
4.4.2 Change Password
1.
Enter the old password
2.
If old password is correct, next screen is displayed. If wrong, the control
comes out of the change password screen
3.
When the next screen is displayed, enter the new password
4.
Re-enter new password
5.
If new password matches both the entries, the password will be updated.
If mismatch occurs, the control goes back to step 3.
Pressing Esc will bring the control back to the main menu screen
4.4.3 Dryer
#

Item

Min

Max

Option

Default

Unit

Dryer mode

on/off

off

Dryer Delay

10

Minute

This mode is enabled, if dryer is part of the compressor. The dryer is switched
on and off through the controller, provided the compressor is switched On.
When the compressor is On, dryer is switched On; and the dryer is switched
Off when the compressor is on Off mode. The time interval between the stop
and start operations is decided by dryer delay time setting, which enables the
safe operation of dryer and compressor.
4.5 Customer Care
Dis. Pr

6.0 bar

Dis. Tr

32 C

Status
Toll Free No
1800-425-3544
e-mail ccs@elgi.com

25.14

Data Interface
Neuron II has two types of Data Interface
N

Analog output

DCS Port

5.1 Analog output


Two channels are available for analog output. The first channel will output the
current discharge pressure value from 0.0 -16.0 bar, converted from 1 - 5V.
The Second channel is programmable. User can select any one of the following
menu: Operator/ Machine/ Mode/ Analog output
a. Dis. Temperature

0 -160 C, converted from 1 - 5V

b. Sump Pressure

0 - 16.0 bar, converted from 1 - 5V

c. Pt100 Temperature

-65 - 95 C, converted from 1 - 5V

Note: Analog output will be 0V, in case of probe failure.


5.2 DCS Port
DCS port can be of Modbus RTU type to interface to Generic DCS system or
SCADA type to interface to ELGI SCADA software.
User can select the Port type in menu Operator/ Machine/ DCS Port. The
ID, Baud Rate, Parity, data Length, Stop Bit are also user settable. The Modbus
data table will be provided based on the request (A CD contains address table
and activation key)

26.0

Construction
N

Corrosion & dust protected back cover

IP65 polyethylene front keypad

Inputs and outputs through terminal block, board to wires, disconnect


able, screw terminals

Front plate dimensions 260 x 145mm

Enclosure dimensions 235 X 120 X 70 mm

Operating temperature - 0C to +75C

Relative humidity <85% RH non-condensing @ 40C

6.1 Dimension Drawing

Panel Front Plate

260
100

145

133

Panel Cut out Dimension


70

235

X01

X05

X07
ISP

X03

All dimensions are in mm


27.0

X02

120

120

X04

X06

Controller Identification
While Communicating to Elgi, please mention the following:
Type of controller
SL no
Batch NO

Revision Details
Version

Date

Changes

1.0

2 April 2009

Initial Draft

1.1

13 July 2009

Pilot Batch S/W Version 1.1

1.2

01.02.2010

Pilot batch SW version 1.1D

For any other clarification in the controller please contact ELGI

Toll Free No : 1800-425-3544


e-mail ccs@elgi.com

28.0

Appendix A
Mimic Led Table
#
1

LED
Auto

Air Filter

Main Motor Overload

Reverse Rotation

Cooler fault

Pressure

Temperature

Differential Pressure

Differential Pressure

10

Start & Stop

Description
Indicates the machine is in Automatic
on/off mode. LED glows in Amber
Colour when
1. Pressure Schedule is enabled (or)
Auto Restart is enabled
Glows in Amber colour when 1.
Air Filter Service is due based on
service hours2. Air Filter Digital Input
(DPAF) is Open & DPAF is enabled
Glows in Red when the Main Motor
Overload Digital Input is Open.
Glows in Red when the Reverse
Rotation Digital Input is Closed
Glows in Red when the cooler Digital
Input is Open
Glows in Red when 1. HSP Digital
Input is Open 2. Analog Pressure
Input is Open (Probe Failure) Dis.
Pressure is higher than set HSP
Glows in Red when 1. Analog
Temperature Input is Open (Probe
Failure) 2. Dis. Temperature is higher
than set Trip temp.
Glows in Amber when 1. DPOF
Digital Input is Open & DPOF is
enabled Oil Filter Service is due
Glows in Amber when 1. Oil Separator
Filter Service is due 2. On High
Differential Pressure (Only if Sump
Pressure enabled)
1. Glows in Red when machine is
stopped / idle 2. Glows in Green
when machine is running

29.0

Appendix B
APPENDIX B: Short Cut Key Functions
Note1: All shortcut key functions only when the display is on Main Screen.
Note2: On every press of the key NEXT message is displayed.
WLEFT Warning messages
Warning
DPAF

Description
Differential Pressure Air Filter Due For
Service
DPOF
Differential Pressure Oil Filter Due For
Service
Dryer Probe Failure
Pt100 Sensor Probe Failure
Low Dew Point
Live Dew Point less than the Set Low
Dew Point
High Dew Point
Live Dew Point greater than the Set High
Dew Point
High Differential pressure Difference Between the Sump & Discharge
Pressure is greater than the set max
Differential Pressure value.
Warn Temperature
Discharge Temperature exceeds the set
Warn value
Change Air Filter
Air Filter Due For Service
Change Oil Filter
Oil Filter Due For Service
Change Oil Separator
Oil Separator Due For Service
Change Oil
Oil Change Due For Service
Change Grease
Re Grease Due For Service
Start Stop Exceeded
No. of Start and Stop per hour exceeded

30.0

Appendix B
XRIGHT - Live analog values
1. Live differential pressure
2. Live sump pressure
3. Live Pt100 temperature
S UP Set analog values
1. Set load pressure
2. Set unload pressure
3. Set start sump pressure
4. Max differential pressure

dDOWN Today report


1.
2.
3.
4.
5.

Date
Load and stop hours
Unload and fault hours
Run and standby hours
Start count and load count

30.1

Appendix C
APPENDIX C: Modbus Table [Function Code: 0x03(Read) & 0x10(Write)]
#

Data
Description

Address

Type Bytes

Example/
Format

Access

Cumulative Time & Count Registers


1

Load Hours

1010

BCD

HHHHHH:MM

Unload Hours

1012

BCD

HHHHHH:MM

Run Hours

1014

BCD

HHHHHH:MM

Stop Hours

1016

BCD

HHHHHH:MM

Fault Hours

1018

BCD

HHHHHH:MM

Standby Hours

101A

BCD

HHHHHH:MM

No of Start

101C

BCD

NNNNNNNN

Load Count

101E

BCD

NNNNNNNNNNNN

Utilization %

1022

BCD

10

Rem AFCT
Minutes

11

Rem OFCT
Minutes

XXXX

Service Remaining Time Registers


1029

ULong

H800927BF =
-599999

102C

ULong

H800927BF =
-599999

12

Rem OSCT
Minutes

102F

ULong

H800927BF =
-599999

13

Rem OCT
Minutes

1032

ULong

H800927BF =
-599999

14

Rem RGT
Minutes

1035

ULong

H800927BF =
-599999

Mode Registers

15 Control Mode

16 Unload Mode
17 Auto Restart

1040

1041
1042

18 Pr Unit

1043

31.0

BCD

BCD
BCD
BCD

2
2
2

0001-DCS
0002-Local
0003-Remote

R/W

0001-Disabled
0002-Enabled

R/W

0001-OFF
0002-ON

R/W

0001-BAR
0002-PSI

R/W

Appendix C

Data
Description

19 Tr unit
20 Pr. Schdl
(on/off)

Address

1044
1045

Type Bytes

BCD
BCD

2
2

Example/
Format

Access

0001-Centi
0002-Farhen

R/W

0001-OFF
0002-ON

1200 (/100) =
12.0 bar

1100 (/10) =
110 C

MSB 01 = +
MSB 02 = LSB = 30

1200 (/100) =
12.0 bar

0100 (/100)
=1.0 bar

0120 (/10)
= 12.0 bar

R/W

0080 (/10) =
8.0 bar

R/W

Analog Registers

27 Dis. Pressure
28 Dis.
Temperature
29 Dew Point /
Ambient
Temperature

30 Sump Pressure
31 Diff Pressure

104A
104B

104C

104D
104E

BCD
BCD

BCD

BCD
BCD

2
2

32 Set Unload
Pressure

104F

33 Set Load
Pressure

1050

34 Set Diff
Pressure

1051

BCD

0010 (/10) =
1.0 bar

R/W

35 Trip Temp

1052

BCD

0110 = 110 C

36 Warn Temp

1053

BCD

0105 = 105 C

R/W

37 Low Dew Point

1054

BCD

MSB 01 = +
MSB 02 = LSB = 30

R/W

MSB 01 = +
MSB 02 = LSB = 30

R/W

0070 = 70 C

R/W

38 High Dew Point

39 Fan Temp

1055

1056

BCD

BCD

BCD

BCD

2
2

31.1

Appendix C
#

Data
Description

Address

Type Bytes

Example/
Format

Access

21 Auto Restart
Delay (Sec)

1060

BCD

0100

R/W

22 Star Delay (Sec)

1061

BCD

0005

R/W

23 DTR Delay (Sec)

1062

BCD

0010

R/W

24 RTS Delay (Sec)

1063

BCD

0010

R/W

25 Standby Time
(Min)

1064

BCD

0005

R/W

26 Max. No of Start
per hour

1065

BCD

0005

R/W

RTC Registers

40 Hour

106A

BCD

0023

41 Minutes

106B

BCD

0059

42 Seconds

106C

BCD

0059

43 Date

106D

BCD

0031

44 Month

106E

BCD

0012

45 Year

106F

BCD

0009

46 Day

1070

BCD

0001Sunday -1

Status Registers

47 General Status

1071

UInt

Refer table

48 Warning Status

1072

UInt

Refer table

49 Fault Status

1073

UInt

Refer table

31.2

Appendix C
Function Code: 0x01(Read Coil) & 0x05(Write Coil)
0x01 Read Coil (Start / Stop)
Frame Type

ID

Function Address
Code

Request

XX

01

Response

XX

01

Quantity of
coils

Data

2000

0001

Byte count: 01

ON 0x01
OFF 0x00

Quantity of
coils

Data

0x05 Write Coil (Start / Stop)


Frame Type

ID

Function Address
Code

Request

XX

01

2000

0xFF00 Start
0x0000 Stop

Response

XX

01

2000

0xFF00 Start
0x0000 Stop

31.3

Appendix C
Note: Function Code 0x10 (Write), 0x05 (Start/Stop) and 0x01 (read Start/Stop)
will function only if Control Mode is set to DCS. Refer: Operator/Machine/
Mode (Chapter 5.2.1)
On improper master request, any one of the following exception response
is sent
Code 01: Illegal function
Code 02: Illegal data address
Code 03: Illegal data value
Status Register Bit Definition:

Bit Position

General

Warning

Fault

Ready

DPAF

HSP

Star

DPOF

Cooler

Run

Dryer probe failure

Main motor
overload

Run load

Low dew point

Reverse rotation

Run unload

High dew point

Pressure probe
failure

Stop busy

High differential
pressure

Temperature probe
Failure

Idle

Warn temperature

Trip temperature

Emergency
stop

Change air filter

Sump pressure not


developing

Start inhibit
filter

Change oil

Sump pressure
probe failure

Start
ack wait

Change oil
separator

Power failure

10

Standby

Change oil

Reserved

11

Reserved

Change grease

Reserved

12

Reserved

Reserved

Reserved

13

Reserved

Reserved

Reserved

14

Reserved

Reserved

Reserved

15

Reserved

Reserved

Reserved

31.4

Appendix D
Appendix-D Flow charts (Start, Stop, Load /unload /standby
sequence)
Start Sequence:
Start Sequence

STAR
ON

Delay for 100msecs


(Fixed)

MAIN

ON

NO. OF. START


INCREMENT

STAR TO DELTA delay x sec


(Star delay)

STAR OFF

DELTA ON

Delta to run delay x sec


(DTR)

Return

32.0

Appendix D
Stop Sequence:
Stop

Is
STAR ON?

Yes

No

Is
MAIN ON?

No

Return

Yes

LOAD OFF

(RTS delay)
Run to stop x sec

DELTA & MAIN


OFF

IDLE delay for 5 secs


Fixed delay

READY

32.1

Appendix D
RUN LOAD/UNLOAD/STANDBY

Is
Delta
ON?

Return
NO

Yes

Is
DIS Pr
< Load pr

NO

Is
DIS pr.
>UL pr

No
Return

Yes

Yes
Load ON

Load OFF

Increment
Load Count

Standby mode: In unload mode, if the pressure exceeds the set load pressure
in the preset standby time, and is less than number of start/stop cycles during
that time, the compressor goes into the standby mode ( or the compressor
stops as per the stop sequence).
In standby mode, if the pressure drops below the set load pressure, the
compressor starts automatically as per the start sequence.

32.2