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Date Printed .................... 11/01/2007
Instruction Book
ES 130 - 130 V - 130 T
Copyright Notice
Any unauthorized use or copying of the contents or any part thereof is
prohibited.
This applies in particular to trademarks, model denominations, part numbers
and drawings.
2
Tab|e of contents
1 $aIety precautions ......................................................................................... 4
1.1 S#('6; +%105 ........................................................................................................................ 4
1.2 S#('6; 24'%#76+105 &74+0) +056#..#6+10 .................................................................................. 4
1.3 S#('6; 24'%#76+105 &74+0) 12'4#6+10 ...................................................................................... 6
1.4 S#('6; 24'%#76+105 &74+0) /#+06'0#0%' 14 4'2#+4..................................................................... 7
2 Genera| description ...................................................................................... 10
2.1 I0641&7%6+10 .......................................................................................................................10
2.2 F'#674'5.............................................................................................................................13
2.3 M'#574'/'065 .....................................................................................................................15
2.4 P4'5574' 4')7.#6+10.............................................................................................................16
2.5 P4'5574' 4')7.#6+10 /1&'.....................................................................................................1B
2.6 P4'5574' 4')7.#6+10 611.5....................................................................................................20
2.7 S;56'/ P4'5574' S'6 (SPS) %10641........................................................................................23
3 |nsta||ation .................................................................................................. 25
3.1 D+/'05+10 &4#9+0)...............................................................................................................25
3.2 M1706+0) +05647%6+105 .........................................................................................................25
4 Operating instructions .................................................................................. 29
4.1 P4'2#4#6+10 (14 +0+6+#. 56#46-72 ...........................................................................................29
4.2 C10641. /1&' $766105 .........................................................................................................30
4.3 P4'2#4+0) %1/24'55145 61 $' +06')4#6'& +061 6*' ES 5;56'/.....................................................30
4.4 I06')4#6+0) %1/24'55145 +061 6*' ES 5;56'/ ..........................................................................33
4.5 I51.#6+0) %1/24'55145 (41/ 6*' ES 5;56'/ ............................................................................34
5 User interIace.............................................................................................. 35
5.1 M#+0 5%4''0 ........................................................................................................................35
5.2 P41)4#//+0) S;56'/ P4'5574' S'6 (SPS) 5'66+0)5...................................................................36
3
5.3 A761/#6+% F70%6+105 ........................................................................................................... 41
5.4 S2#4' C#2#%+6; ................................................................................................................... 42
5.5 F14%'& S'37'0%' ................................................................................................................. 43
5.6 E37#. W'#4 ........................................................................................................................ 46
5.7 G4172 M#0#)'/'06 ............................................................................................................. 47
5.B C1/24'5514 +0(14/#6+10 5%4''0 ............................................................................................ 49
5.9 C*#0)+0) 6*' 24'5574' 4')7.#6+10 /'6*1&.............................................................................. 52
Instruction manua|
4
1 Safety recaut|ons
1.1 Safety |cons
Ex|anat|on
1.2 Safety recaut|ons dur|ng |nsta||at|on
Genera| recaut|ons
1. The operator must emp|oy safe working practices and observe a|| re|ated |oca| work safety
requirements and regu|ations.
2. If any of the fo||owing statements does not comp|y with |oca| |egis|ation, the stricter of the two
sha|| app|y.
3. Insta||ation, operation, maintenance and repair work must on|y be performed by authorised, trained,
specia|ised personne|.
4. The compressor is not considered capab|e of producing air of breathing qua|ity. For air of breathing
qua|ity, the compressed air must be adequate|y purified according to |oca| |egis|ation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the vo|tage and depressurise the
compressor. In addition, the power iso|ating switch must be opened and |ocked.
6. Never p|ay with compressed air. Do not app|y the air to your skin or direct an air stream at peop|e.
Never use the air to c|ean dirt from your c|othes. When using the air to c|ean equipment, do so with
extreme caution and wear eye protection.
Danger for |ife
Warning
Important note
A|| responsibi|ity for any damage or injury resu|ting from neg|ecting these
precautions, or non-observance of the norma| caution and care required for
insta||ation, operation, maintenance and repair, even if not express|y
stated, wi|| be disc|aimed by the manufacturer.
Instruction manua|
5
Precaut|ons dur|ng |nsta||at|on
1. The machine must on|y be |ifted using suitab|e equipment in accordance with |oca| safety
regu|ations. Loose or pivoting parts must be secure|y fastened before |ifting. It is strict|y forbidden
to dwe|| or stay in the risk zone under a |ifted |oad. Lifting acce|eration and dece|eration must be
kept within safe |imits. Wear a safety he|met when working in the area of overhead or |ifting
equipment.
2. P|ace the machine where the ambient air is as coo| and c|ean as possib|e. If necessary, insta|| a
suction duct. Never obstruct the air in|et. Care must be taken to minimise the entry of moisture at
the in|et air.
3. Any b|anking f|anges, p|ugs, caps and desiccant bags must be removed before connecting the
pipes.
4. Air hoses must be of correct size and suitab|e for the working pressure. Never use frayed, damaged
or worn hoses. Distribution pipes and connections must be of the correct size and suitab|e for the
working pressure.
5. The aspirated air must be free of f|ammab|e fumes, vapours and partic|es, e.g. paint so|vents, that
can |ead to interna| fire or exp|osion.
6. Arrange the air intake so that |oose c|othing worn by peop|e cannot be sucked in.
7. Ensure that the discharge pipe from the compressor to the aftercoo|er or air net is free to expand
under heat and that it is not in contact with or c|ose to f|ammab|e materia|s.
B. No externa| force may be exerted on the air out|et va|ve; the connected pipe must be free of strain.
9. If remote contro| is insta||ed, the machine must bear a c|ear sign stating: DANGER: This machine is
remote|y contro||ed and may start without warning.
The operator has to make sure that the machine is stopped and that the iso|ating switch is open
and |ocked before any maintenance or repair. As a further safeguard, persons switching on
remote|y contro||ed machines sha|| take adequate precautions to ensure that there is no one
checking or working on the machine. To this end, a suitab|e notice sha|| be affixed to the start
equipment.
10. Air-coo|ed machines must be insta||ed in such a way that an adequate f|ow of coo|ing air is
avai|ab|e and that the exhausted air does not recircu|ate to the compressor air in|et or coo|ing air
in|et.
11. The e|ectrica| connections must correspond to the |oca| codes. The machines must be earthed and
protected against short circuits by fuses in a|| phases. A |ockab|e power iso|ating switch must be
insta||ed near the compressor.
12. On machines with automatic start-stop system or if the automatic restart function after vo|tage
fai|ure is activated, a sign stating "This machine may start without warning" must be affixed near
the instrument pane|.
13. In mu|tip|e compressor systems, manua| va|ves must be insta||ed to iso|ate each compressor. Non-
return va|ves (check va|ves) must not be re|ied upon for iso|ating pressure systems.
14. Never remove or tamper with the safety devices, guards or insu|ation fitted on the machine. Every
pressure vesse| or auxi|iary insta||ed outside the machine to contain air above atmospheric pressure
must be protected by a pressure-re|ieving device or devices as required.
15. Pipework or other parts with a temperature in excess of B0C (176F) and which may be
accidenta||y touched by personne| in norma| operation must be guarded or insu|ated. Other high-
temperature pipework must be c|ear|y marked.
16. For water-coo|ed machines, the coo|ing water system insta||ed outside the machine has to be
protected by a safety device with set pressure according to the maximum coo|ing water in|et
pressure.
Instruction manua|
6
17. If the ground is not |eve| or can be subject to variab|e inc|ination, consu|t the manufacturer.
1.3 Safety recaut|ons dur|ng oerat|on
Genera| recaut|ons
1. The operator must emp|oy safe working practices and observe a|| re|ated |oca| work safety
requirements and regu|ations.
2. If any of the fo||owing statements does not comp|y with |oca| |egis|ation, the stricter of the two
sha|| app|y.
3. Insta||ation, operation, maintenance and repair work must on|y be performed by authorised, trained,
specia|ised personne|.
4. The compressor is not considered capab|e of producing air of breathing qua|ity. For air of breathing
qua|ity, the compressed air must be adequate|y purified according to |oca| |egis|ation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the vo|tage and depressurise the
compressor. In addition, the power iso|ating switch must be opened and |ocked.
6. Never p|ay with compressed air. Do not app|y the air to your skin or direct an air stream at peop|e.
Never use the air to c|ean dirt from your c|othes. When using the air to c|ean equipment, do so with
extreme caution and wear eye protection.
Precaut|ons dur|ng oerat|on
1. Use on|y the correct type and size of hose end fittings and connections. When b|owing through a
hose or air |ine, ensure that the open end is he|d secure|y. A free end wi|| whip and may cause
injury. Make sure that a hose is fu||y depressurized before disconnecting it.
2. Persons switching on remote|y contro||ed machines sha|| take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitab|e notice sha|| be affixed
to the remote start equipment.
3. Never operate the machine when there is a possibi|ity of taking in f|ammab|e or toxic fumes,
vapours or partic|es.
A|so consu|t fo||owing safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions app|y to machinery processing or consuming air or inert gas.
Processing of any other gas requires additiona| safety precautions typica| to the
app|ication which are not inc|uded herein.
Some precautions are genera| and cover severa| machine types and equipment; hence
some statements may not app|y to your machine.
A|| responsibi|ity for any damage or injury resu|ting from neg|ecting these
precautions, or non-observance of the norma| caution and care required for
insta||ation, operation, maintenance and repair, even if not express|y
stated, wi|| be disc|aimed by the manufacturer.
Instruction manua|
7
4. Never operate the machine be|ow or in excess of its |imit ratings.
5. Keep a|| bodywork doors shut during operation. The doors may be opened for short periods on|y,
e.g. to carry out routine checks. Wear ear protectors when opening a door.
6. Peop|e staying in environments or rooms where the sound pressure |eve| reaches or exceeds 90
dB(A) sha|| wear ear protectors.
7. Periodica||y check that:
A|| guards are in p|ace and secure|y fastened
A|| hoses and/or pipes inside the machine are in good condition, secure and not rubbing
There are no |eaks
A|| fasteners are tight
A|| e|ectrica| |eads are secure and in good order
Safety va|ves and other pressure-re|ief devices are not obstructed by dirt or paint
Air out|et va|ve and air net, i.e. pipes, coup|ings, manifo|ds, va|ves, hoses, etc. are in good
repair, free of wear or abuse
B. If warm coo|ing air from compressors is used in air heating systems, e.g. to warm up a workroom,
take precautions against air po||ution and possib|e contamination of the breathing air.
9. Do not remove any of, or tamper with, the sound-damping materia|.
10. Never remove or tamper with the safety devices, guards or insu|ations fitted on the machine. Every
pressure vesse| or auxi|iary insta||ed outside the machine to contain air above atmospheric pressure
sha|| be protected by a pressure-re|ieving device or devices as required.
1.4 Safety recaut|ons dur|ng ma|ntenance or rea|r
Genera| recaut|ons
1. The operator must emp|oy safe working practices and observe a|| re|ated |oca| work safety
requirements and regu|ations.
A|so consu|t fo||owing safety precautions: Safety precautions during insta||ation and
Safety precautions during maintenance.
These precautions app|y to machinery processing or consuming air or inert gas.
Processing of any other gas requires additiona| safety precautions typica| to the
app|ication which are not inc|uded herein.
Some precautions are genera| and cover severa| machine types and equipment; hence
some statements may not app|y to your machine.
A|| responsibi|ity for any damage or injury resu|ting from neg|ecting these
precautions, or non-observance of the norma| caution and care required for
insta||ation, operation, maintenance and repair, even if not express|y
stated, wi|| be disc|aimed by the manufacturer.
Instruction manua|
B
2. If any of the fo||owing statements does not comp|y with |oca| |egis|ation, the stricter of the two
sha|| app|y.
3. Insta||ation, operation, maintenance and repair work must on|y be performed by authorised, trained,
specia|ised personne|.
4. The compressor is not considered capab|e of producing air of breathing qua|ity. For air of breathing
qua|ity, the compressed air must be adequate|y purified according to |oca| |egis|ation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
compressor, press the emergency stop button, switch off the vo|tage and depressurise the
compressor. In addition, the power iso|ating switch must be opened and |ocked.
6. Never p|ay with compressed air. Do not app|y the air to your skin or direct an air stream at peop|e.
Never use the air to c|ean dirt from your c|othes. When using the air to c|ean equipment, do so with
extreme caution and wear eye protection.
Precaut|ons dur|ng ma|ntenance or rea|r
1. A|ways wear safety g|asses.
2. Use on|y the correct too|s for maintenance and repair work.
3. Use on|y genuine spare parts.
4. A|| maintenance work sha|| on|y be undertaken when the machine has coo|ed down.
5. A warning sign bearing a |egend such as "work in progress; do not start" sha|| be attached to the
starting equipment.
6. Persons switching on remote|y contro||ed machines sha|| take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitab|e notice sha|| be affixed
to the remote start equipment.
7. C|ose the compressor air out|et va|ve before connecting or disconnecting a pipe.
B. Before removing any pressurized component, effective|y iso|ate the machine from a|| sources of
pressure and re|ieve the entire system of pressure.
9. Never use f|ammab|e so|vents or carbon tetrach|oride for c|eaning parts. Take safety precautions
against toxic vapours of c|eaning |iquids.
10. Scrupu|ous|y observe c|ean|iness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a c|ean c|oth, paper or tape.
11. Never we|d or perform any operation invo|ving heat near the oi| system. Oi| tanks must be
comp|ete|y purged, e.g. by steam-c|eaning, before carrying out such operations. Never we|d on, or
in any way modify, pressure vesse|s.
12. Whenever there is an indication or any suspicion that an interna| part of a machine is overheated,
the machine sha|| be stopped but no inspection covers sha|| be opened before sufficient coo|ing
time has e|apsed; this to avoid the risk of spontaneous ignition of the oi| vapour when air is
admitted.
13. Never use a |ight source with open f|ame for inspecting the interior of a machine, pressure vesse|,
etc.
14. Make sure that no too|s, |oose parts or rags are |eft in or on the machine.
15. A|| regu|ating and safety devices sha|| be maintained with due care to ensure that they function
proper|y. They may not be put out of action.
Instruction manua|
9
16. Before c|earing the machine for use after maintenance or overhau|, check that operating pressures,
temperatures and time settings are correct. Check that a|| contro| and shut-down devices are fitted
and that they function correct|y. If removed, check that the coup|ing guard of the compressor drive
shaft has been reinsta||ed.
17. Every time the separator e|ement is renewed, examine the discharge pipe and the inside of the oi|
separator vesse| for carbon deposits; if excessive, the deposits shou|d be removed.
1B. Protect the motor, air fi|ter, e|ectrica| and regu|ating components, etc. to prevent moisture from
entering them, e.g. when steam-c|eaning.
19. Make sure that a|| sound-damping materia|, e.g. on the bodywork and in the air in|et and out|et
systems of the compressor, is in good condition. If damaged, rep|ace it by genuine materia| from
the manufacturer to prevent the sound pressure |eve| from increasing.
20. Never use caustic so|vents which can damage materia|s of the air net, e.g. po|ycarbonate bow|s.
21. The fo||owing safety precautions are stressed when hand|ing refrigerant:
Never inha|e refrigerant vapours. Check that the working area is adequate|y venti|ated; if
required, use breathing protection.
A|ways wear specia| g|oves. In case of refrigerant contact with the skin, rinse the skin with
water. If |iquid refrigerant contacts the skin through c|othing, never tear off or remove the |atter;
f|ush abundant|y with fresh water over the c|othing unti| a|| refrigerant is f|ushed away; then
seek medica| first aid.
22. Protect hands to avoid injury from hot machine parts, e.g. during draining of oi|.
A|so consu|t fo||owing safety precautions: Safety precautions during insta||ation and
Safety precautions during operation.
These precautions app|y to machinery processing or consuming air or inert gas.
Processing of any other gas requires additiona| safety precautions typica| to the
app|ication which are not inc|uded herein.
Some precautions are genera| and cover severa| machine types and equipment; hence
some statements may not app|y to your machine.
Instruction manua|
10
2 Genera| descr|t|on
2.1 Introduct|on
Genera| v|ew
Ceneral view of the FS 13O Central control system
Funct|on
Today customers want more than just peace of mind. They want to continuous|y reduce their
production costs without jeopardizing the avai|abi|ity of compressed air.
Moreover, environmenta| awareness ca||s upon industria| faci|ities to |imit CO2 emissions (Kyoto) by
reducing their energy consumption. Compressors, with their significant power needs, are an important
area for improvement.
The At|as Copco ES 130 centra| contro||er is the perfect so|ution to meet these needs by:
improving the efficiency of the comp|ete compressed air system
reducing the air system
reducing the |ife cyc|e cost to the abso|ute minimum
meeting stringent environment |egis|ation.
Descr|t|on
Independent of the function (contro| and/or monitoring) of the product, the insta||ation set-up wi|| remain
the same. The core of the insta||ation is a Windows CE 5.0 based ES device. This device wi|| retrieve
and process information coming from the compressors or dryers. The ES device can on|y receive
information if the unit (compressor or dryer) is connected to the ES device via a CAN network.
Instruction manua|
11
Text on figure
The process in the ES device depends on the product (monitoring and/or contro|). In case the contro|
feature is avai|ab|e, up|oading and down|oading compressors wi|| contro| the net pressure.
In case of monitoring, an internet connection is required. The monitored information is sent over an
internet connection to the At|as Copco Airpower server and stored in the centra| data warehouse.
Access to the internet (e.g. ana|ogue |ine, ISDN |ine, GSM/GPRS |ine, ADSL, Internet provider ) is the
responsibi|ity of the customer. For monitoring the site (picture be|ow) a user and site must be created.
(1) ES Device
(2) Network
Instruction manua|
12
Two pressure transmitters are required. A f|ow meter, dewpoint meter, etc. are optiona|. If a pressure
transmitter fai|s, the system generates a warning but can continue regu|ating. If the deviation between
the two is too |arge, the ES system wi|| generate a shutdown.
Compressors must be connected with the ES device by means of a CAN network. The ES is ab|e to
receive data and send commands to the compressors.
The ES wi|| regu|ate the net pressure within a se|ectab|e and changeab|e pressure band. Pressure
regu|ation is done app|ying different regu|ation ru|es. These different pressure regu|ation modes are:
Optimized Energy Saving
Forced Sequence
Equa| Wear
Group Management
See section Pressure regu|ation modes for a detai|ed description.
The ES 130 is avai|ab|e in three versions:
ES 130: Contro| of Load/No-Load compressors
ES 130V: Contro| of Load/No-Load and VSD compressors
ES 130T: Contro| of Load/No-Load, VSD and Turbo compressors.
A tota| number of thirty compressors can be contro||ed by the a|gorithm. The restriction comes from the
CAN network which is |imited to maximum 32 nodes. One node is used by the ES device and another
for programming nodes. Thus, 30 nodes are |eft for compressors and dryers.
Instruction manua|
13
2.2 Features
SPS Management
System Pressure Setpoint (SPS) management is a co||ection of pressure set points and too|s. It provides
the regu|ation system with the correct data to work with. SPS management is sp|it up in a configuration
and a process part. The process part exists of:
Ca|cu|ation
Ramping
SPS Ca|cu|at|on
Interna||y the a|gorithm wi|| try to keep the pressure In-band (Load-Un|oad). Different actions are taken
when the pressure is Out-Band (Load-Un|oad) but sti|| within Regu|ation-Band (Pmax-Pmin) and again
when the pressure is Out-Regu|ation Band. By defau|t the pressure Setpoint is the midd|e between the
Load- and Un|oad pressure. The Minimum and maximum pressure is ca|cu|ated in function of the
Pressure band and is 40% |ower/higher than the Load/Un|oad Pressure.
Pressure Low/High Warnings are ca|cu|ated in function of the Load/Un|oad Pressures and the Pressure
Low/High Shutdown Leve|s.
SPS Trans|t|on
When changing from SPSx to SPSy, the setpoint and pressure bands wi|| move smooth|y to their new
setting with a speed equa| to the transition time. A|| Pressure |eve|s wi|| reach their new va|ue at the
same time.
During the transition the highest and the |owest pressure shutdown |eve| of the o|d and new SPS is
app|ied.
SPS changes wi|| be app|ied direct|y instead of smooth|y when:
1. the ES status is in Loca| or Centra| Stop Mode
2. the previous ES Status was Centra| Stop
3. a|| compressors are iso|ated
SPS changes are not a||owed when:
1. a compressor switch is activated
Load aIter Sbutdown
In an insta||ation where one or more compressors are running |oaded, pressure undershoots may occur if
one of those compressors is shut down. A compressor shutdown is raised unexpected|y. Regard|ess of
the pressure in the air net, avoiding undershoots is not guaranteed. Anticipation actions (before the
pressure reaches the standard Compressor Start trigger |eve|) wi|| |imit the amount of undershoots to a
minimum.
The goa| is to find a so|ution which resu|ts in the sma||est pressure drop regard|ess of the se|ected
pressure regu|ation mode. Therefore a compromise needs to be found taking fo||owing parameters into
account:
Compressor capacity
Time between starts
If the defau|t ca|cu|ations shou|d not meet the requirements, they can be changed
manua||y using the Advanced settings.
Instruction manua|
14
Start-up time
If a shutdown occurs fo||owing actions are taken:
a|| |oaded range compressors wi|| be p|aced in se|f-regu|ation
the contro||er wi|| |ook for the minimum required f|ow to compensate the |ost f|ow
the contro||er wi|| |ook for the minimum required f|ow among the stopped compressors.
Compressors wi|| be started respecting the time between two starts
If more then one compressor is found to meet the minimum required f|ow, a|| compressors but one
wi|| be |oaded immediate|y. The |ast one in the co||ection wi|| be |oaded app|ying the Pressure
Regu|ation ru|es.
Sare Caac|ty
In some cases, the cost of production |oss is so high that the energy costs having a compressor running
in un|oad are neg|igib|e. Spare Capacity can reduce the risk of production |oss due to a shortage of
avai|ab|e air. Spare Capacity can a|so offer a so|ution if a |arge vo|ume of air is required on short notice.
Spare Capacity is the minimum amount of f|ow that needs to be avai|ab|e at a|| times. The Spare
Capacity definition depends on the option:
Spare Capacity with avai|ab|e up|oad capacity inc|uded:
The avai|ab|e up|oad f|ow among the |oaded range compressors is seen as Spare Capacity (see
section Spare Capacity).
Spare Capacity with avai|ab|e up|oad capacity not inc|uded:
The avai|ab|e up|oad f|ow among the |oaded range compressors is not seen as Spare Capacity (see
section Spare capacity).
A hysterisis is bui|t in to stabi|ize the system and avoid starts and stops of compressors to fu|fi|| the
Spare Capacity requirements.
A shortage or overp|us of 5% or more of Spare Capacity during a period, equa| to the De|ay at Signa|
setting, triggers a search for a Spare Capacity mix so|ution.
Note that a Spare Capacity compressor can be se|ected/|oaded by pressure regu|ation and wi|| no |onger
be a Spare Capacity compressor. After a period, the a|gorithm wi|| search again for a spare compressor.
It might be that during a period (de|ay at signa|) there is no Spare Capacity avai|ab|e. This wi|| be the
case when the f|ow profi|e changes.
The Spare Capacity is de|ivered as efficient|y as possib|e, taking the Pressure Regu|ation Mode
conditions into account:
Forced Sequence: sequence number
Equa| Wear: running hours
Group Management: depends on the profi|e and group regu|ation mode
Mecban|ca| Ru|es
Mechanica| Ru|es is a modu|e imp|emented in order to describe ru|es and mechanica| |imitations for
compressors. The a|gorithm (e.g. pressure regu|ation / Optimizer / ) wi|| take those ru|es into account
further in the decision process.
VSD Seed ||m|tat|on
The maximum speed of VSD compressors can be |imited if the compressor has been running
continuous|y above this |imitation for a programmab|e period.
Instruction manua|
15
Optimization and Pressure Regu|ation wi|| ca|cu|ate whether this compressor can de|iver the necessary
f|ow whi|e running within that |imitation.
T|me Contro||ed Iso|at|on
When a shutdown occurs on the ES, a|| compressors wi|| be iso|ated immediate|y. In this case, there is a
risk that mu|tip|e compressor wi|| be started simu|taneous|y. If the Time Contro||ed Iso|ation option is
enab|ed, a|| running (|oaded and un|oaded) compressors wi|| be iso|ated at once. In order to prevent
stopped compressors from starting simu|aneous|y, a|| stopped compressor wi|| be iso|ated one by one,
respecting the Time To Next Iso|ation Timer. During this period, a|| integrated compressors wi|| remain
under ES contro|.
2.3 Measurements
Read|ngs
On the main screen, 6 readings can be disp|ayed. These can either be ana|ogue input readings (e.g. air
net pressure) or virtua| reading (e.g. ca|cu|ated f|ow and power).
A sensor error is indicated by a ye||ow background.
Pressure Grab
Instruction manua|
16
The pressure graph disp|ays the ana|ogue va|ue of the actua| airnet pressure. If the actua| pressure is in
band or not more than 20% out band, the graph is sca|ed automatica||y between the Load and Un|oad
Pressure |eve|. If the pressure is more than 20% out band, the automatic sca|ing is done between the
High and Low Pressure Shutdown Leve|.
2.4 Pressure regu|at|on
Pressure Regu|at|on Concet
The main goa| for Pressure Regu|ation is to keep the pressure in band, as stab|e as possib|e and as
efficient as possib|e.
Pressure Regu|ation determines what the best so|ution/action is to meet the f|ow demand and when the
action shou|d be executed. The Pressure Regu|ation Modes wi|| a||ow or disa||ow certain actions in the
pressure regu|ation (see section Pressure regu|tion modes).
The Pressure Regu|ation Too|s are functiona|ities to he|p to perform pressure regu|ation (e.g. Stabi|izer)
and to execute some specific actions (e.g. Compressor Switch) initiated by other modu|es (see section
Pressure Regu|ation Too|s).
The concept is designed in a way that different modu|es can be used by others and that each modu|e
has its specific responsibi|ity. These responsibi|ities (or functiona|ities) are exp|ained be|ow.
Pressure Regu|at|on So|ut|on
The a|gorithm is ab|e to regu|ate the system pressure with a combination of three types of compressors
(Load/No Load - VSD - ZH). Depending on the compressor mix and the f|ow demand, the found so|utions
can differ.
A so|ution is re|ated to a score, which is the sum of different sub scores. A Sub score can either be:
Points re|ated to the action (e.g. Start VSD).
The resu|t of a ca|cu|ation (dynamic va|ue) mu|tip|ied by a factor
F|ow Mismatch
Switched F|ow
In this way, so|utions can be inf|uenced by changing those points and factors. This is done in the tuning
part of the commissioning process.
F|ow M|smatcb
The f|ow mismatch during the regu|ation is the difference between the Required F|ow and the De|ivered
F|ow, further ca||ed respective|y F|ow Out and F|ow In.
A F|ow Mismatch can be either positive, negative or zero. By means of an examp|e, the f|ow mismatch
is exp|ained:
The f|ow out is 790 |/s (1672 cfm) and the F|ow in is 200 |/s (423 cfm). This means that there is a
shortage of 590 |/s (1249 cfm) to meet the f|ow demand. This resu|ts in a pressure drop (size depends
on the Airnet vo|ume).
Instruction manua|
17
Loading Compressor 2 means:
F|ow in = 200 500 = 700 |/s
F|ow out = 790 |/s
F|ow mismatch = 790 - 700 = 90 |/s
Resu|t: The pressure wi|| continue dropping as the f|ow out is sti|| |arger than the f|ow in, but wi|| not
drop as fast anymore as in the previous situation.
This resu|t is ca||ed: Positive F|ow Mismatch (Pos FMM)
Loading Compressor 3 means:
F|ow in = 200 600 = B00 |/s
F|ow out = 790 |/s
F|ow mismatch = 790 - B00 = -10 |/s
Resu|t: The pressure wi|| no |onger drop, but start rising as the f|ow out is sma||er than the f|ow in.
This resu|t is ca||ed: Negative F|ow Mismatch (Neg FMM)
This method is a|so app|icab|e when the pressure is rising, on|y the F|ow out needs to be |arger than the
f|ow in to become a negative f|ow mismatch.
If the pressure s|ope changes from direction (towards the set point) after an action, the f|ow mismatch
is negative, if the pressure s|ope changes from ang|e after an action, but sti|| moves away from the set
point, then the f|ow mismatch is positive.
Sw|tcbed F|ow
The Switched F|ow is the tota| (summarized) changed f|ow in the compressor mix, due to an action. In
the examp|e above the switched f|ow is (if compressor 2 is |oaded) 500 |/s. If the so|ution is a
combination of an actor and reactor, then the Switched F|ow is the abso|ute sum of both changes in
f|ow, thus a|ways positive.
Pressure Regu|at|on Execut|on
The resu|t of a so|ution can be:
Load a stopped compressor
Load an un|oaded compressor
Instruction manua|
1B
Un|oad a |oaded compressor
Keep or p|ace a |oaded compressor in regu|ating mode
T|me To Command eIore Pdro/Pr|se:
Depending on the Airnet vo|ume, the f|ow profi|e and the insta||ation set-up (e.g. MD dryers or FD
dryer), the Load/start or an un|oad action of a compressor wi|| have an inf|uence on the reaction de|ay.
In order to avoid under- or overshoot and the pressure going out band, a Load/Un|oad or a Start
command wi|| be sent to a compressor seconds before the pressure wi|| reach the 'Load' or 'Un|oad'
Pressure.
A different time is taken into account when the compressor needs to be started or not.
T|me To Next Command In and/Cut and:
As the pressure regu|ation is a re|ative|y s|ow process (due to the airnet vo|ume and de|ays),
commands cannot be sent e.g. every second as the insta||ation wou|d not have the time to adjust to the
new situation. As not a|| insta||ations are identica|, the minimum time between two commands can be
programmed.
The minimum time between two commands app|ies between two down|oads and between two up|oads.
An up|oad can be given straight after a down|oad, if required and if the time between two up|oads is
e|apsed (the same is app|icab|e for down|oads).
2.5 Pressure regu|at|on mode
Genera|
To meet the f|ow demand, Pressure Regu|ation wi|| |ook first for a base |oad, then for the most efficient
so|ution among the a||owed compressors.
Ct|m|zed Energy Sav|ng
In the Optimized Energy Saving mode no extra conditions are app|icab|e to take decisions. The best
so|ution (to |oad, un|oad or modu|ate a compressor) is se|ected based on the current f|ow demand and
the compressor capacities. F|ow mismatch and switched f|ow are the key parameters in this regu|ation
mode.
Forced Sequence
The basic ru|es for Forced Sequence are:
Compressors wi|| be |oaded (and/or started) or un|oaded (and/or stopped) according to a fixed
sequence.
Regu|at|on, the sequence number is not re|evant for |oaded range compressors to determine the
modu|ating compressor in the mix. It does not necessari|y have to be the |ast |oaded compressor in the
sequence.
Instruction manua|
19
Ct|m|zat|on: power optimization is on|y possib|e with the |ast |oaded compressor in the mix. For
optimization the sequence number is a|so not re|evant.
When a sequence shift is triggered, compressors are se|ected, starting from the first compressor in the
new sequence, unti| the required f|ow is reached.
A|| the rep|acing compressors wi|| be put in un|oad. When the compressor(s) reach the un|oad stage,
Compressor Switch wi|| |oad these compressor(s) and un|oad the compressor(s) to be rep|aced (see
section Pressure Regu|ation too|s).
Equa| Wear
Equa| Wear has two functions:
monitoring the deviation of the running hours
monitoring the behavior during the decisions in pressure regu|ation.
In Equa| Wear Mode, the running hours are kept within a programmab|e range. When the running hours
of a compressor exceed that range, this compressor wi|| be rep|aced by another one with |ess hours.
Equa| Wear wi|| on|y work correct|y with compressors of equa| capacity. In case the capacities differ too
much, it is recommended to use the Group Management Mode.
Grou Management
In group management, a|| compressors are p|aced in groups based on their capacity and/or type. For
each group fo||owing modes are avai|ab|e :
Group Optimized Energy Saving
Group Equa| Wear
Group Forced Sequence
Fo||owing master regu|ation modes (profi|es) can be app|ied:
Capacity Management (or Optimized Energy Saving)
Equa| Wear
Forced Sequence
The profi|e ru|es are derived from the corresponding Pressure Regu|ation Modes, but are app|ied on
group |eve| instead of on compressor |eve|.
ProI||e Caac|ty Management
Simi|ar as in Optimized Energy Savings, no extra conditions are app|icab|e to se|ect a group/action
during pressure regu|ation. Depending on the regu|ation mode in the groups, some compressors might
not be a va|id so|ution.
ProI||e Equa| Wear
Simi|ar as in the Equa| Wear Regu|ation Mode, the tota| number of running hours per group is ba|anced
within a programmab|e range.
The number of group running hours is the average of the compressor running hours of that group.
ProI||e Forced Sequence
Simi|ar as in Forced Sequence Regu|ation Mode, a|| compressors must be |oaded before a compressor of
the next group in the sequence can be started/|oaded. Un|oading/stopping a compressor is on|y a||owed
if a|| compressors in the higher sequence number are un|oaded/stopped.
Instruction manua|
20
2. Pressure regu|at|on too|s
Comressor Sw|tcb
The responsibi|ity of this modu|e is to switch two compressors, to switch two compressor groups or to
un|oad a compressor in a contro||ed way in order to keep the pressure in band. Compressor Switch wi||
on|y hand|e the preparation steps and force the pressure into a certain direction, decisions and
executions are sti|| hand|ed by the Pressure Regu|ation a|gorithm.
Compressor Switch can be initiated by fo||owing modu|es:
1. Forced Sequence (Compressor switch)
2. Equa| Wear (Compressor switch)
3. Power Optimizer (Compressor Un|oad)
4. Stabi|izer (Compressor Un|oad)
The three major steps in Compressor Switch are:
1. Preparation:
In case of a switch, stopped compressors wi|| be p|aced in un|oad. The stopped compressors wi||
be started, respecting the minimum required time between two starts, and kept in un|oad before
going to the next |eve| in the compressor switch procedure.
In case of an un|oad, this step is skipped.
2. Compressor switch/un|oad actions:
In case of a compressor switch, the compressors to be rep|aced must be un|oaded and the
rep|acing compressors need to be |oaded. In order to force the pressure down to |oad rep|acing
compressors, the set point of the range compressors wi|| be ramped down to the |oad |eve|.
When a rep|acing compressor is |oaded, the set point of the range compressors wi|| be ramped
up from the SPS set point to the un|oad |eve| in order to force the pressure upwards.
Expected behavior:
Pressure is ramped down
Rep|acing compressor is |oaded
Pressure is ramped up
Compressor to be rep|aced is un|oaded
A|| other, |oaded range compressors are |ocked in their current state to avoid disturbing the
compressor switch.
In case of a compressor un|oad, extra f|ow wi|| be prepared whi|st the f|ow of the compressor to
be un|oaded wi|| be reduced by ramping down the set point to the |oad |eve|. The set point of
the remaining |oaded range compressors is ramped up to the un|oad |eve|. The compressor to be
un|oaded wi|| un|oad app|ying the basic pressure regu|ation ru|es.
Expected behavior:
Pressure is ramped up
To be un|oaded compressor is un|oaded
If the required (|oad/un|oad) actions are not done within the expected time, the basic
pressure regu|ation ru|es wi|| be overru|ed and Forced Ru|es wi|| be app|ied and
executed unconditiona||y:
If the pressure is rising faster than the stab|e s|ope and the pressure is above the set
point, an un|oad is forced. In a|| the other conditions a |oad is forced.
Instruction manua|
21
3. Re|ease:
A|| |oaded range compressors are p|aced in se|f-regu|ation. After the se|f-regu|ation time has
e|apsed, a|| |oaded range compressors wi|| be fixed one by one.
Ct|m|zer
When a|| triggers are fu|fi||ed, the optimizer modu|e wi|| |ook for a so|ution to run the insta||ation in the
most efficient way, regard|ess of what the active pressure regu|ation mode is.
There are two types of optimization:
Power Ct|m|zat|on
Reducing the tota| power consumption by checking the possibi|ity to un|oad a compressor and sti|| be
ab|e to de|iver the required f|ow to maintain the pressure |eading to energy saving.
Zone Ct|m|zat|on
Some compressors, depending on the type, wi|| run with a better Specific Energy Consumption in a
particu|ar zone. Optimizing the zone wi|| bring the running compressors in the mix in their best zones
to become the best tota| specific energy consumption.
The Optimizer wi|| ca|cu|ate the current specific energy consumption of the insta||ation, the best specific
energy consumption when a compressor is un|oaded and the specific consumption after a|| compressors
are p|aced as much as possib|e in their optimum zone. The so|ution which provides the best specific
power consumption wi|| be executed.
Optimization wi|| run every 3 minutes. The optimization timer wi|| be reset:
if the pressure is out band
after integrating a compressor
during a |oad after shutdown hand|ing
during a compressor switch
when the stabi|izer is active
after each optimization
Stab|||zer
During norma| operation, on|y one compressor wi|| be in se|f-regu|ation. Due to pressure regu|ation it is
possib|e that more than one compressor is in se|f-regu|ation. Mu|tip|e compressors in se|f-regu|ation can
regu|ate against each other and cou|d |ead to unstab|e behavior. A specia| action to avoid this is
required.
A|though, in some cases the regu|ation requires mu|tip|e compressors to be in se|f-regu|ation at the
same time to correct a situation as fast as possib|e. When the pressure is stabi|ized, compressors need
to be sent to a fixed state again and on|y the |eader shou|d operate in se|f-regu|ation.
The stabi|izer has two independent functions:
Se|I-Regu|at|on:
Se|f-Regu|ation modu|e wi|| send a range command to a|| |oaded range compressors and is activated:
During SPS transition
When the compressor is out band
During compressor integration
Send-F|x-State:
Instruction manua|
22
Once the system is stabi|ized, a|| range compressors (except for the |eader) wi|| be sent to a fixed
state again one by one.
F|ow Damer
A PI regu|ator regu|ates a process va|ue (air net pressure) towards a set point. The behavior of a PI
contro||er depends on the settings of the Proportiona| band and the Integration time.
By means of the Proportiona| Band and Integration Time Settings, a PI-contro||er can react aggressive|y
or very s|ow|y.
A PI contro||er configured to react aggressive|y resu|ts in a good regu|ation when operating around the
set point. An aggressive regu|ator wi|| resu|t in an overreaction (over- and undershoot) when it becomes
active with a |arge error (e.g. when a VSD is sent to |oad) (error = Set point - Process va|ue).
Changing the Proportiona| Band and Integration Time parameters to become a |ess aggressive PI
contro||er resu|ts in a better behavior and |ess undershoot during a compressor |oad, but wi|| not regu|ate
fast enough when operating around the set point.
Idea||y wou|d be the combination between an aggressive and |ess aggressive PI contro||er depending on
the situation. Using a damper wi|| resu|t in having an aggressive PI regu|ator around the set point area
and a |ess aggressive PI regu|ator when required.
The Damper wi|| reduce the error on the PID regu|ator which resu|ts in a smooth behavior, even with
aggressive parameters. The Damper can be enab|ed or disab|ed.
Besides tuning parameters, a PI contro||er a|so needs two input signa|s to be ab|e to regu|ate. The two
input parameters are the set point and the process va|ue (actua| pressure).
The difference between those two parameters is the error the contro||er needs to regu|ate with.
E.g. increasing the set point with a certain offset, starting with a va|ue equa| to the actua| pressure,
|eads to a sma|| error. Even with aggressive PI parameters, the contro||er wi|| not overreact.
A F|ow Damper wi|| be active if:
the option is enab|ed
the compressor has a range command (PI active)
compressor Switch is not active
pressure not in stab|e band
(Un|oad Pressure - Load Pressure) 20%
pressure between Pmax/Pmin
If the Damper is triggered, a set point for the PI wi|| be ca|cu|ated
if Actua| Pressure S|ope < F|ow Damper Min S|ope
The pressure is not rising (or dropping) fast enough and PI acce|eration is required. The PI wi||
regu|ate towards Pset
if Actua| Pressure S|ope F|ow Damper Max S|ope
The pressure is rising (or dropping) too fast and PI dece|eration is required. The PI wi|| regu|ate
towards a new setpoint in the opposite direction of the pressure s|ope.
If Actua| Pressure Pset
Damper Set Point = actua| pressure step
step = (Un|oad Pressure - set point) 20%
If Actua| Pressure < Pset
Damper Set Point = actua| pressure - step
Instruction manua|
23
step = (set point - Load Pressure) 20%
If the F|ow Damper Min S|ope is equa| to or greater than the Actua| Pressure S|ope equa| to or greater
than the F|ow Damper Max S|ope, the pressure is rising (dropping) fast enough and no PI action is
required.
Comressor Sto
Stopping a compressor wi|| be managed by the ES, taking severa| conditions into account:
DSS timer
id|ing Timer
pressure Condition
avai|abi|ity Condition
A|| conditions need to be fu|fi||ed before a compressor is a||owed to stop.
DSS T|mer
The De|ay Second Stop or DSS Timer avoids a compressor having too many starts per day. When a
compressor stops, the fo||owing stop command is a||owed when the DSS-time has e|apsed. The DSS
timer is ca|cu|ated by dividing 24 hours by the a||owed number of motor starts per day.
Id||ng T|mer
The Id|ing Time is the minimum time a compressor needs to run in un|oaded condition, before it can be
stopped.
Pressure Cond|t|on
A Stop Command is not a||owed when the Actua| Pressure is be|ow the Load Pressure.
Ava||ab|||ty
A compressor wi|| be avai|ab|e again when the sum of fo||owing timers has e|apsed after a stop
command:
Minimum Stop Time
Required Stop Time
Y and YD-Time (If not D.O.L)
Load De|ay Time
If the pressure s|ope is negative (drops) and wi|| reach the |oad pressure before the compressor wi|| be
avai|ab|e again, a Stop Command wi|| not be a||owed.
2.7 System Pressure Set (SPS) contro|
Descr|t|on
Two system pressure set contro| modes can be se|ected in the user interface:
There wi|| on|y be one compressor stopped at a time.
A||owing a compressor to stop can a|so depend on the active regu|ation mode.
Instruction manua|
24
Weektimer Mode: interna||y based on week timer
Manua| Mode: |oca||y (= defau|t)
On|y one contro| mode can be active at a time. The se|ection of a system pressure contro| mode is
protected by a password. It is possib|e to program 3 different Pressure Sets (SPS1, SPS2 and SPS3).
The SPS1 is activated by defau|t.
In automatic mode (Week Timer), a Centra| Stop command can be programmed. When Centra| Stop is
activated, a|| compressors wi|| be stopped.
A number of commands can be programmed in the Week Timer with fo||owing programmab|e items:
Day of the week (Mon . . . Sun)
Time of the day (00:00. . . 23:59)
Command to activate (SPS1, SPS2, SPS3, Centra| Stop)
Instruction manua|
25
3 Insta||at|on
3.1 D|mens|on draw|ng
D|mens|ons
3.2 Mount|ng |nstruct|ons
Procedure
Mount the ES to a wa|| in the room taking into account the maximum cab|e |ength of the network and
a maximum |ength of 1000 m to the pressure transmitters.
The pressure transmitters shou|d preferab|y be connected:
To an air receiver to avoid pressure pu|sations (vibrations shou|d a|so be avoided).
Via va|ves, a||owing the pressure transmitter to be removed after iso|ating and depressurising it.
In vertica| position to avoid inf|uence of condensate.
Iso|ate and depressurise that part of the air net to which the pressure transmitters wi|| be connected.
Instruction manua|
26
Provide two ho|es with thread 1/B NPT in the depressurised part of the air net.
Screw the pressure transmitters into p|ace.
Wire the pressure transmitter. Connect the first transmitter to ana|og input 1 (pins 11 and 12 on
connector XAI1) of the I/O board, the second transmitter to ana|og input 2 (pins 14 and 15 on
connector XAI1).
These sensors have a working temperature |imit from -40 C up to 125 C (-40 F up to 257 F). For
higher temperatures an extension pipe shou|d be used to coo| off the air:
Number|ng and os|t|on oI ana|og |nuts
Use screw termina| strip XAI1 to connect ana|og signa|s. Ana|og inputs are numbered from 1 up to B,
termina|s are numbered from 11 up to 34.
If the pressure transmitters have a fixed cab|e with shie|ding attached, the shie|ding
must not be connected to the shie|ding of the extension cab|e to the I/O board of the
ES to prevent |oop-currents in the system.
The CE device has eight 4-20 mA ana|ogue inputs on board. The pressure wi|| a|ways
be measured twice for security reasons. On the remaining inputs a|| kind of sensors,
using a 4-20 mA signa|, can be connected.
Two different kinds of sensors can be used:
Active I/O sensor.
Passive I/O sensor.
Ana|og |nut number Screw term|na| number S|gna| tye
1 11 24V DC
12 SIGNAL (4-20 mA)
13 GROUND
2 14 24V DC
15 SIGNAL (4-20 mA)
16 GROUND
3 17 24V DC
1B SIGNAL (4-20 mA)
19 GROUND
4 20 24V DC
21 SIGNAL (4-20 mA)
22 GROUND
Instruction manua|
27
D|g|ta| oututs
The I/O board of the ES 130 contains four digita| outputs. A digita| output is set when one or a
combination of conditions is fu|fi||ed.
Specifications
Number|ng and os|t|on
Connect the digita| outputs to termina| strip XDO1 of the ES 130. Digita| outputs are numbered from 1
up to 4, screw termina|s are numbered from 41 up to 52.
Cond|t|ons
Fo||owing conditions must be used to set a digita| output true:
5 23 24V DC
24 SIGNAL (4-20 mA)
25 GROUND
6 26 24V DC
27 SIGNAL (4-20 mA)
2B GROUND
7 29 24V DC
30 SIGNAL (4-20 mA)
31 GROUND
B 32 24V DC
33 SIGNAL (4-20 mA)
34 GROUND
Ana|og |nut number Screw term|na| number S|gna| tye
Limiting continuous current (at maximum ambient temperature) 3 A
Maximum switching vo|tage 240 V AC
Maximum switching power 750 VA
Minimum |oad 5 V; 10 mA
D|g|ta| outut Screw term|na| S|gna| tye
1 41 N/C CONTACT
42 MAIN CONACT
43 N/O CONTACT
2 44 N/C CONTACT
45 MAIN CONACT
46 N/O CONTACT
3 47 N/C CONTACT
4B MAIN CONACT
49 N/O CONTACT
4 50 N/C CONTACT
51 MAIN CONACT
52 N/O CONTACT
Instruction manua|
2B
D|g|ta| Cutut 1:
Dig_Out_1 represents an ES Warning
IF [(Pressure Low Warning) or (Pressure High Warning) or (Sensor Deviation Warning) or (Pressure
Sensor 1 error and Not Pressure Sensor 2 error) or (Pressure Sensor 2 error and Not Pressure Sensor
1 error)J Then Dig_Out_1 = True E|se Dig_Out_1 = Fa|se
D|g|ta| Cutut 2:
Dig_Out_2 represents an ES Shutdown
IF [(Pressure Low Shutdown) or (Pressure High Shutdown) or (Sensor Deviation Shutdown) or
(Pressure Sensor 1 error and Pressure Sensor 2 error)J Then Dig_Out_2 = True E|se Dig_Out_2 =
Fa|se
D|g|ta| Cutut 3:
Dig_Out_3 represents an ES Status
IF (Loca| contro|) Then Dig_Out_3 = Fa|se E|se If (ES Contro| or Centra| Stop) Then Dig_Out_3= True
D|g|ta| Cutut 4:
Spare
True represents a c|osed re|ay; Fa|se represents an open re|ay when using the N/O and MAIN
contact.
When using the MAIN and N/C contact, True and Fa|se are turned round.
Instruction manua|
29
4 Oerat|ng |nstruct|ons
4.1 Prearat|on for |n|t|a| start-u
Serv|ce d|agram
Procedure
Stick |abe|s on the contro| pane|s of the compressors connected to the ES as we|| as on an obvious
p|ace inside these compressors, warning the operator that the compressor is remote|y started and
stopped by a separate contro||er. These |abe|s must warn the operator that, after vo|tage fai|ure, the
Energy Saver can remote|y start and stop the compressors, depending on the air demand and
programmed va|ues.
Connect a 110 - 240 VAC, 50/60 Hz power supp|y to termina|s L1 and L2 of the ES contro||er, make
sure the earthing is connected to termina| PE
Switch on the vo|tage.
Have the network configured (commissioned) by the At|as Copco Customer Centre.
It is not necessary to stop compressors running in cascade to integrate the ES into the
compressor insta||ation.
Instruction manua|
30
4.2 Contro| mode buttons
Descr|t|on
The b|ue frame indicates which of the fo||owing contro| modes is active:
Loca| Contro| (1):
A|| compressors are |oca||y contro||ed. The contro||er is disab|ed and performs no regu|ation.
Therefore it is necessary to program the pressure settings of the compressors in cascade to prevent
simu|taneous starting of mu|tip|e compressors.
ES Contro| (2):
The ES contro|s a|| integrated compressors. At this moment the contro||er is maintaining the system
pressure by addressing the integrated compressors.
Centra| Stop (3):
The contro||er wi|| immediate|y un|oad and stop a|| compressors. Norma||y this function is disab|ed
and can be enab|ed by pushing the checkbox next to the centra| stop button (3). To avoid
unauthorized stopping, disab|e the (Centra| Stop) button when the ES is operative again.
4.3 Prear|ng comressors to be |ntegrated |nto tbe ES system
Descr|t|on
Compressors equipped with an E|ektronikon MkI or MkII regu|ator are a|ways ready to be integrated.
The contro||er wi|| on|y react to a new contro| mode if the contro| mode button is
pushed for minimum 3 seconds.
Instruction manua|
31
Flektronikon Mk/ and Mk// regulators
On ZR and GA compressors with an E|ektronikon MkIII HR regu|ator, turn the key switch on the
compressor contro| pane| to remote 2.
Flektronikon Mk/// HR regulator
Flektronikon Mk/// 4X4O regulator
Instruction manua|
32
ZR and GA compressors with an E|ektronikon II or E|ektronikon MkIV regu|ator must be set to LAN
contro| and an individua| node address must be programmed in their regu|ators (consu|t the re|evant
instruction book of the compressor).
Flektronikon // regulator
Flektronikon Mk/V regulator
On ZH compressors with PLC contro||er, turn the key switch on the compressor to remote, fo||owed
by pushing the F10 button in the main screen (indication: F10 BITMAP in main screen wi|| b|ink).
P/C regulator
Instruction manua|
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4.4 Integrat|ng comressors |nto tbe ES system
Descr|t|on
Make sure that the compressors are prepared to be integrated as described in section Preparing
compressors to be integrated in the ES system. Activate the password. Touch the Integrate fie|d (1) of
the compressor to be integrated. If the Integrate and Iso|ate fie|ds show grey, the compressor is not
ready to be integrated or the password has expired.
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4.5 Iso|at|ng comressors from tbe ES system
Descr|t|on
One or more compressors can be iso|ated from the ES contro||er. This can be done either on the ES or on
the compressor. The sequencer wi|| ignore the iso|ated compressors for the pressure regu|ation. Iso|ated
compressors are |oca||y contro||ed unti| they are integrated again.
To iso|ate a compressor on the ES contro||er: touch the iso|ate fie|d (1) on the contro| screen. The
(Iso|ate) bu||et becomes b|ack.
To iso|ate a compressor with MkIII regu|ator, turn the key switch from remote 2 contro| mode to Loca|
Contro| Mode.
To iso|ate a compressor with PLC regu|ator, iso|ate the compressor by turning the key switch to Loca|
Mode or by pressing the F10 button when the key switch is in remote.
To iso|ate a compressor with an E|ektronikon II regu|ator, press the Menu button on the contro||er (F1),
press the arrow down key unti| the option Modify Params is fo||owed by a horizonta| arrow. Press the
tabu|ator key to activate the menu. Use the arrow down key unti| the option Configuration is fo||owed
by a horizonta| arrow. Press the tabu|ator key to activate the menu, scro|| through the disp|ay unti| the
option CCM. is shown and activate the menu by pressing the tabu|ator key. Change the setting from
LAN to Loca|.
To iso|ate a compressor with MkIV regu|ator: press the Menu button on the MkIV contro||er (F1),
press the arrow down key unti| the option Modify Parameters is fo||owed by a horizonta| arrow. Press
the tabu|ator key to activate the menu. Use the arrow down key unti| the option Configuration is
fo||owed by a horizonta| arrow. Press the tabu|ator key to activate the menu, scro|| through the disp|ay
unti| the option C.C.M. is shown and activate the menu by pressing the tabu|ator key. Change the
setting from LAN contro| to Loca| Contro|.
Instruction manua|
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5 User |nterface
5.1 Ma|n screen
Descr|t|on
When vo|tage is switched on, the main screen is shown automatica||y.
1 Button to activate the |anguage se|ection screen
2 Button to activate the input pane| (keyboard)
3 Button to activate the compressor command viewer
4 Button to |ock the contro| pane|
5 Button to activate the change password screen
6 Button to activate Windows
7 Button to activate a soft restart
B Button to ca|| up the System Pressure Set configuration screen
9 Button to ca|| up the Automatic Functions screen
10 Button to ca|| up the Spare Capacity screen
11 Button to ca|| up the Forced Sequence screen
12 Button to ca|| up the Equa| Wear screen
13 Button to ca|| up the Group Managment screen
14 Shows the compressor mode or ES commands
Instruction manua|
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Comressor statuses
Be|ow a tab|e showing a|| existing statuses, their description and conditions for the supported
compressors.
5.2 Programm|ng System Pressure Set (SPS) sett|ngs
Descr|t|on
Three SPS settings can be programmed into the ES contro||er. To modify or program an SPS, proceed as
fo||ows:
15 Button, shows the compressor number. When the compressor number is shown
constant|y, the compressor is integrated; when f|ashing, the compressor is iso|ated.
This button is used to ca|| up the Compressor Information screen.
16 Shows the Compressor Communication status
17 Fie|ds showing Compressor Information
1B Fie|ds to integrate/iso|ate the compressor. If the fie|ds show grey, the compressor is
not ready to be integrated.
19 Button to ca|| up Version Information
20 Buttons to activate the contro| modes (Loca| Contro|, ES Contro| or Centra| Stop)
21 Button to change the Pressure Regu|ation method, the button shows the actua|
method.
22 Fie|ds showing the ana|og input readings
23 Pressure Graph fie|d
24 Fie|d showing the actua| time
Status Descr|t|on Load-No Load VSD ZH
NR
Start
Stopped and Not
Ready To Start
Stop Stop Stop
R Start Stopped and Ready To
Start
Stop Stop Stop
UL Un|oad UL UL and Speed=Min
Speed
IGV=0%
BOV=0%
MML Minimum
Minimum Load (Max
B|ow-off)
Not app|icab|e Not app|icab|e IGV=IGV Min
BOV=BOV Min
L2 Regu|ation in B|ow-off Not app|icab|e Not app|icab|e IGV=IGV Min
BOV MinBOV<100%
ML Minimum Load Not app|icab|e Speed=Min Speed IGV=IGV min
BOV=100%
L1 Regu|ation in turn-
down
Not app|icab|e Min
Speed<Speed<M
ax Speed
IGV Min<IGV< IGV Max
BOV=100%
FL Fu|| Load FL Speed=Max Speed IGV=IGV max
BOV=100%
Or motor |imitation
Instruction manua|
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C|ick the button to activate the SPS configuration screen (see section Main screen) or c|ick on the
Pressure Graph in the main window; fo||owing screen appears:
C|ick the button (1) of the SPS number to be programmed or modified; fo||owing screen appears:
Two methods can be used to program the SPS settings:
Instruction manua|
3B
Fixed Band (B): Enter the Load and Un|oad pressure using buttons (9)
Fixed Point (10): Enter a Setpoint and an offset using buttons (11)
Define the High Shutdown and Low Shutdown protection settings (15) using buttons (12).
The system wi|| ca|cu|ate the Warning and Regu|ation Settings, the resu|t of this ca|cu|ation can be
ca||ed up by c|icking button (16); fo||owing screen appears:
If the proposed system settings do not meet the requirements, they can be individua||y changed using
buttons (19).
C|ick the OK button (17) to program the settings or c|ick the Cance| button (1B) to quit without
programming. The ES contro||er wi|| return to the previous screen, press the OK button (14) to accept
the programmed SPS settings or the Cance| button (13) to quit without programming. The ES contro||er
wi|| return to the previous screen.
Two Operating Modes can be se|ected:
Manua| Mode (7):
If it is required to change over to another SPS setting manua||y, c|ick on the check box (7) of Manua|
Mode to se|ect this operating mode.
C|ick on the Set-up Manua| Mode button (2); fo||owing screen appears:
Changing the proposed setting can have consequences on the regu|ation and shou|d
on|y be done by qua|ified persone|.
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39
Se|ect the required SPS number and c|ick the OK button.
Weektimer Mode (6):
If it is required to change over to another SPS setting using a Week Timer, c|ick on the checkbox (6)
of Weektimer Mode to se|ect this operating mode.
C|ick on the Set-up Weektimer Mode button (3) to configure or change the week timer; fo||owing
screen appears:
Instruction manua|
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Define the number of weeks in a cyc|e using the arrow up or arrow down key of the Weeks in
Cyc|e Option (26), it is possib|e to create a cyc|e inc|uding up to fourty weeks.
Define the current week in the cyc|e by using the arrow up or arrow down key of the option
Current week (25)
To add a timer, c|ick on the Add Timer button (20); fo||owing screen appears:
Se|ect the week to add a timer command using the drop down menu in the window Week.
Se|ect the week day to add a timer command using the drop down menu in the window
Weekday.
Set the hour and minute settings using the arrow up or arrow down key next to the re|evant
window.
Se|ect the SPS setting command in the |ower window
C|ick the OK button to program the new Timer or the Cance| button to quit without
programming, the ES contro||er wi|| return to the previous screen.
To modify a timer, c|ick on the Modify button (21), the same screen as above appears. Modify the
parameters as necessary and c|ick the OK button to program the new parameters or c|ick the Cance|
key to quit without programming, the contro||er wi|| return to the previous screen.
To remove a timer, se|ect the timer to be removed and c|ick on the Remove timer button (22). A
confirmation screen appears, c|ick Yes to remove the timer or No to quit without removing the timer.
When a|| the timer settings are programmed, c|ick the OK button (24). From now on the ES contro||er
wi|| regu|ate the air net according to the settings programmed in the week timer.
Instruction manua|
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5.3 Automat|c Funct|ons
Descr|t|on
C|ick the button to open the Automatic Function configuration screen (see section Main screen).
Fo||owing screen appears:
Four Automatic Functions can be se|ected:
Automatic Restart After Vo|tage Fai|ure (ARAVF):
The ARAVF function wi|| set the ES and the integrated compressors back in the requested state after
a vo|tage fai|ure. The different configurations and settings are exp|ained be|ow. The ARAVF function
is disab|ed by defau|t.
Fo||owing parameters can be programmed:
De|ay Time:
After a vo|tage fai|ure, the ES wi|| on|y execute the ARAVF function and set the ES and
compressor in the correct state after the de|ay time has e|apsed.
Abort Time:
When the period of the vo|tage fai|ure takes |onger than this setting, the ARAVF function wi|| not
be executed. When the setting is set at "zero", the ARAVF function wi|| a|ways be active.
ES Request State:
Loca| Contro|:
Regard|ess of what the State before the Vo|tage fai|ure was, the ES wi|| a|ways start up in
Loca| Contro|
Last Known State:
Be aware that some of the Automatic Functions wi|| cause compressors to start
automatica||y. Stick |abe|s on the contro| pane|s of the compressors connected to the
ES as we|| as on an obvious p|ace inside these compressors, warning the operator that
the compressor is remote|y started and stopped by a separate contro||er. These |abe|s
must warn the operator that, after vo|tage fai|ure, the ES 130 can remote|y start and
stop the compressors, depending on the air demand and programmed va|ues.
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The ES wi|| go to the state as it was before the power fai|ure respecting the De|ay and Abort
Time.
Compressor Request State:
Remain Iso|ated:
Regard|ess of what the state was before the vo|tage fai|ure, the Compressor Request wi||
a|ways be iso|ated.
Last Known State:
The Compressor state wi|| remain in the request state as it was before the power fai|ure.
Automatic Integration After Communication Error:
When a communication error occurs, an integrated compressor wi|| be iso|ated. If this option is
enab|ed, the compressor wi|| be integrated again as soon as the communication prob|em is so|ved.
During a communication error, it is sti|| possib|e to change the compressor request (integrated or
iso|ated).
Automatic Integration After LAN Se|ection:
If this option is enab|ed and the compressor mode is switched from LAN to Loca| on the compressor
regu|ator, an integrated compressor wi|| be iso|ated. When the compressor is put back into LAN
mode, it wi|| be integrated again automatica||y.
Automatic Pressure Shutdown Recovery:
If the pressure shou|d exceed the Pressure Shutdown Leve| in ES contro|, the ES contro||er wi||
switch to Loca| Contro| and a|| compressors wi|| be handed back to Loca| Contro| (direct or
contro||ed).
If the Automatic Pressure Shutdown Recovery option is enab|ed, the ES wi|| recover when fo||owing
conditions are fu|fi||ed:
amount of retries per period are not exceeded
pressure must be in band for a certain period (Stabi|ization De|ay)
5.4 Sare Caac|ty
Descr|t|on
C|ick the button to open the Spare Capacity configuration screen; see section Main screen. Fo||owing
screen appears:
ES State beIore vo|tage Fa||ure ES State aIter Power Ia||ure
Loca| Contro| Loca| Contro|
ES Contro| ES Contro|
Centra| Stop ES Contro|
Request beIore vo|tage Fa||ure Request aIter Power Fa||ure
Iso|ate Iso|ate
Integrate Integrate
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If a minimum (spare) f|ow needs to be avai|ab|e immediate|y at a|| times, the spare capacity option needs
to be enab|ed and configured.
ConI|gurat|on
Spare Capacity:
Enter the minimum amount of f|ow that needs to be avai|ab|e at a|| times using button (1)
De|ay at Signa|:
If a shortage or an over p|us of 5% on the Spare Capacity is detected for a continuous period equa|
to the De|ay At Signa| Time, a new Spare Capacity mix is searched for. Program the De|ay At Signa|
Time using button (2)
Inc|ude avai|ab|e up|oad capacity:
Enab|ed:
The avai|ab|e up|oad f|ow among the |oaded range compressors is seen as Spare Capacity.
This option needs to be enab|ed to guarantee that a minimum amount of air f|ow is immediate|y
avai|ab|e to avoid undershoot due to a sudden increase in the f|ow demand.
Disab|ed:
The avai|ab|e up|oad f|ow among the |oaded range compressors is not seen as Spare Capacity.
This option needs to be disab|ed to guarantee that a minimum amount of air is immediate|y
avai|ab|e to avoid undershoot due to f|ow |oss (e.g. shutdown of one of the |oaded compressors).
5.5 Forced Sequence
Descr|t|on
C|ick the button to open the Forced Sequence configuration screen; see section Main screen. Fo||owing
screen appears:
Instruction manua|
44
ConI|gurat|on
Fo||owing buttons are avai|ab|e:
Add Sequence (1):
When pressed, fo||owing screen appears:
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To create an additiona| Sequence, se|ect a compressor in the Avai|ab|e window (15) and c|ick on the
Add button (17), the se|ected compressor moves to the Se|ected window (16). Repeat this hand|ing
unti| a|| compressors have their p|ace in the new sequence. If it is necessary to move compressors in
the Se|ected window (16), the Move Up (19) or Move Down button (20) can be used. C|ick the OK
button (22). The new sequence wi|| appear in the Sequences window (14). When a new sequence
must be created between two excisting sequences, se|ect the sequence under which the new
sequence must be p|aced, create the new sequence as described above. The new sequence wi|| be
added be|ow the se|ected sequence.
Modify Sequence (2):
To modify an existing sequence, se|ect the sequence to be modified and press the Modify sequence
button (2) a screen simi|ar to the one above wi|| appear. The se|ected Sequence can be modified by
changing the compressor position in the sequence using the Move Up (19) or Move Down button
(20). When the sequence is modified, c|ik the OK button (22)
Remove Sequence (3), Move Up (4), Move Down (5):
With these buttons, a se|ected sequence can be moved up, moved down or comp|ete|y removed
from the configuration.
Cerat|ng Mode
Fo||owing operation modes are avai|ab|e:
Periodica| Mode (13):
A sequence shift, in ascending order, wi|| be executed every defined period. To define the period,
c|ick on the Set Up Periodica| Mode button (6), a screen appears in which the period (in hours and
minutes) can be programmed.
Manua| Mode (12):
To change the sequence manua||y, c|ick the Set Up Manua| Mode button (7), a screen appears in
which the new sequence can be se|ected, press the OK button. The ES contro||er wi|| change over to
the manua| se|ected sequence.
Weektimer mode: (11)
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A sequence shift wi|| be executed on a predefined time/date in a week or over a cyc|e of more
weeks. Programming the Weektimer is simi|ar as described in section Programming System Pressure
Set (SPS) settings.
5. Equa| Wear
Descr|t|on
C|ick the button to open the Equa| Wear configuration screen; see section Main screen. Fo||owing screen
appears:
ConI|gurat|on
Restrict to certain periods (1):
When Equa| Wear is detected, some compressors wi|| most |ike|y switch. It might be that the
insta||ation or the production prefers to postpone a compressor switch. Therefore, when this option
is activated, Equa| Wear Contro| wi|| be restricted to certain periods.
To program the periods in which Equa| Wear Contro| is active, press button Set Up Periods (2),
fo||owing screen appears:
Instruction manua|
47
C|ick the Add button (9) to add a period in which Equa| Wear contro| is a||owed. A screen appears
a||owing to configure a period.
If it is necessary to modify a period, se|ect the period and c|ick the Modify button (10)
If it is necessary to remove a period, se|ect the period and c|ick the Remove button (11)
Maximum hour difference (5):
This setting wi|| determine within which range Equa| Wear wi|| be executed.
Equa| Wear hours:
The regu|ation a|gorithm wi|| take the Equa| Wear hours into account in case the Equa| Wear
regu|ation method is se|ected.
Tota| (Equa| Wear) hours = Running hours Offset hours
Set (6):
The Equa| Wear hours can be configured for each compressor individua||y by simp|y changing the
offset hours.
Reset a|| (7):
The Equa| Wear hours of a|| compressors wi|| be set to zero.
C|ear a|| (B):
The offset hours of a|| compressors wi|| be set to zero.
5.7 Grou Management
Descr|t|on
C|ick the button to open the Group Management Configuration screen; see section Main screen.
Fo||owing screen appears:
Instruction manua|
4B
ConI|gurat|on
The Configuration of Group Management is done by means of a wizard. If an existing configuration
needs to be modified, the wizard must be run through comp|ete|y.
There are three basic steps in the configuration of Group Management for each profi|e:
1. Group Configuration
2. Group Regu|ation Configuration
3. Profi|e Configuration
A|| Basic ru|es (e.g. Forced Sequence) and standard configurations (e.g. Equa| Wear, Week Timer, ) in
Group Management are simi|ar as if the ru|es wou|d be app|ied for that Pressure Regu|ation mode itse|f.
1. Group Configuration
For a correct Group Configuration, each compressor must be p|aced in a group. There are two
ways to do so:
Automatic:
C|ick on the Create By Capacity button (6). The groups wi|| be created automatica||y based on a
fraction of the tota| capacity of the insta||ation as fo||ows:
Hysteresis = Fraction Tota| F|ow
Add a compressor to a group if its design f|ow is sma||er or equa| to the sma||est design f|ow
of a compressor (not yet a||ocated) increased with the ca|cu|ated Hysteresis.
The resu|t of the automatic function can sti|| be changed if required by assigning a compressor
to another or new group in the next screen
Manua|:
Instruction manua|
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C|ick on the Add profi|e button (1) in the main Group Management configuration screen to
create the groups manua||y. Assign each compressor to the desired group.
2. Group Regu|ation Mode
For each individua| group, a Pressure Regu|ation Mode (Optimized Energy Saving, Equa| Wear or
Forced Sequence) must be se|ected, inc|uding the configuration of the Operation Modes (e.g.
Periodica|, Manua| or Week Timer Mode) or extra configuration in some cases (e.g. Equa| Wear
Offset). The pressure Regu|ation Mode must be configured in the same way as described in the
sections Forced Sequence or Equa| Wear.
3. Profi|e Configuration
A Profi|e can be defined as a pressure regu|ation ru|e that app|ies over the groups.
Profi|e Forced Sequence:
Loading, un|oading, stopping and starting compressors is done in ascending order of the group
sequence.
E.g. a compressor be|onging to a group can on|y be started/|oaded if a|| compressors in the
group of the previous sequence are |oaded.
Profi|e Equa| Wear:
The Equa| Wear hours between groups wi|| be kept within a defined range. Equa| Wear hours for
each group is ca|cu|ated as fo||ows:
Average Running hours of the compressors in the group offset
Profi|e Capacity Management:
In this profi|e the ru|es are app|ied as in Optimized Energy Savings mode. The se|ection to |oad,
un|oad and start compressors wi|| be based on the actua| f|ow demand and the cost of a
so|ution. The cheapest or best so|ution to meet the required f|ow demand wi|| be executed.
5.8 Comressor |nformat|on screen
Deta|| oI ma|n screen
Un|t Contro||er Mode/Comressor messages (1)
This fie|d is used to show compressor messages and the compressor contro||er mode.
If the compressor is iso|ated, the information wi|| be disp|ayed in fo||owing priority:
1. Shutdown
Instruction manua|
50
2. Contro||er Mode (Loca|/LAN/Remote)
If the compressor is integrated, the information wi|| be disp|ayed in fo||owing priority:
1. Shutdown
2. Not Ready To Start
3. Warning
4. Compressor Commands
5. Contro||er Mode (Loca|/LAN/Remote)
The Compressor contro||er mode can on|y be changed on the compressor itse|f and can be:
Loca|: compressor is not ready to be integrated
LAN: compressor is ready to be integrated
Remote: compressor contro||er is contro||ed by a third party system
C|ick on the Compressor Command Viewer button (see section Main screen) to monitor the commands
towards a compressor. This is on|y possib|e for an integrated compressor and for users with the highest
access |eve|.
Un|t ID (2)
A b|inking number indicates that the compressor is iso|ated, a steady number indicates that the
compressor is Integrated and under ES contro|.
A screen with unit data information pops up by c|icking on the number.
The screen shows a|| readings of the compressor. Depending on the compressor type, the readings on
the screen may differ.
Commun|cat|on Status (3)
-: Communication OK
?: Communication Error
!: Not Responding (The compressor did not respond within a reasonab|e time to an ES command)
Un|t Tye/name (4)
Unit Type and Unit Name are to be defined during the commissioning process.
Instruction manua|
51
Un|t Status (S)
Some statuses are type dependent.
Compressors
Dryers
Status Descr|t|on Load/NoLoad VSD ZH
NR Start Not Ready To Start X X X
R Start Ready To Start X X X
UL Un|oad X X X
L2 Regu|ating B|ow-off X
ML Minimum Load X X
L1 Regu|ating X X
FL Fu|| |oad X X X
Status MD FD CD D XD Zero
Purge
XD S||t
F|ow
X3D
Started X X
Stopped X X X X X X
Starting X X X X X
Stopping
Purge Saving
Shifting Towers AB X X X X X
Shifting Towers BA X X X X X
Pressure Re|ief Tower A X X X
Pressure Re|ief Tower B X X X
Regenerating Tower A X X X X X
Regenerating Tower B X X X X X
Coo|ing Tower A X X X X
Coo|ing Tower B X X X X
Pressure Equa|isation
Tower A
X X X
Pressure Equa|isation X X X
Tower B X X X
Standby Tower A X X X X
Standby Tower B X X X X
Pressurising Tower A X
Pressurising Tower B X
Instruction manua|
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5.9 Cbang|ng tbe ressure regu|at|on metbod
Descr|t|on
Press the button to change the pressure regu|ation method. Fo||owing screen appears:
Se|ect the desired pressure regu|ation method and press the OK button.
Instruction Book
ES 130 - 130 V - 130 T
What sets Atlas Copco apart as a company is our
conviction that we can only excel in what we do if we
provide the best possible know-how and technology to
really help our customers produce, grow and succeed.
There is a unique way of achieving that - we simply call it
the Atlas Copco way. It builds on interaction, on
long-term relationships and involvement in the customers
process, needs and objectives. It means having the
flexibility to adapt to the diverse demands of the people
we cater for.
Its the commitment to our customers business that
drives our effort towards increasing their productivity
through better solutions. It starts with fully supporting
existing products and continuously doing things better, but
it goes much further, creating advances in technology
through innovation. Not for the sake of technology, but
for the sake of our customers bottom line and
peace-of-mind.
That is how Atlas Copco will strive to remain the first
choice, to succeed in attracting new business and to
maintain our position as the industry leader.