Compressor Basics

Compressor Basics - Electric
COMPRESSOR
BASICS -
ELECTRIC
21st MAY , 2003 AIF-TRAINING 1
s i c
Ba
Compressor
tri cs
Ele c

Content :
• Some definitions and basic laws
- DC, AC Single phase, AC Three phase
• Three phase systems - Star and Delta connections
• Motor Data
• Motor Insulation Class and service factor
• Motor protections - Electrical protections
- Overload protections
• How to read a service diagram
• Device connections and measurements


ELECTRICITY - What ?
Something - INVISIBLE
- POWERFULL
- DANGEROUS !!
Something - SIMPLE for

QUALIFIED PEOPLE
TAKE CARE !!!

Power sources Direct Current (DC)
Voltage
Udc
Ex: 12 Volt
Time
Voltage is polarised with + and -
• Examples : Batteries
Rectified power supplies ; 12….24 V
• Applications : Electronic instrument supplies
Control equipment
Supply for pressure transmitter, etc...
• Safety : Voltages up to 24 VDC are safe, higher voltages can be
dangerous for people.

Alternating Current (AC) - Single Phase
Characteristic : Voltage and current regularly changes
strength and direction in a sinusoidal variation
Application : General use

Alternating Current (AC) - Single Phase
Characteristic parameters :
• Period T = Time for 1 cycle
• Frequency (Hz) = 1/T
• 50 HZ = 50 periods per second
• 60 Hz = 60 periods per second
• RMS value : = max amplitude divided by sqrt 2 (For sinus)
Safety : - A.C. Voltage <= 24 V is Safe for personnel

> 24 V is dangerous
Terminology : < 50 V : extra low voltage
< 1000 V : Low voltage
1000 V < U < 10000 V : Medium voltage
> 10000 V : High voltage

Alternating Current (AC) - Three Phase
Characteristics :
• Three phase alternating current is produced in a generator with three
separate windings.
• All values on the sinusoidal voltage are displaced 120° in relation to each
other

Alternating current system
L1
IL
Phase 1
L2 UL UL Phase 2
L3 UL Phase 3
Uf
N Neutral
Grounding
UL=Line voltage = UL1-UL2

1-Phase
Uf =Phase voltage = UL
3-Phase Y 3-Phase Delta √3
In a net 3 x 400 V UL = 400 V and Uf = 230 V
Power factor - cos ϕ
Reactance
X
X
Uac Z
R
Resistance
ϕ R
Relation between Reactance (X) - Resistance (R) -

Impedance (Z) - Phase displacement (ϕ )

Basic laws
Direct Current
• Law of Ohm
I = U / R with I = Current in Ampere
U = Voltage in Volt
R = Resistance in Ohm
• Absorbed power
P=UxI with U = Voltage in Volt
I = Current in Ampere
P = Power in Watt
Alternating Current
• Law of Ohm I= U/Z with
I = Current in Ampere
U = Voltage in Volt
Z = Impedance in Ohm
= Sqrt (R² + X²) where X is the reactance
• Power in a single phase system
P = U x I x cos ϕ
• Power in a three phase system
P = UL x IL x cosϕ x Sqrt (3) with
P = Power in Watt ( other units as stated above)

Units and measurements
Tension : Difference in potential between two
points
L1
Unit = VOLT 220 V
L2
Example :
Measurement in V ac Between V and Com
Current : Measures current flow in a circuit Unit = Ampere
L1
PS
L2
Measurement in A (of mA) between A and Com

Motor connection in Star
400 V
V1 400 V
U1
Terminal box
U2 V2 V
0
23 Un
W2 U2 V2
W2
400 V
U1 V1 W1
W1
U v1-v2
= Un/root 3 Power = Pn
3
Motor connection in Delta
400 V
U2 V1
40
Terminal box
0
Un
V
U1 W2 U2 V2
V2
400 V
W2 W1
U1 V1 W1
400 V
Uw1-w2 = Un Power = Pn
• TORQUE
• A turning force applied to a shaft , tending to cause
rotation . Torque is equal to the force applied , times the
radius through which it acts.
• Continuous [rated]torque
• The maximum torque a motor can deliver continuously
• Starting [breakaway] torque
• The torque required to start a machine /
compressor from stand-still. It is always greater
than the torque required to maintain motion.

• Full load torque
• The torque necessary to produce the rated HP
at full load speed
• Locked rotor torque
• The minimum torque that a motor will develop
at rest for all angular positions of the rotor
[with rated voltage applied at rated frequency]
• Pull-out torque
• The maximum running torque of a
synchronous motor .


MOMENT OF INERTIA…!!!
• Definition…???
• A measure of a body’s resistance to changes in velocity , whether the body is at rest or moving at a constant velocity.The velocity can be linear or rotational. The moment of inertia [ WK square] is the product of weight [W] of an object
• and the square of the radius of gyration [ K Square ].
The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation. WK square is expressed in units like lb-ft square , kg-met square etc.
•
Total Moment of Inertia = motor +coupling +compressor

• GD square = 4 X WK square
•

Torque curve for a short circuited, induction motor
Torque
Tstart Tmin Tmax
Tnom
RPM

Torque curve of a screw compressor - started in Star/Delta
Torque curve (∆ )
Loaded compressor
Torque curve (Y)

Unloaded compressor
Speed
Speed : +/- 90-95 %


MOTOR DATA PLATE
SIEMENS
3 f Mot 1LA8 315 4AB91 - Z
V Hz A KW cos ϕ t/m IA / In IP 55
400 ∆ 50 430 250 0,87 1488
+/- 10 %
460 ∆ 60 430 285 0,87 1784
ROTOR SQU. CAGE KL 13 EN 60034 IEC 34-1 W eight : 1,3 t

Ambient temp : 40°C Temp rise : 105 K SF : 1,1 SFA : 470 A
Ambient temp : 55°C Temp rise : 80 K SF : 1,0
Nmax : 3000 RPM
1080 2846 42

PROTECTION CLASS (According IEC 34-5)
• States how an electrical device is protected

• against contact and
• against water
Code : I PXY
Protection against water
Protection against human contact
and penetration by a solid object
• Example : IP 55
Protected against water jet
Protection against dust

Protection degree of electrical equipment : IP xy
Values for x Values for y
0 Open motors 0 No protection
PROTECTED AGAINST PROTECTED AGAINST
1 Bodies with a diameter > 50 mm 1 Vertical dripping
2 Bodies with a diameter > 12 mm 2 Water falling as a spray at an
3 Bodies with a diameter > 2.5 mm angle equal to or smaller than
4 Bodies with a diameter > 1 mm 15° with respect to vertical
3 Iden. as 2 but angle of 60°
5 Dust can still penetrate, but not
in such a quantity that it 4 Water splashed against the
disturbs motor from any direction
6 Full dust protection 5 Against water jet
6 Against condition on ship’s
decks
7 Against the effect of immersion
Most frequently used are IP23, 44 and 54

MOTOR DATA PLATE
SIEMENS
3 f Mot 1LA8 315 4AB91 - Z
400 ∆ 50 430 250 0,87 1488
+/- 10 %
460 ∆ 60 430 285 0,87 1784
ROTOR SQU. CAGE KL 13 EN 60034 IEC 34-1 W eight : 1,3 t

Ambient temp : 40°C Temp rise : 105 K SF : 1,1 SFA : 470 A
Ambient temp : 55°C Temp rise : 80 K SF : 1,0
Nmax : 3000 RPM
1080 2846 42

Insulation class
Scope
• The toughness of winding insulation is influenced by
• The temperature of the winding
• The insulation class
• The maximum allowable temperature rise of the
windings is defined by the insulation class
• The power delivered by a motor is limited by the
temperature rise of the winding !!
IMPORTANT REMARK :
If the upper limit winding temperature is exceeded
by 10 °C, the service life of the insulation is shortened
by about half

MOTOR TEMPERATURE RISE
INSULATION CLASSES
Insulation class A E B F H
Ambient temp °C 40 40 40 40 40
Temp increase °C 60 75 80 105 125
Thermal margin °C 5 5 10 10 15
Max. final temp °C 105 120 130 155 180
200
180
160
Te m p (°C)
140
120
100
80
60
40
20
0
A E B F H
Ambient temp °C Temp increase °C Thermal margin °C

MOTOR DATA PLATE
SIEM ENS
3 f Mot 1LA8 315 4AB91 - Z
400 ∆ 50 430 250 0,87 1488
+/- 10 %
460 ∆ 60 430 285 0,87 1784
ROTOR SQU. CAGE KL 13 EN 60034 IEC 34-1 W e ight : 1,3 t

Am bie nt te m p : 40°CTe m p rise : 105 K SF : 1,1 SFA : 470 A
Am bie nt te m p : 55°CTe m p rise : 80 K SF : 1,0
Nm a x : 3000 RPM
1080 2846 42

Service factor …!!!
Definition …???
• When used on a motor name plate , a number that

indicates how much above the name plate rating a motor
can be loaded without causing serious de-gradation .
•That is a motor with 1.15 S.F. can produce 15% more

torque than one with 1.0 S.F.

Service factor ?
What ??
• The service factor of an electric motor is :
•A multiplier which, when applied to the related power,
indicates a permissible higher loading
which may be carried out,
on condition that the maximum ambient temperature
limit of 40 °C is not exceeded
Example : - Motor rated power : 100 KW

- Service factor : 1,2
- Motor may be loaded to : 120 KW
- If Ambient temp <= 40 °C

Service factor ?
Used why ??
MARKET DRIVEN
• Competitors even use higher service factors
ATLAS COPCO POLICY
• Only use service factor within the safe limits

of the insulation class
• the thermal margin ( see table of insulation class)

is never used.

Development of the motor-weight (4-pole TOFC-motor 30 kW) from 1900 until today
1500
Kg
1000
Kg
500
Kg
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990

Service factor
Criteria for Atlas Copco motor selection :
• High efficiency
• No oversizing for efficiency and starting torque
• Class F winding
• High protection degree (IP55)
• Long life time for bearings and windings
Minimum 40 000 hours
• Service factor
Motors are selected to work in the worst

conditions within the SAFE AREA of the
insulation class !!!
Service factor
Motor power is influenced by :
• Spreading of the compressor element performance

• Fouling of the coolers
• Tolerances on the nominal voltage
Atlas Copco is testing very thoroughly by :

• Measurement of the electrical parameters on
different voltages and power output
• Measurement of temperatures around the motor
• Measurement of DT winding temperatures on
various voltages



Motor protection
Possible protection based on the line current :

• FUSE : - Prevent sustained overcurrent while avoiding
blow out on starting
- For larger motors, mainly used as short circuit
protection
• THERMAL RELAY
- A bimetallic element is heated by the line
current, to actuate the protection mechanism

Motor protection
• MAGNETIC RELAY
- Respond to magnetic field set up by the line
current
- Almost no time function
Above mentioned protections do not respond to :

•Over temperature caused by hot ambient conditions
• Blocked ventilation or cooling

Motor protection
OPTIONAL
TEMPERATURE RESPONSIVE PROTECTORS :
THERMISTORS and RTD’s
• Integrated (embedded) in the motor windings to

protect against dangerous overheating
• Closely thermally coupled to the motor windings
• Need additional conditioning equipment to

interrupt the contactor

Termistor protector
Power supply
PTC
Conditioning relay
Alarm Trip
Outputs for control

Remarks :
• Thermistors can not be used for measuring
• Thermistors can be connected in series
(R total cold < 1500 ohm)
• Same sensor can be used for protections
Alarm and Trip

Motor protection
RTD’s = Resistance Temperature Detector
RTD’s used in Atlas Copco :

• Pt 1000 : used in almost all compressors
• Pt 100 : Sometimes used to measure motor winding
temperatures
Pt 1000
Resistance value - 1000 Ohm - at 0 °C
Platin based resistor
• Pt 100 : Resistance value of Pt 1000 divided
by 10 for the same temperature
Values : See table and chart
TEMP Resistance(in Ohm) of PT 1000 element as a function of the temperature
(°C) 0 1 2 3 4 5 6 7 8 9
-10 960,9 964,81 968,72 972,63 976,54 980,45 984,36 988,27 992,18 996,09
0 1000 1003,9 1007,8 1011,7 1015,6 1019,5 1023,4 1027,3 1031,2 1035,1
10 1039 1042,89 1046,78 1050,67 1054,56 1058,45 1062,34 1066,23 1070,12 1074,01
20 1077,9 1081,78 1085,66 1089,54 1093,42 1097,3 1101,18 1105,06 1108,94 1112,82
30 1116,7 1120,57 1124,44 1128,31 1132,18 1136,05 1139,92 1143,79 1147,66 1151,53
40 1155,4 1159,26 1163,12 1166,98 1170,84 1174,7 1178,56 1182,42 1186,28 1190,14
50 1194 1197,84 1201,68 1205,52 1209,36 1213,2 1217,04 1220,88 1224,72 1228,56
60 1232,4 1236,23 1240,06 1243,89 1247,72 1251,55 1255,38 1259,21 1263,04 1266,87
70 1270,7 1274,52 1278,34 1282,16 1285,98 1289,8 1293,62 1297,44 1301,26 1305,08
80 1308,9 1312,71 1316,52 1320,33 1324,14 1327,95 1331,76 1335,57 1339,38 1343,19
90 1347 1350,8 1354,6 1358,4 1362,2 1366 1369,8 1373,6 1377,4 1381,2
100 1385 1388,79 1392,58 1396,37 1400,16 1403,95 1407,74 1411,53 1415,32 1419,11
110 1422,9 1426,67 1430,44 1434,21 1437,98 1441,75 1445,52 1449,29 1453,06 1456,83
120 1460,6 1464,36 1468,12 1471,88 1475,64 1479,4 1483,16 1486,92 1490,68 1494,44
130 1498,2 1501,96 1505,72 1509,48 1513,24 1517 1520,76 1524,52 1528,28 1532,04
140 1535,8 1539,53 1543,26 1546,99 1550,72 1554,45 1558,18 1561,91 1565,64 1569,37
150 1573,1 1576,83 1580,56 1584,29 1588,02 1591,75 1595,48 1599,21 1602,94 1606,67
160 1610,4 1614,12 1617,84 1621,56 1625,28 1629 1632,72 1636,44 1640,16 1643,88
170 1647,6 1651,3 1655 1658,7 1662,4 1666,1 1669,8 1673,5 1677,2 1680,9
180 1684,6 1688,3 1692 1695,7 1699,4 1703,1 1706,8 1710,5 1714,2 1717,9
190 1721,6 1725,28 1728,96 1732,64 1736,32 1740 1743,68 1747,36 1751,04 1754,72
200 1758,4 1762,07 1765,74 1769,41 1773,08 1776,75 1780,42 1784,09 1787,76 1791,43
210 1795,1 1798,76 1802,42 1806,08 1809,74 1813,4 1817,06 1820,72 1824,38 1828,04
220 1831,7 1835,35 1839 1842,65 1846,3 1849,95 1853,6 1857,25 1860,9 1864,55
230 1868,2 1871,83 1875,46 1879,09 1882,72 1886,35 1889,98 1893,61 1897,24 1900,87
240 1904,5 1908,12 1911,74 1915,36 1918,98 1922,6 1926,22 1929,84 1933,46 1937,08
250 1940,7 1944,32 1947,94 1951,56 1955,18 1958,8 1962,42 1966,04 1969,66 1973,28
260 1976,9 1980,5 1984,1 1987,7 1991,3 1994,9 1998,5 2002,1 2005,7 2009,3
270 2012,9 2016,49 2020,08 2023,67 2027,26 2030,85 2034,44 2038,03 2041,62 2045,21
280 2048,8 2052,37 2055,94 2059,51 2063,08 2066,65 2070,22 2073,79 2077,36 2080,93
290 2084,5 2088,07 2091,64 2095,21 2098,78 2102,35 2105,92 2109,49 2113,06 2116,63
300 2120,2

Sensor PT 1000
2200
2100
2000
1900
1800
1700
Ohm
1600
1500
1400
1300
1200
1100
1000
900
0
10
30
50
70
90
0
0
10
11
13
15
17
19
-1
2
°C

RTD’s Pt 100 and Pt 1000
RTD’s Can be connected to Elektronikon extension
module without other conditioning amplifiers
Remark for trouble shooting :
Always disconnect both wires of a RTD for checking

its value in case of troubles. Elektronikon
RTD

RTD’s Pt 100 and Pt 1000
RTD’s Can be connected to Elektronikon extension
module without other conditioning amplifiers
Remark for trouble shooting :
Always disconnect both wires of a RTD for checking
its value in case of troubles.
Elektronikon
RTD
Readings in Ohm

Cables and dimensions
• Low Voltage power cables and connections
• The cable connection points have to be connected in the
correct way
• Loose connection points can be the source of
mechanical damage to the compressor and will damage
the cables
• Use cables with dimensions as specified in the A.C.
instruction manual of each compressor. Cables with too
small dimensions cause excessive voltage drop.

Cables and dimensions
• Medium Voltage cables
• Selection of M.V. cables is the work for electrically

qualified people.
• Cable connections and insulation at both ends have to
be done extremely careful

How to read a service diagram ?
• Symbols : ref condensed symbol list (details ref A.C. Standard
E1282 K)
• Numbering of components
• Numbering of aux. Contacts
• circuit numbers on diagram
• Cross reference
• Terminal rows Ex: 1 X1- 74
Terminal number
Terminal row
1 = Cubicle
2 = Elektronikon Master module
3 = Consecutive module or component
numbers Cables and wires

Basic symbols

Basic symbols

Part of wiring diagram

Transformer for auxiliary power
Table as example only !
F1 TRANSFORMER
F3 VOLT CONNECTIONS
208 1-37 & 31-2
220 1-36 & 32-2
PRIMARY
Uin Uout 230 1-35 & 33-2
380 32-38
440 31-35
460 33-35
575 34-35
F2 110 3-4 & 5-6
SEC
220 4-5
Important
• Always take out fuses F1,F2,F3 before commissioning
• Measure Uin and make primary connections acc table
• Put F1,F2 in place and measure Uout
• If Uout is correct, close F3; otherwise adjust connections

Attention :
Remark about the 24 Vac

secondary :
• Secondary 24 V ac may
never be grounded
• secondary is protected by
two circuit breakers
• NEVER change this !!!

Part of wiring diagram( for compressor supplied without starter)
K02 and K03
can be used for
control of
Y - D starter

(for compressor supplied without starter)
Important
Take care of
interfacing
connections
to be in phase with
ECB AIF 1133

Interfacing connections with Elektronikon
Auxiliary inputs
Relay contact
outputs

Interfacing connections with Elektronikon
Temp inputs Pressure sensor

Relay outputs Pt 1000 inputs

Interfacing connections
Device connections
Pressure transducers Temp sensors Pt1000

3 - wire connection 2 - wire connection

PRESSURE SENSORS A = Ground (-)
B = Supply voltage(+5 V)
C = Signal (+)
B
Range :
Zero = 0.5 Volt DC
Full scale = 4.5 Volt DC
C
Measurement in Volts DC
A
Sensor must remain connected to Elektronikon

SERVICE DIAGRAM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
D R IV E M O T O R FANM OTOR CANO PY A

LEG END NO TES
[b ] P o w e r s u p p ly t o b e c o n n e c t e d f o r
C U B IC L E c o u n te r c lo c k w is e r o t a t io n o f
c o m p re s s o r m o to r a n d
F1/5 FUSE LINKS, CONTROL CIRCUIT - c lo c k w is e r o t a tio n fa n m o to r fo r Z R 3 0 0 -7 5 0 B
K11 AUXILIARY RELAY LOADING R o t a t io n t o b e o b s e r v e d w h i l e
K13 AUX. RELAY FOR STARTER CONTROL (4NO+4NC)
fa c in g th e e n d s h a ft o f 1X4 X
0 2 /1
VAA 21 C u s t o m e r ' s i n s t a ll a t i o n
X X
1
X
K14,15 VAA 11- (2NO,2NC) th e m o to r.

K21 POWER CONTACTOR FOR FAN MOTOR M28 ( N T P C - R IH A N D 3 .3 K V )
F21 OVERLOAD RELAY-MAIN MOTOR.
3
C
1
F21A OVERLOAD RELAY-FAN MOTOR-M28. [b ]
K31 T i m e r e la y w a t e r s h u t - o f f v a lv e
S2 MUSHROOM-SHAPED PUSH BUTTON
EMERGENCY STOP F3 1
S6 SELECTOR SWITCH 415 VAC, 3PH, 50HZ, BHEL
T1 MAIN TRANSFARMER
T2 TRANSFORMER 110V AC / 24 V AC LT LINE FROM THE [f] 2
1X1 TERMINAL STRIP SAME FEEDER OF D

1X3 EARTH BOLT HT LINE
33
Q28 MINIATURE CIRCUIT BREAKER FOR FAN MOTORS
A AMMETER
COM PRESSOR CO NTROL M O D ULE [g ] W h e n r e m o t e s t o p b u tt o n is 1x1

i n s t a l le d , t h e b r id g e s s h o u l d E
E 1 E le k t r o n ik o n R e g u la t o r b e r e m o v e d o n t h e c o r r e s p o n d in g K11
K 0 1 B l o c k in g r e l a y te rm in a ls o f 1 X 4 a n d 1 X 6 . (IAC)
PANEL
K 0 2 A u x . r e la y Y - c o n t a c t o r FROM
TUBE LIGHT
K 0 3 A u x . r e la y D - c o n t a c t o r [i] P re s s u re tra n s d u c e r [ f] F21B
(IAC) (DRYER)
(PAC)
L1 F0 108 230 VAG 3 PIN
K 0 4 A u x . r e la y l o a d / u n lo a d p i n c o n f ig u r a t i o n
30 32 31
[e ]
230V 50Hz
L2 F1 SOCKET FOR
K 0 5 A i r P r e s s . H ig h /A ir P r e s s . L o w r e la y S6 F
62
L3 LAPTOP.
F2
K 0 6 D r y e r + fa n s ta r t 1 : s u p p ly v o lt a g e
F6
K 0 7 A u t o m a t ic o p e r a t i o n r e l a y 2 4 2 : gro u n d U < [l]
K 0 8 G e n e r a l a la r m r e la y M
3 : o u tp u t AIR DRYER
K 0 9 G e n e r a l s h u t - d o w n r e la y 3 1
4 : s e a le d w ith d u m m y 109
1~
START / STOP / TRIP SCHEME.
2 X 1 /1 2 P r i n t e d c ir c u i t b o a r d c o n n e c t o r s
G
S ta r t b u tt o n (+) START STOP/TRIP
CUSTOMER H.T. PANEL

T1
24
CONTROL CIRCUIT.
P r o g r a m m e d S to p b u t to n A 1
HT SW.GEAR
1x1 1x1
[ l] I n c a s e o f H i g h V o l t a g e s u p p ly K21
2
63 65
f o r th e d r iv e m o t o r , u s e a A 2
H
s e p a r a t e 3 - p h a s e s u p p ly f o r K14 K15
C U S T O M E R 'S IN S T A L L A T IO N
2
t h e f a n m o t o r a n d s i n g le - p h a s e K13
s u p p ly f o r th e r e g u la t o r . 0 2 /2
F6 U n d e r v o l t a g e r e la y 1X4 X 1X4 X
F21 O v e r lo a d r e la y c o m p r e s s o r m o t o r
X X X X
1x1 1x1
2
X X
9 5
64 66
K21 C o m p r e s s o r m o to r s t a r te r F 2 1 I>
9 6 I
S 1 ' R e m o te s ta r t b u tt o n
53
[n ] T o a v o id E l e c t r o M a g n e t ic
S 2 ' R e m o te e m e rg e n c y s t o p b u tto n In te rfe r e n c e : s c r e e n e d c a b le s h a ll CLOSING
SHUNT
/TRIP
S 3 ' R e m o te / lo c a l p r e s s . s e n s i n g b e u s e d a n d e a r th e d . COIL. COIL. 1X1
S 5 ' R e m o te s e t p o in t c h a n g e 1
[o ] F o r f ie l d w i r in g : U S E C O P P E R W I R E O N L Y
415 v 31
tig h te n in g t o r q u e fo r b o lts :
J
m e t r ic t h r e a d s i z e M 5 : 5 N m ( 4 l b f t ) (-) F1 2
110 VAC
m e t r ic t h r e a d s i z e M 6 : 8 N m ( 6 l b f t )
A (F)
L1
m e t r ic t h r e a d s i z e M 8 : 2 0 N m ( 1 5 l b f t ) NTPC`S INSTALLATION
1
m e t r ic t h r e a d s i z e M 1 0 : 4 0 N m ( 2 9 lb f t ) DOL HT STARTER WITH ALL MOTOR
L2
PROTECTIONS. 1
F2
C .P .E . = C u s to m e r P r o v id e d E q u ip m e n t
(F)
2
K
32
T1
[l]
[t] MAIN ELECTRIC MOTOR SPACE HEATERS TO BE 1 3 5 2 1 13
1X1 1X1 PE
POWERED DIRECTLY FROM CUSTOMER'S HT SWITCH CT
GEAR WITH NECESSARY INTERLOCKS. 2 2 14 [b ] 2
(THIS IS NOT IN ACIL SCOPE.)
2 4 6 1X 3 L
Q 28
1X3
(T 1 ) (T 3 ) ( T 2 )
U 1 W 1 V 1
M
3 M
PE
M
3 M 28
F a n m o to r c ir c u it
o n ly fo r u n it s
M 1 w it h o u t c o m p r . m o t o r
C o m p re s s o r m o to r
[m ] N
N TPC
NATIONAL THERMAL POWER CORPORATION LTD.
R 96
R IH A N D S U P E R T H E R M A L P O W E R P R O JE C T .
Space
2 x 5 0 0 M .W .
O
Heater
T o b e in s t a l le d b y c o s t u m e r [ n ] 0 2 /0 1 BHARAT HEAVY ELECTRICALS LTD.
P R O JE C T E N G IN E E R IN G M A N A G E M E N T ,
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R25
N E W D E L H I , I N D IA .
R24
R26
R27
R28
R29
R30
R31
R32
R33
R34
T N 230VAC POWER SUPPLY

X
X
X
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X
FROM HT SWITCH GEAR

3 2 0 3 /0 2 BY CUSTOMER NTPC DRG. NO. : 1230-001-10PE-PVM-B- .
P
BHEL BHEL
: 200 : PE-VO-200-555- .
PT100 PT100 PT1 00 PT100 PT100 PT1 00 PT100 PT100 JOB NO. DRG. NO.
AC 1350K AC 1356K AC 1356K
Tolerance if not indicated
00
Mach.surf./drilled
according to punched holes
Sheet metal Welding REVISION
M o t o r w i n d in g 1 U 1 M o t o r w in d i n g 2 U 2 M o t o r w in d in g 1 V 1 M o t o r w i n d in g 2 V 2 M o t o r w in d in g 1 W 1 M o to r w i n d in g 2 W 2 B e a r in g D - e n d B e a r in g N - e n d flame cutted holes flame cutting
tem p. sen sor te m p . se n so r te m p. se n sor tem p. sensor te m p . s e n s o r te m p . s e n s o r te m p . s e n s o r te m p . s e n s o r

DN:PNA900000 Q
Class 2 Class 3 Class 4
Name PAR
WIRIN
TNGAM
DIAG
E RAM FOR CONTROL PANEL
XA 125
M O TO R HEATER 2 See drg
(FO.R
area
ZR 355 AIR COMPRESSOR.)
M/s. A TLA S COP CO INDIA LTD.
Confidential Property of ATLAS COPCO INDIA LTD.
3
FINISH :
Not to be used without the permission of
Ref.no.
Scale 1: 1 Compare -
9096 3823 00
R
Drawn
SGK. Blank no. Replaces
-9823 1897 32
ATLAS COPCO (I) LTD Blank wt.
Std.chd. finished wt. Designation Sheet
Transferred to Kg. Kg. (1/1)
(1/2
Note: Position: Modified from: Date: Intr/Appd:
Appurtenant drawings and documents.
Design chd. Prod.chd. Appd. Date
DD
07/0
/M
2/0
M/Y
3Y A1 90919
1515 ----
000005.
0
A000000
CT.03.1118.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 A
A U X I L IA R Y I N P U T S
V O LTA G E FREE CO N TAC TS

1X1
3 B
Fan motor overload ZT110-275

Remote/local press.sensing
Remote setpoint change
Dryer (+fan) overload

Overload drive motor
EC drain (warning)+
Remote load/unload
1X1 02/43 1X1 1X1 1X1
Remote start/stop
Starter feedback
( link = remote )
( closed = load )
1
Emergency stop
1
Automatic operation
6 6 6
General shut down

53
General warning
230VAC 3A AC15
230VAC 6A AC15
31 1X1
EC dryer
Motor running
1
Load-Unload
230VAC 10A
230VAC 10A
230VAC 10A
11 6 3
S2 32 15 C
1 X 6 X 1 X 6 X 1 X 6 X 1X 6 X 1X 6 X 1X 6 X 1X 6 X 1X 6 X
54 T31
X X X X X X X X X X X X X X X X
2 12 1 2 S3 53 53 5 3 5 3 53 53 5 3 5 3
X X X X X X X X
02/43 K13
F3 F4 16
53
53
1X1 6 1 X7 1 X7 1 X7 1X 7 1X 7
1 1 X X X X X
F21
44
X X X X X X X X X X
11 13 15 1 7 19 Q2 5
X X X X X
(F) (F)
53
(G) I> 13
[r]
11
13
15
17
19
1X1 K13 K13 K13 K13 K13 S 14 0 2 /3 9
45 K21 2X 1 2
1
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4
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7 D
2X7 17
33 2X8 5 0 2 /3
39 13 53 S1' 13 13 S3' 13
F6 S5' 13 Q4 1 13
C1 p
K01 K21 F21A
K04 K0 7 K0 8 K0 9 K1 1 K1 3
14 14 14 U < 14
[r ]
14 54 0 2 /3 14
(E) 110 VAC

B1 A1 T2 T1 2X7 18
2X8 6 2 X 1 22 2 X 1 25 2 X 1 28 1 X 6
24 VAC
F21A
415 v 31
X
X X
A1 5 4
X
53
12
14
16
18
20
1 X4
REFER FROM
1X1 1X1
2 0 2 /3 9 E
X
F1 [r]
110 VAC
X X
3 3 3
X
1 X7 1 X7 1 X7 1X 7 1X 7
(F) 9 X X X X X
SHEET 1/2
[g ]
X X X X X X X X X X
12 14 16 1 8 20
L1
X X X X X
1 1x1
100 1X 5
1x1 0 2 /2 2
64
60
T3 9
L2
F2
1 3 A1 A1 A1 1 X 6 X
X
X
1 X 6 X
X
X
1 X 6 X
X
X
1 X 6 X
X
X
1X 6 X
X
X
1X 6 X
X
X
1 X6 X
X
X
1X 6 X
X
X
1X 6 X
X
X
K21 T1 K15 5 5 56 57 5 8 5 9 60 62 6 3 6 4
X X X X X X X X X
(F) 3 A1 40 1X1
6
2 YS1 8
K13 A2 A2 A2
1K 13 F
32
T1 A2 K2
A1 A1
1X1
S10 14 63 X
2X 9 1 2 3 4 5 6 7 8 9 10 11 12 13
[s ] T2 K14 1 8 0 2 /5 1 2X11
DI02
24 V a c
DI01
DI03
DI04
DI05
DI06
DI07
DI08
DI09
DI10
A2 A2
Supply
M1 M1 M1 F5 8
M 5
2
NO
9 8 7 6 5 4 3 2 1
6
ON OFF TRIP 2
1X 5 K04
(F) Y1 K11 A1 C
9
PE F AN 21 13 2X12
A1 K2 K1 0 2 /2 0 L /U L G
7 NC
RED GREEN YELLOW
K31 22 14
12 11
NO NO
10 9 8 7 6 5 4 3 2 1
1 X4 A2 A2 re m o te e m e rg e n c y s to p C
K05 M K IV D K07
C
A P L /A P H A U T .O P E R A T I O N
1X1 1X1 X 1X1 1X1 1X1 1X1 NC NC
14 13
NO NO
X X
2 2 7 99 7 7 1X 4 1X 6 K06
H
X
K2 K1 X
X
X X
X
X
D R Y E R (+ F A N ) K08
4 4 5 4 C C
X X
N O NC NO NC NO NC
/ST A R T G . W A R N IN G
3
4
1 2
1 3
C U S T 'S - C U S T 'S - NC NC H
HT PANEL HT PANEL S2'
[g ]
16 15
11 1 5
K09 NO
14 C U S . H T P A N EL 2X10 G . S H U TD O W N C
45 NC
NO
1 2 3 4 5 6 7 8 9
1X 4 1X 6 3 K01 1 X7
C
X X
0 2 /3 2
X X X X
4 5 5 5 B LO C KIN G
X X
2X 1 1 NC
02 /38 3 2X 3
1X4 NO E1 I/ O I
4 K02
0 2 /3 8 0 2 /1 7 C
K Y
9
NC
0 3 /0 2 3
2X10 2X12 NO
1 ...
0 2 /3 8 2X9
[r] 0 2 /5 3 5
C K03
D
0 2 /4 1 [r] NC
20A
[r] 0 2 /1 2 2X 2 0 3 /0 8 J
13
15
16
45
11
12
14
3
3
4
5
6
6
6
7
7
R S 4 85
2X1
1X7
1X0
1X3
1X6
1X9
1X4
1X5
24
31
44
71
73
53
53
53
55
56
58
59
63
66
12
14
15
18
19
98
L1
L2
L3
L3
32
45
53
53
53
53
54
57
60
62
64
65
67
11
13
16
17
20
96
97
99
0
1
1
1
2
2
2
2
2
3
3
3
4
5
6
6
6
7
7
7
9
L1
L2
LA N
9
2X 5 2X6 2X 7 2X8
9
[g ] [g ]
1 ...
1 ...
Sign P01
Sign P02
Sign P03
Sign P04
Sign T01
Sign T02
Sign T03
Sign T04
Sign T05
Sign T06
Sign T07
Sign T08
Sign T09
Sign T10
20A
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
Gnd
V+
V+
V+
V+
K
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4
10B
11A
10A
12A
3D
3C
1D
2D
4D
6A
7A
8A
9A
1B
2B
3B
4B
5B
6B
7B
8B
9B
1C
2C
4C
5C
6C
1A
2A
3A
4A
5A
TO SCANNER
L
B C D
90
E
7
E
7
9
6
7
1X 1 8 1X 1 7 1 X1 1 0 2 /2 2 0 2 /2 9 02/3 5
53
62
24
2 1 3 2 1 3 2 1
2
1X11
1X10
109
108
110
111
0 1 /1 0 T o b e in s t a l l e d b y c u s t o m e r [ n ]
90
E
7
E
7
9
B C
0 2 /4 6 0 2 /4 9
N
A
NATIONAL THERMAL POWER CORPORATION LTD.
20A
20A
20A
20A
20A
20A
20A
20A
20A
20A
20A
20A
N T PC
R IH A N D S U P E R T H E R M A L P O W E R P R O JE C T .
71
73
10A
11A
12A
10B
E
1C
3C
4C
6C
1B
2B
3B
5B
7B
9B
3A
4A
6A
7A
9A
2C
5C
4B
6B
8B
1A
2A
5A
8A
90
2 x 5 0 0 M .W .
7
9
E
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 A B C A B C 2 1 3 A B C O
M u u u u u u u u BHARAT HEAVY ELECTRICALS LTD.
1 P P P P P R O JE C T E N G I N E E R IN G M A N A G E M E N T ,
PT1000 PT1000 PT 1000 PT1000 P T1000 PT1000 P T1000 PT 1000
N E W D E L H I, IN D IA .
Y 1 Y 51 M 40 TT 2 9 TT 11 TT 18 TT 21 TT 51 TT 58 TT 59 TT 44 PT 29 PD T 02 PT 49 PT 18
NTPC DRG. NO. : 1230-001-10PE-PVM-B- .
L o a d in g C o o li n g w a t e r G e a rm o to r C om pressor out E le m e n t 1 o u t E l e m e n t 2 in E le m e n t 2 o u t c o o li n g w a t e r C o o lin g w a t e r I C C o o l in g w a t e r A C O il C o m p re s s o r o u t D P a ir f ilt e r O il I n t e r c o o le r P
s o l e n o id v a lv e s o l e n o i d v a lv e d ry e r te m p . s e n s o r te m p . s e n s o r te m p . s e n s o r te m p. se n so r in l e t o ut tem p. sen sor o u t te m p . se n so r te m p. se nso r p r e s s . tr a n s d u c e r p r e s s . tr a n s d u c e r p r e s s . tr a n s d u c e r p re s s . tr a n s d u c e r BHEL BHEL
: 200 : PE-VO-200-555- .
JOB NO. DRG. NO.
AC 1350K AC 1356K AC 1356K
Tolerance if not indicated
00
Mach.surf./drilled
according to punched holes
Sheet metal
flame cutted holes
Welding
flame cutting
REVISION
DN:PNA900000 Q
Class 2 Class 3 Class 4
Name PA
WIR
RIN
TNGAM
DIA
E GRAM FOR CONTROL PANEL XA 125
2 See drg.
(FOR area
ZR 355 AIR COMPRESSOR.)
M/s. ATLAS COPCO INDIA LTD.
Not to b e u sed with out th e p ermission of
Confidential Property of ATLAS COPCO INDIA LTD.
3
FINISH :
Ref.no.
Scale 1:1 Compare -
9096 3823 00.
R
Drawn
SGK. Blank no. Replaces
-9823 1897 32
ATLAS COPCO (I) LTD Blank wt.
Std.chd. finished wt. Designation Sheet
Transferred to Kg. Kg. (1/2
(2/1)
Note: Position: Modified from: Date: Intr/Appd:
Appurtenant drawings and documents.
Design chd. Prod.chd. Appd. Date
DD/MM/YY
07/02/03 A1 9511
10959----
0000
005.
A000000
CT.03.1118.00

ELECTRICITY
ATTENTION !!!
Something - INVISIBLE
- POWERFULL
- DANGEROUS !!
Something - SIMPLE for

QUALIFIED PEOPLE
TAKE CARE !!!

INSTRUMENTATION & ELECTRONICS
Elektronikon MkIV
State-of-the-art
compressor control

What is the Elektronikon?
State of the art electronic controller that optimizes all aspects of

compressor maintenance and operation

The Elektronikon monitors
The Elektronikon system continuously and accurately monitors

all defined critical functions of the compressor package
The Elektronikon display is

clear and easy to read

Older electro-pneumatic control Elektronikon elegant simplicity
•Many more components required than

with Elektronikon regulation
•More opportunity for failure due to

complexity than with Elektronikon regulation
•More involved trouble shooting than with

Elektronikon regulation
•More simplified due to reduction of components
•More reliable and easier to troubleshoot

than electro-pneumatic regulation
Advanced electronic control

Elektronikon electronic precision
Advanced electronic control
Older
electropneumatic
control
Elektronikon advanced electronic

advantage in accuracy...
•A mechanical switch's setpoint can drift over •Electronic sensors maintain setpoint with same
its lifetime accuracy throughout lifetime
•A mechanical switch requires inaccurate •Electronic sensors’ setpoint is easily adjusted through
manual adjustment the Elektronikon faceplate
•The reaction of the control system to a process •Reaction of the Elektronikon system is very fast
deviation is slow with electropneumatic control insuring tight system pressure band and assured
compressor protection [ better response time ]
•Display versus switch readout of parameter
has deviation •The process value readout is a function of the sensor’s
electrical signal

Chapter 1
Differences with MkIII

Improvements compared to MkIII – 1
Hardware related improvements:
• Better viewing angle of LCD screen
• No more expansion modules for standard machines
(except ZH)
• Expansion and communication modules DIN rail
mounted => less wiring to cubicle door
• No more COM module for VSD compressors
• Key switch integrated in software
• Improved hardware, better electrical connections
to terminals
Improved LCD
• LCD glass has updated technology
• This allows for better reading in all

conditions
• Viewing angle less restricted than in

Mk3

Software related improvements:
• Improved menu structure
• Improved troubleshooting
– E.g. to check module connection
• Help Screen for Service contact (e.g. web site, e-mail
address)
• Readout in MPa possible
• 2 pressure settings possible
– Automatic switching with a week timer
– Manual switching
– Remote switching
• Digital input
– “1” = pressure setting 1
– “0” = pressure setting 2

Double Pressure Setting
• Each compressor can have 2 sets of pressure settings

• E.g. to have lower pressure during the weekend.
• You don’t have to pump-up your compressor network.
• Selection can be made

• by hand
• based on the timer function
• Timer can start/stop compressor and change pressure band

Other improvements:
• Field programming simplified
– Only master module has to be downloaded
– All components in the CAN network can be downloaded from 1
point
• Multiple Compressor Control (MCC) function as option
– Energy savings
• No more cascading => smaller pressure band
• With remote pressure sensor in the air net => better control of
the net pressure
– Equal wear
• Easier networking: CAN does not require interfaces
• Only 1 module required for external communication

New
Features
More intelligent user interface for improved navigation

Help screen for service contact
2 sets of pressure settings
Improved LCD (better visibility)
Relay Expansion Box is integrated
Hardware improvements in general resulting in neat professional look
Improved communication skills via Computer Automation Network or CAN
Optimised & modified menu to accommodate new functions
3 languages (3rd=Dutch For factory use only)
°C/F and PSI/Bar can be defined independently

Chapter 2
Hardware

Elektronikon MKIV The family •Physically the same size as
Elektronikon II
•Uses symbols instead
of text
•No programming required,
parameter set selection based on
machine type at assembly
•No communication, options or
Elektronikon I expansions. No clock functions.
Hardware I/O
Input Output Controller functions

• 1 Pressure • DSS
• Star contactor
– Compressor outlet • ARAVF
• 2 Temperatures • Line contactor
• ID control
– Element outlet • Delta contactor • Service indication
– LAT • Load/unload sol. • Counters
• 3 Digital Inputs Valve
• Remote start/stop
– Emergency stop • General • Protections
– Motor overload shutdown
– Remote start/stop • Dryer control

•Physically the same size as Elektronikon I Elektronikon MKIV The family
•Two out of a selection of 23 languages can be
downloaded
•Two pressure sets can be programmed, selected
manually or timer based
•Full expansion capability, up to eight modules per
compressor
•Two hardware versions, MKIV-IIA or MKIV-IIB
•4x16 back lit LCD
Elektronikon II
Hardware I/O Version A Version B
•1 pressure input •2 pressure input
•2 RTD temp inputs •3 RTD temp inputs
•8 digital inputs •10 digital inputs
•9 digital outputs •9 digital outputs
•No RS485 (no VSD) •RS485 (VSD)
•CAN connection •CAN connection
•I/O expansion port •I/O expansion port

Elektronikon MKIV The family •Physically larger than the Elektronikon I and II
•Two out of a selection of 23 languages can be

downloaded
•Two pressure sets can be programmed, selected
manually or timer based
•Full expansion capability, up to eight modules

per compressor
•Two hardware versions, MKIV-IIIC or MKIV-

IIID
•4x40 backlit LCD
Elektronikon III Hardware I/O
Version C Version B
•4 pressure input •4 pressure input
•8 RTD temp inputs •10 RTD temp inputs
•10 digital inputs •10 digital inputs
•9 digital outputs •9 digital outputs
•No RS485 (no VSD) •RS485 (VSD)
•CAN connection •CAN connection
•I/O expansion port •I/O expansion port
Elektronikon MKIV The family
Where the Elektronikon MKIVs are used
MKIV regulator type Compressors it is installed on as standard
Type I Pack style GAs, GA 5-11C and SF 1-5
Type IIA WorkPlace style GA 11-90C, GA 5-

11C(optional) and SF Multi core
Type IIB GA less than 90 VSD
Type IIIC ZT less than 55 kW
Type IIID ZR, ZVSD and all other AIF compressors

MkIV Master Module for AIF
• On all AIF machines the “D-controller” is used:

D-Controller
The D-controller has following features:
• User Interface
– 4 * 40 characters
– Higher Quality LCD than MkIII
• Inputs and outputs:
– 4 * pressure inputs (0-5 V)
– 10* temperature inputs (PT1000)
– 10 * digital inputs
– 9 * digital outputs
=> No expansion modules for standard machines (except ZH)
• RS485 connection for converters
• CAN connection => communication without interface
• I²C connection for I/O
• 24 Vac power supply required

Expansion modules
• All modules are DIN rail mounted (less wires to door)
• Some modules require 24 Vac power supply
• Expansion modules are mainly used for machine-options (but are also
available as sales kit)
– AIE1 = 2 * pressure inputs (0-5 V) + 2 * PT1000 inputs
• E.g. for delta p over integrated DD-filter
– AIE2 = 4 * 4-20 mA inputs
• E.g. for dew point meter on IMD or remote
speed control on VSD machines
– AIE3 = 5 * PT100 inputs
• E.g. for motor winding/bearing temperatures
– AIE4 = 5 * PT1000 inputs
• E.g. for motor winding/bearing temperatures
– DIOE = 2 * digital inputs + 2 * digital outputs
• E.g. for thermistors in motor windings
– SPM 5/7 = for 5 or 7 SPM inputs (= NEW option)

• AIE1 : 1900 0710 41
• 2 Kavlico Pressure inputs
• 2 Jumo Temperature inputs
• No supply
• No download
• Low power consumption (mA)
• AIE2 : 1900 0710 51

• 4x 4..20mA passive (2 wires)
• Needs external power supply (17…30VDC)
• No download
• Low powerconsumption (mA)
• AIE3 : 1900 0710 61

• 5x Pt100 for motorprotection
(2bearings, 3 windings)
• No supply
Mountable on DIN rail • No download
• AIE4 : 1900 0710 81

• 5x Pt1000 for motorprotection
(2bearings, 3 windings)
• No supply
• No download

• DIOE : 1900 0710 71
• 4 voltage Free contacts
K01 … K04
• 4 digital inputs
• No download
• 24Vac 50/60Hz supply
• consumption 9VA
Mountable on DIN rail
• SPM : 1900 0711 11
• I/O for7 SPM channels
• No supply
• consumption not known
• COM Box :
• MODBUS to CAN 1900 0711 41
• COM1(RS232) to CAN 1900 0711 41
• PROFIBUS to CAN 1900 0711 42
• Communication with compressor network
& customers system
• modbus, profibus, ethernet to be
downloaded

Updated !
21st MAY , 2003 AIF-TRAININGUpdated ! 89
Communication modules
• All modules are DIN rail mounted
• All modules require 24 Vac power supply
• Communication modules are only available as sales kit:
Combox-S (CAN to Serial)
• For external communication via Modbus
• To connect old units (MkI/II/III and E/P) to the CAN network
• To connect ES100/300 to the CAN network
Combox-P (CAN to Profibus)
• For external communication via Profibus
Combox-E (CAN to Ethernet)
• For external communication via Ethernet
• Will also be used for the AIRmonitor (communication to
Internet for Service contracts)

A typical compressor controller
24Vac
RS485 Converter on models B/D
attention software PROTOCOL defines converter type
Available : Siemens,ABB & Vacon
Extra Inputs,
P&T Sensors Relay Outputs Outputs or both
Digital Inputs 24Vac
(some module types
= CABLE 1622 0661 01, -02, -03 require external
To be ordered seperately. power supply, others
3 lengths available. get there power from
Number ofmodules
Updated ! is limited by 1622 0661 00 the Main Controller)
Updated !
Hardware

Improved connectors
Mk3
Mk4
• Weidmüller & Phoenix screw

• Wago ‘spring’ connectors
terminals
• Sometimes became loose
• Also mechanically better
fixed
• PartNr: 1088 0014 xx
• PartNr: 1088 0031 xx
1088 0031 00_ed1.pdf

Other hardware
CAN connectors
– To connect modules to a CAN network
– Connector 1 for single node
– Connector 2 for 2 nodes or laptop connection
CAN repeater
– For longer CAN networks (2 * 250 m)
MCC (Multiple Compressor Control) dongle
– Hardware key to activate the MCC function
I²C cables
– To connect modules (lengths of 150/600/1100 mm)
ES002
– To connect an E/P unit to CAN
ES003 = ES002 + Combox-S
– To connect an E/P unit via CAN to ES100/300

e.g. GA 55-90C Digital inputs Pt1000 inputs Pt1000 inputs Digital Inputs
Option CONDR Feature COOL=WATER Option ENREC Option THERM
D7 = Cond. Drain T1: Water In T1 = ER Water In DI01 : Thermistor
Standard Option FIKIT T2 :Water Out T2 = ER Water Warning
Digital Inputs D8 = DD filter Out DI02 : Thermistor
D1 = Emergency Stop D9 = PD filter Shutdown
D2 = start/stop Option PHSR
D3 = load/unload D10 =Phase sequence DI03 : QD Filter (not
D4 = local/remote pressure used)
D5 = main motor overload DI04 : not used
D6 = fan motor overload
AIE1 AIE1 DIOE AIE3
Kavlico Kavlico Digital Outputs Pt100 inputs

inputs P1 : inputs DO1=CD dryer (not used) Option Bearings (not
not used P1 : not used DO2 : not used used)
P2 : not used P2 : not used DO3 : not used T1 : D bearing
DO4 : not used T2 : ND bearing
Standard Option Windings (not
Digital outputs used)
Standard K01 = Line T3 : U winding
Kavlicoinputs K02 = Star T4 : V winding
P1 = delivery air K03 = Delta T5 : W winding
P2 = DP oil separator K04 = Load/Unload
Pt1000 inputs Solenoid
T1 = element outlet K05 = APH / APL
Feature MDVAR= FF K06 = FD Dryer Control
T2 = Dryer LAT K07 = Automatic
Operation
T3 = not used K08 = General Warning
K09 = General Shutdown

Hardware data
• INTERESTING TO KNOW :
• Line Voltage Limits
• + 40 % to - 30 % of the nominal supply voltage.
• Supply drop-out
• The device will operate without disturbance with a supply voltage drop-out of
40 ms every second.
• Degree of Protection of Enclosure and Connectors
• degree of protection at the front of IP 55 and at the back of IP 23, both

according to IEC 529. Other devices have an overall protection of IP 23.

Chapter 3
Main functions

The Elektronikon controls
The Elektronikon regulates the

compressor to maintain the
desired system pressure
Control
Load/no load
fixed speed
machines
or
System pressure System pressure is

Variable Speed
compared to the
Drive, VSD,
programmed machines
pressure band

The Elektronikon protects
Electronic precision scans all vital functions…shuts

the compressor down if trouble exists...
Cooling fan motor
Compressor Drive motor

element

The Elektronikon advises
System pressure
Compressor status and data Service requirements

Compressor control
The MkIV has following control functions:
• Manual start/stop of the compressor
– Emergency stop is separate button
• Choice between “forced unload” and “automatic control” (=
pressure control)
Load/unload
• Pressure control pressure control
– For load/unload
• By loading and unloading the compressor
– For VSD
• By speed control between min and max speed VSD
(in this zone the MkIV tries to reach the set point) pressure
• By stop/start (and unload for Z VSD) < min speed control
– Required pressure band (and set point for VSD’s) to be specified
• Choice between local and remote control
Compressor monitoring
The MkIV has following monitoring functions:
• Status of the compressor
– Voltage on/off
– Loaded/unloaded/stopped
– Warnings and shutdown
• Control mode
– Forced unload/automatic
– Local/remote control
• Measured values
– Pressures/temperatures/…
– Speed of the motor and accumulated volume for VSD’s
– “Running”/”Loaded”/”Module” hours
– Number of motor starts
– …
For details: see MkIV Instruction Books

Compressor protection
The MkIV has following protection functions:
• To stop the machine (shutdown)
– When an input indicates that the machine can be damaged
– E.g. element outlet temperature too high (HH)
• To give a shutdown warning
– When the machine comes close to a shutdown
– E.g. element outlet temperature high (H)
• To give a service warning
– When the machine needs service
– E.g. air inlet filter high (H)
• Delay second stop (DSS)
– To protect overheating of motor windings
– Motor can only stop once every 20 minutes (if 3 starts per hour
allowed by motor vendor)

Converter control
• Each VSD device has a frequency converter
• Our compressors can have 3 converters:
– For the main motor
– For the dryer (in FF machines or behind the machine)
– For the fan motor (in air cooled machines)
• The converter controllers are linked with the MkIV; but the
MkIV is the master controller
• Advantages:
– Only 1 User Interface (of the MkIV)
– Because of the integrated controls
• More stable dew point with MD VSD and ID VSD
• Better fine-tuning of the main motor converter
– Bigger operating range (higher max and lower min speed)
– More energy savings (lower energy consumption by fan-
motor and ID-dryer)

Chapter 4
Special options (sales kits):
sequencing + external communication

Multiple Compressor Control – What ?
• Multiple compressor Control (MCC)
• = sequencing
• = central control
Without MCC
With MCC
• Purpose
– Pressure band reduction => energy savings
– Equal wear of the compressors
• Limitations
– Max. 4 compressors
– Of the 4 compressors max. 1 can be a VSD

Net pressure Elektronikon Multiple Compressor Control
Traditional cascade
control
Comp 1
Typical overall
pressure band 1.5 With MCC overall
Comp 2
Avg pressure bar system pressure
Comp 3
can be drastically
reduced
•Up to four compressors can be •Reduce system pressure band -

controlled with MCC, one of which save energy, reduce leakage and
can be a VSD stabilize system pressure
•Equalize running hours of all

compressors integrated

Multiple Compressor Control – How ?
Set-up
– Compressors to be connected in a CAN network
– No extra controller required
• The sequencing software is installed in every MkIV
• Hardware key (dongle) on 1 of the master modules to activate the sequencing
software (=> 1 MkIV machine in the network is enough)
Algorithm
– MCC keeps the pressure at the outlet of the “master compressor” in the require
pressure band
• In Q1 2003 a remote pressure sensor will be possible:
with pressure transmitter (4-20 mA) and AIE2 module
– If present VSD controls the pressure
– Compressor with lowest running hours is started/loaded
– Compressor with highest running hours is stopped/unloaded
• Hour counters can be initialized
• Change-over at regular intervals can be forced
– Week timer with 2 pressure bands

External communication
• There are 3 ways to go to the customer’s plant management system (DCS):
– Via Modbus with Combox-S
– Via Profibus with Combox-P
– Via Ethernet with Combox-E
• 1 Combox is enough for a complete CAN network
• Combox is sold as a sales kit (not a machine option)
• Functionality:
– Monitoring of all compressors in the network:
• compressor status
• all measured values
– Control of all compressors in the network:
• Start/stop
• Forced unload/automatic
• Change of pressure band (and set point for VSD)
• Remote speed control (for VSD)
For details => see User Guide on Elektronikon software market

Chapter 5
The CAN network

Elektronikon MKIV Communication Networking
• The MKIV regulators use a field bus called CAN
Controller Area Network (CAN) is an ISO approved standard for a low cost
real time communication protocol. It has a relatively high transmission speed (up
to 1Mbps). It is a fault tolerant and robust system.
CAN was initially developed by Bosch for in-vehicle data transfer and was
defined in 1984

Overview of the CAN network

Elektronikon MKIV Communication
CAN graphical network representation
MKIV MKIV MKIV MKIV
CAN
Combox Combox
ES002
Conversion Box Conversion Box
“Communication” “Communication”
RS232 RS232
Relay(s)/Wiring
COM1
MkI/MkII E-P and Competition

MkIII
Other LAN graphical network
representation
MKIV MKIV MKIV
Combox
CAN
Conversion Box
“Communication”
Combox Combox
ES002
Conversion Box Conversion Box
“Communication” “Communication”
RS232 RS232
Customer’s LAN
Relay(s)/Wiring
COM1
Electro-Pneumatic and Competition

MkIII MkI/MkII

The Compressor Network for Control

Updated
Updated! !
Electro
Mk1..3 Pneumatic
E/P Central
RS232C Hard wired Control Unit
COM box ES002

System Bus
(CAN)
CAN cable : LAPP cable UNITRONIC BUS-CAN – AC p/nr : 0017 2610 10
2x2x0.34mm²
Alternative : Belden3106A – AC p/nr : 1900 0707 92 (300M)
• Reduced & simpler wiring

• Simplification of software
• CAN = very reliable connection
• Every model of Elektronikon II or III can be
directly connected to this network
• Max. length = 200M without CAN repeater

• Max. length = 500M with CAN repeater every
250M
!! IMPORTANT !! : Never ADD/REMOVE any device from the

network without disconnecting the power supply
The Compressor Network for Communication
Updated !
Updated !
Mk1…3 E/P
RS232C Hard wired Central

Control Unit
COM box ES002 System Bus

(CAN)
2x2x0.34mm²
COM-Box
Locate in any of
the cubicle, or
outside
Customer PLC
e.g. Simatic S7
Profibus Network


The Compressor Network
for Communication : Next Step
Updated !

Updated !
Mk1…3 E/P
RS232C Hard wired Central

Control Unit
System Bus
(CAN)
2x2x0.34mm²
E-Box
Locate in any of
Internet the cubicle, or
Explorer outside
Ethernet Commercial Outside World

Modem or
Router


Means for communication
• Local communication
Communication and control of the regulator is done by an operator locally at the
face plate of the module by manipulation of the modules screens through its
membrane switches
• Digital communication
Communication and control of the regulator is done remotely by digital, potential
free, contacts or switches. An operator in a remote station can control the machine
and see the status of the digital outputs that are free for use. Could also mean
control or monitoring by a PLC or similar device.
• Network communication
Communication and control of the regulator is done remotely over a computer local
area network connection. This could mean central control using an Atlas Copco ES
product, including the new MCC, or network monitoring using our standard protocol
conversions modules or the new e-Box and monitor over the world wide web.

How to wire a CAN network ?
• Components (compressors, etc.) are connected in a “Daisy-
chain” = multi-drop
• CAN connector on each component in the network
– E.g. 2 compressors + Modbus = 3 connectors
• 2 types of wires possible:
– Lapp-cable Unitronix ( AC nr. 0017 2610 10)
– Belden 3106A (AC nr. 1900 0707 92)
• Limitations:
– Max. 30 components in the network
– Max. 250 meter total length
– With a repeater max. length = 500 meter
• More details in the “How to wire a CAN network” instruction
– On Lotus Notes
=> Database called “Elektronikon software market”
=> Programs => Technical Notes

Elektronikon MKIV Communication modules
Description Remarks
ComBox-Modbus Communication module that converts CANto

Modbus protocol
Application software dependent load at
commmissioning CAN
ComBox-Profibus Communication module that converts CANto

Profibus protocol
Conversion Box
ComBox “Communication”
ComBox-Ethernet Communication module that converts CANto
Ethernet protocol
ComBox-RS232 Communication module that converts RS232

fromCOM1 to CAN “X”- bus
Can be used to connect an older generation
Elektronikon to the CAN
Application software dependent load at
commmissioning
ComBox-DIOE Communication device that converts

digital inputs to CAN
Can be used to connect an elpn regulated Customer DCS
compressors or digital accessory to CAN
Separate enclosed product similar to ES001

Elektronikon MKIV Monitoring
Description Remarks
e -Box I Devicethat allows anauthoriseduser to

monitor acompressor installationover
thewebfromaremotePC. Application CAN
softwareis imbeddedinthedevice.
e -Box II Devicethat allows anauthoriseduser to

e-Box
connect acompressedair installationto
Atlas Copco's WorldWideWebe-services.
Cable Connects anexpansionmoduletothemaster

600mminoverall lengthwithendconnectors
Cable Connects anexpansionmoduletothemaster

Modem
150mminoverall lengthwithendconnectors
Instruction HowtowiretheCAN
Instruction MCCoperationandinstructionmanual
Instruction ComBox instructionmanuals, Modbus

World Wide Web
Profibus andEthernet
Instruction e -Box instructionmanual

Chapter 6
Flexibility + Remote monitoring +
Operating costs

Elektronikon comprehensive flexibility
Simple
modification of
Electronic gearing Remote control parameters at
and annunciation faceplate
standard
Multiple language Timer based

selections possible control as standard
Automatic restart
after power failure
as standard
Additional non standard Two programmable

Elektronikon platform used on
inputs possible pressure sets
AII and AIF compressors as
well as AIQ dryers

Elektronikon remote monitoring
The Elektronikon allows a compressor

installation to be monitored over a computer
network
•Standard protocols available
•Modbus
•Profibus
•Ethernet
•Customized monitoring packages available,

as part of standardized service plans
•Monitoring via your own PC over your network

or the internet
•Monitoring via Atlas Copco trained engineers

over the internet

Elektronikon lowers For each bar reduction in working pressure a
operating cost 7% energy savings is realized
For each bar reduction in working pressure a
Facts about working pressure: 13% lower leakage rate is realized
Savings potential of up 30% in energy costs
over conventional electropneumatic control
Saves energy
Elektronikon lowers operating pressure...
•Electronic precision - more accurate
•Electronic decision making - anticipates

•Electronic decision making - DSS algorithm
•Two programmable pressure bands - flexible
•Electronic sophistication - Multiple Compressor Control,
MCC

Chapter 7
MK-IV REGULATOR
ENERGY SAVER

Elektronikon MKIV ES evolution Energy Saver sequencing
Today Tomorrow
Product Use Product Use
ES100 Sequences 2 to 7 load/no load MCC Sequences 2 to 4 compressors

compressors load/no load with 1 VSD from MKIV
ES200 Sequences 2 to 8 compressors ES1000 Sequences an unlimted number

mix of load/no load and ZH of load/no load compressors
ES300 Sequences 2 to 16 load/no load ES2000 Sequences an unlimted number

compressors of load/no load and VSD
compressors
ES3000 Sequences an unlimted number

of load/no load, VSD and ZH
Atlas Copco compressors
ES4000 Sequences an unlimted number

of load/no load, VSD and
turbo compressors of other mfrs
The new ES Millennium series sequencers

•Based on the CRC hardware platform from Oil Free •Three modes; Energy savings, Equal wear
and forced sequence
•Can be combined with monitoring, each is up gradable
to the next series with software

Elektronikon MKIV ES evolution Energy Saver monitoring
Today Tomorrow
Product Use Product Use
ES400 Monitors up to seven Atlas e -Box I Allows up to four compressors

Copco compressors over serial to be monitored. Web application
connection built in device
e -Box II Allows up to four compressors

to be connected to the Atlas Copco
web services of monitoring or PM
service by Atlas Copco reps
ES - X Local monitoring of installation

based on CRC hardware platform
ES - XX Internet monitoring of installation

based on CRC hardware platform
Atlas Copco web services can be
used
The new ES Millennium series monitoring •Web services will be fee related based on
level of services contracted with local
•Based on the CRC hardware platform from Oil Free customer centers
•Can be combined with sequencing, each is upgradable
to the next series with software


• RS - 232 - C
An EIA standard that specifies electrical , mechanical and functional characteristics for serial binary communication circuits in a point - to - point link.
• RS - 485
An EIA standard that specifies electrical characteristics of balanced -voltage digital interface circuits in a multi-point link
• SCADA
Supervisory Control And Data Acquisition
• RTD
Resistance Temperature Detector. A resistor for which the electrical resistivity is a known function of the temperature

•POWER FACTOR
A measurement of the time phase difference between the voltage and current in an
ac circuit. It is represented by the cosine of the angle of this phase difference.
Power factor is the ratio of real power [ in watts ] to apparent power
[ in volt-amperes ]

&
INSTRUMENTATION &
ELECTRONICS
Time to have coffee ...

Compressor Basics

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Compressor Basics

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Compressor Basics - Electric

21st MAY , 2003 AIF-TRAINING 2

21st MAY , 2003 AIF-TRAINING 3

21st MAY , 2003 AIF-TRAINING 4

Something - SIMPLE for

TAKE CARE !!!

21st MAY , 2003 AIF-TRAINING 6

21st MAY , 2003 AIF-TRAINING 7

Safety : - A.C. Voltage <= 24 V is Safe for personnel

21st MAY , 2003 AIF-TRAINING 8

21st MAY , 2003 AIF-TRAINING 9

UL=Line voltage = UL1-UL2

Relation between Reactance (X) - Resistance (R) -

21st MAY , 2003 AIF-TRAINING 11

21st MAY , 2003 AIF-TRAINING 13

Current : Measures current flow in a circuit Unit = Ampere

Measurement in A (of mA) between A and Com

21st MAY , 2003 AIF-TRAINING 14

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Total Moment of Inertia = motor +coupling +compressor

21st MAY , 2003 AIF-TRAINING 20

Tstart Tmin Tmax

21st MAY , 2003 AIF-TRAINING 21

Torque curve (Y)

Speed : +/- 90-95 %

21st MAY , 2003 AIF-TRAINING 22

21st MAY , 2003 AIF-TRAINING 23

ROTOR SQU. CAGE KL 13 EN 60034 IEC 34-1 W eight : 1,3 t

21st MAY , 2003 AIF-TRAINING 24

• States how an electrical device is protected

21st MAY , 2003 AIF-TRAINING 25

Most frequently used are IP23, 44 and 54

ROTOR SQU. CAGE KL 13 EN 60034 IEC 34-1 W eight : 1,3 t

21st MAY , 2003 AIF-TRAINING 27

21st MAY , 2003 AIF-TRAINING 28

21st MAY , 2003 AIF-TRAINING 29

ROTOR SQU. CAGE KL 13 EN 60034 IEC 34-1 W e ight : 1,3 t

21st MAY , 2003 AIF-TRAINING 30

• When used on a motor name plate , a number that

•That is a motor with 1.15 S.F. can produce 15% more

21st MAY , 2003 AIF-TRAINING 31

Example : - Motor rated power : 100 KW

21st MAY , 2003 AIF-TRAINING 32

• Competitors even use higher service factors

ATLAS COPCO POLICY

• Only use service factor within the safe limits

• the thermal margin ( see table of insulation class)

21st MAY , 2003 AIF-TRAINING 33

21st MAY , 2003 AIF-TRAINING 34

Criteria for Atlas Copco motor selection :

Motors are selected to work in the worst

Motor power is influenced by :

• Spreading of the compressor element performance

Atlas Copco is testing very thoroughly by :

21st MAY , 2003 AIF-TRAINING 37

21st MAY , 2003 AIF-TRAINING 38

21st MAY , 2003 AIF-TRAINING 39

Possible protection based on the line current :

21st MAY , 2003 AIF-TRAINING 40

Above mentioned protections do not respond to :

21st MAY , 2003 AIF-TRAINING 41