Instruction Book ES4i

Atlas CopcoControl solutions

ES 4i

Instruction book

Atlas CopcoControl solutions

ES 4i

Instruction book

Copyright noticeAny 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.

This instruction book meets the requirements for instructions specified by the machinerydirective 98/37/EC and is valid for CE as well as non-CE labelled machines.

2010 - 07

No. 2920 7048 01Replaces No. 2920 7048 00

www.atlascopco.com

Table of contents

1 Safety precautions..........................................................................................................4

1.1 SAFETY ICONS...................................................................................................................................4

1.2 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................4

1.3 SAFETY PRECAUTIONS DURING OPERATION..............................................................................................5

1.4 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................6

2 General description........................................................................................................8

2.1 INTRODUCTION...................................................................................................................................8

2.2 LOCAL AREA NETWORK (LAN)............................................................................................................9

3 Installation instructions...............................................................................................10

3.1 CONNECTING MACHINES EQUIPPED WITH A MKIV CONTROLLER.................................................................10

3.2 CONNECTING ATLAS COPCO MACHINES WITH AN ELEKTRONIKON MKI OR MKII REGULATOR...........................12

3.3 CONNECTING OF ATLAS COPCO MACHINES WITH AN ELEKTRONIKON MKIII REGULATOR.................................12

3.4 CONNECTING ELECTRO-PNEUMATICALLY CONTROLLED MACHINES AND MACHINES OF OTHER BRANDS.................14

4 Set-up of the parameters.............................................................................................15

4.1 INTRODUCTORY REMARKS..................................................................................................................15

4.2 COMMISSIONING VIA THE DISPLAY........................................................................................................15

4.3 COMMISSIONING VIA FSP..................................................................................................................17

5 Operation.......................................................................................................................20

5.1 REMARKS.......................................................................................................................................20

5.2 BEFORE STARTING............................................................................................................................20

5.3 STARTING.......................................................................................................................................21

5.4 DURING OPERATION..........................................................................................................................22

5.5 ISOLATION AND RE-INTEGRATION OF A COMPRESSOR...............................................................................23

5.6 STOPPING.......................................................................................................................................23

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair,even if not expressly stated, will be disclaimed by the manufacturer.

General precautions

1. The operator must employ safe working practices and observe all related local work safety requirementsand regulations.

2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply.3. Installation, operation, maintenance and repair work must only be performed by authorised, trained,

specialised personnel.4. Before carrying out any maintenance, repair work, adjustment or any other non-routine checks, stop the

device. In addition, the power isolating switch must be opened and locked.

Precautions during installation

1. Place the device where the ambient air is as cool and clean as possible.2. During installation or any other intervention on one of the connected machines, the machine must be

stopped, de-energized and the isolating switch opened and locked before any maintenance or repair. As afurther safeguard, persons switching on remotely controlled machines shall take adequate precautions toensure that there is no one checking or working on the machine. To this end, a suitable notice shall beaffixed to the start equipment.

3. The electrical connections must correspond to the local codes. The device must be earthed and protectedagainst short circuits by fuses in all phases. A lockable power isolating switch must be installed near thedevice.

4. For machines controlled by a central control system, a sign stating "This machine may start withoutwarning" must be affixed near the instrument panel.

5. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-returnvalves (check valves) must not be relied upon for isolating pressure systems.

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6. Never remove or tamper with the safety devices.

Also consult following safety precautions: Safety precautions during operation and Safetyprecautions during maintenance or repair.These precautions apply to electrical devices.For precautions applying to the connected equipment consult the relevant instruction book.Some precautions are general and cover several machine types and equipment; hence somestatements may not apply to your device.

1.3 Safety precautions during operation


General precautions





Precautions during operation

1. Persons switching on remotely controlled machines shall take adequate precautions to ensure that thereis no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remotestart equipment.

2. Never operate the device in the presence of flammable or toxic fumes, vapours or particles.3. Never operate the machine below or in excess of its limit ratings.4. Keep all bodywork doors and panels closed during operation. The doors may be opened for short periods

only, e.g. to carry out routine checks. Wear ear protectors when opening a door if applicable.5. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)

shall wear ear protectors.6. Periodically check that:

• All guards and fasteners are in place and tight• All hoses and/or pipes are in good condition, secure and not rubbing• There are no leaks• All electrical leads are secure and in good order

7. Never remove or tamper with the safety devices.

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Also consult following safety precautions: Safety precautions during installation and Safetyprecautions during maintenance or repair.These precautions apply to electrical devices.For precautions applying to the connected equipment consult the relevant instruction book.Some precautions are general and cover several machine types and equipment; hence somestatements may not apply to your machine.

1.4 Safety precautions during maintenance or repair


General precautions





Precautions during maintenance or repair

1. Use only the correct tools for maintenance and repair work.2. Use only genuine spare parts.3. A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting

equipment, including all remote start equipment.4. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there

is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remotestart equipment.

5. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions againsttoxic vapours of cleaning liquids.

6. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the partsand exposed openings with a clean cloth, paper or tape.

7. Never use a light source with open flame for inspecting the interior of the device.8. All regulating and safety devices shall be maintained with due care to ensure that they function properly.

They may not be put out of action.9. Before clearing the device for use after maintenance or repair, check that operating pressures, temperatures

and time settings are correct. Check that all control and shut-down devices are fitted and that they functioncorrectly.

10. Never use caustic solvents which can damage materials of the air net.

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Also consult following safety precautions: Safety precautions during installation and Safetyprecautions during operation.These precautions apply to electrical devices.For precautions applying to the connected equipment consult the relevant instruction book.Some precautions are general and cover several machine types and equipment; hence somestatements may not apply to your machine.

Units and/or used parts should be disposed of in an environmentally friendly and safe manner and inline with the local recommendations and legislation.

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2 General description

2.1 Introduction

ES 4i

Elektronikon II and Elektronikon III regulators of the fourth generation (MkIV) can be used to control up to4 compressors in order to regulate the air net pressure within programmable limits by automatically starting,loading, unloading and stopping the connected compressors.

This so-called ES 4i functionality (also referred to as MCC, abbreviation of Multi Compressor Control) is anintegrated feature of the mentioned regulator types. A dongle (part number 8092 2482 62) is required toactivate this extra feature. On the regulator display this function is shown as MCC (Multiple CompressorControl).

Elektronikon II - MkIV (B controller)

Elektronikon III - MkIV (D controller)

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Dongle

2.2 Local Area Network (LAN)

The compressors to be controlled must be connected with each other in a Local Area Network (LAN) usingCAN (Controller Area Network) technology.

Elektronikon I, Elekronikon II and Elektronikon III regulators (Mk IV) can be directly connected to the localarea network (LAN).

The regulator with the integrated ES 4i (MCC) function and the dongle serves as master regulator for thecompressors. The dongle must be connected with the regulator of this compressor, using the free I/O-connection. The regulators of the other compressors act as slave regulators. Elektronikon I regulators can onlyserve as slave.

Apart from load/unload controlled compressors, also one VSD (Variable Speed Driven) compressor can beintegrated in the MCC network.

Besides Elektronikon Mk IV regulators, also Mk I, Mk II, Mk III and relay-regulated compressors can beconnected to the network by means of a conversion box and/or a communication module between regulatorand network (see the next chapters for details).

Select the compressor regulator which will serve as the master regulator for all compressors in the LAN andlabel this compressor as Master Compressor 1.

Select the compressor regulator(s) which will serve as slave regulator(s). Label this (these) compressor(s) asCompressor 2, 3 and 4 respectively.

More information about how to set-up a compressor network can be found in document 9820 3582 00.

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3 Installation instructions

3.1 Connecting machines equipped with a MkIV controller

Always stop each compressor and switch off the voltage before making any connection!Remember that Elektronikon I regulators can only act as slave, because they do not have theES 4i feature.In case expansion modules are provided, the dongle must be plugged in into the I/O connectorof the last expansion module.

Except for the first version of the Elektronikon I (part numbers: see below), all electronic control modules ofthe fourth generation (MkIV), i. e. Elektronikon II or Elektronikon III can directly be connected with eachother using the LAN port as shown in below figure:

LAN set-up in case of MkIV regulators

Reference Description Reference Description(1) Compressor 1

Master(4) Compressor 4

Slave(2) Compressor 2

Slave(5) dongle

(3) Compressor 3Slave

In case an Elektronikon I regulator of the first version has to be connected to a LAN, the most practical solutionis to replace it by a more recent version (Elektronikon I Plus - part numbers: see below), because hardwiringbetween this version of the Elektronikon I regulator and a master regulator is not possible.

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Controller with limitedCAN connectionpossibilities

Part number Used on Replacement controller Part number

Elektronikon I 1900 0711 01 GA5-90C Elektronikon I Plus 1900 0712 71Elektronikon I 1900 0711 02 GA5-90C Elektronikon I Plus 1900 0712 71Elektronikon I 1900 0711 03 GA5-90C Elektronikon I Plus 1900 0712 71Elektronikon I 1900 0711 06 GA5-90C Elektronikon I Plus 1900 0712 71

Elektronikon I regulator - MkIV (A controller)

Elektronikon II regulator - MkIV (B controller)

Elektronikon III regulator - MkIV (D controller)

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3.2 Connecting Atlas Copco machines with an Elektronikon MkI orMkII regulator

There are two ways to connect an Atlas Copco machine fitted with either Elektronikon® MkI or MkII to themaster regulator with the built-in ES 4i feature:

• Connect a ComBox S (part number 8092 2482 54) to the Elektronikon module and connect the ComBoxS to the LAN.

• Use a CANBox interface (part number 1900 0712 61) to connect with the Elektronikon® and connect theCANBox Interface with the LAN.

Connecting Elektronikon MkI or MkII to a LAN

Reference Description Reference Description(1) LAN (4) Elektronikon® MkI or MkII(2) CANBox interface (5) COMBox S(3) hardwired connection

3.3 Connecting of Atlas Copco machines with an ElektronikonMkIII regulator

This generation of the Elektronikon® regulator came in two variants: a Low Range and a High Range version.One of the key differences between these two regulators are the communication possibilities. The detailsbelow explain the possibilities for each variant.

• Elektronikon® MkIII Low Range regulator (part number 1900 0700 0x):There are two connection possibilities for this regulator:

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• Via a CANBox interface (part number 1900 0712 61), which in turn is connected to the LAN tocommunicate with the ES 4i master regulator (see the figure below)

• hardwired directly to the ES 4i master regulatorIn both cases some simple changes are required inside the electrical cubicle. More specifically, two relaysmust be added, one for the signal running status and the other for the signal load/unload status.

• Elektronikon® MkIII High Range regulator (part number 1900 0701 0x).Here also are two possibilities:• The regulator includes an extra module known as COM 1

• The easiest way to connect the machine to the ES 4i master is to add a ComBox S interface (partnumber 8092 2482 54) which converts all communications to the LAN.

• Alternatively the compressor can be hardwired directly to the ES 4i.• If the machine does not include a COM 1 module there are two possibilities:

• Use both a COM 1 (part number 8104 0115 00) and a ComBox S (part number 8092 2482 54)• Use a CANBox interface (part number 1900 0712 61).

Connecting MkIII regulators to a LAN

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Reference Description Reference Description(1) LAN (5) Elektronikon MkIII - Low Range

regulator(2) CANBox interface (6) Elektronikon MkIII - High Range

regulator without COM1(3) ComBox S (7) RS232 connection(4) hardwired connection (8) Elektronikon MkIII - High Range

regulator with COM1

3.4 Connecting electro-pneumatically controlled machines andmachines of other brands

The only way to connect this type of machines to the regulator with the activated ES 4i function is to use aCANBox interface (part number 1900 0712 61) , which in turn is connected to the LAN network viahardwiring.

Connecting electro-pneumatically controlled machines to the LAN

Reference Description Reference Description(1) LAN network (3) hardwired connection(2) CANBox interface (4) Elektro-pneumatically controlled

machine or non- Atlas Copco machine

The connections between the CANBox interface(s) and the master regulator are made using the LAN ports,in exactly the same way as MkIV regulators are connected (see Connecting machines equipped with a MkIVcontroller).

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4 Set-up of the parameters

4.1 Introductory remarks

There are two ways to modify the ES 4i (MCC) parameters in the regulators:

• via the display• via FSP (Field Service Program) software. This is specific software, available to the Atlas Copco

Aftermarket Department. Contact your Atlas Copco Customer Centre for details.

However, some modifications are only possible via the display, while some other modifications are onlypossible via FSP. Consult the survey at the end of this chapter.

Always stop the compressor before making changes to the settings.

4.2 Commissioning via the display

Activating the ES 4i (MCC) function in the master regulator

• From the main screen, press and hold the arrow up key (1) for 3 seconds. The following screen is displayed:

‘C.C.M.’ ‘Remote Control’ ‘Service’ ‘Main’ ‘Mod’ F1 F2 F3

• Next, press the arrow down key (1) until the option ‘M.C.C.’ is shown. By default, the text ‘Not Activated’is blinking.

• Press the F2 key (‘Mod’) to modify . Use the arrow up or down key (1) to change the setting.• With ‘Activated’ blinking, Press F1 (‘Prog’) to save the modification.• Use the F1 key to go back to the min menu

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Selection of the number of compressors in the LAN

• From the main screen, press F1 (‘Menu’)• In the next screen, use the arrow keys (1) to scroll until the option ‘Modify Params’ is shown• Use the tab key (2) to select ‘Modify Params’• Use the arrow keys (1) until option ‘Parameters MCC’ is shown and press the tab key (2) to select.• Press F2 (‘Mod’) to modify. On the screen, number 1 is blinking• Use the arrow keys (1) to change the number of compressors in the LAN• Press key F1 (‘Prog’) to save the selected value:

‘Number Of Compr’ 1

‘Prog’ ‘Lim’ ‘Canc’ F1 F2 F3

• Use the F1 key to go back to the main menu

Programming the node ID number and activation of the LAN for master and slave regulators

Repeat following steps for each slave regulator:

• Switch on the voltage• From the main menu, press the F1 key (‘Menu’)• Use the arrow down keys (1) until the option ‘ Modify params’, followed by a horizontal arrow is shown.

Press the tabulator key (2) to activate this menu.• Press the arrow down key (1) until option ‘Configuration’ is followed by a horizontal arrow on the screen.

Press the tabulator key to activate this menu and scroll down to the option ‘C.C.M.’. The next screenappears:

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‘C.C.M.’ ‘LAN control’

‘Menu’ ‘Mod’ ‘Canc’ F1 F2 F3

Press key F2 (‘Mod’) to modify and use the arrow keys (1) to select ‘LAN control’. To be recognizablein the LAN, each slave regulator must have a unique compressor node address.

• In the configuration menu of each slave regulator, scroll to the option ‘Node ID’. Press key F2 (‘Mod’)and use the arrow up/down keys (1) to select the number. Press the corresponding function key (‘Prog’)to confirm the modification.

It is recommended to set the master regulator as number 1 in the configuration. Each slave regulator needs tobe programmed separately by repeating the above describes actions. Select node ID 2 for compressor 2, nodeID 3 for compressor 3 and node ID 4 for compressor 4.

4.3 Commissioning via FSP

Programming the MCC parameters in the master regulator via FSP

With the Mk IV FSP software , it is possible to change the MCC Master and activate the MCC function.Always use the latest version of the software!

The path to this receipt is: Standard settings\MCC status

Double-click on the receipt MCC Status to open the dialog window:

Next, change the status. There is a choice between following options:

• ‘None’• ‘Exists but non active’• ‘Exists and is active’

Select ‘Exists and is active’, save and close the dialog window to change the settings.

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Survey of parameters that can be changed

Parameter Function minvalue

exfactorysetting

maxvalue

unit Note

Number OfCompr

to program the number of compressorsconnected to the LAN

1 1 4 - (1)

System Stop to allow the master regulator to stop allconnected compressors or not

- enabled - - (4)

SystemForced

to allow the master regulator to forceanother sequencing by starting a newcompressor at the interval programmed inparameter forced time

- enabled - - (4)

Pres BandSel

to select between two different systempressure bands (pressure band 1 and 2)

- activated

- -

running hours1

to enter running hours for compressor 1 toinfluence the MCC control algorithm

0 0 65535 hrs

running hours2


0 0 65535 hrs

running hours3


0 0 65535 hrs

running hours4


0 0 65535 hrs

Min presband 1

to program the minimum setting forpressure band 1

4.0 7.0 bar(e) (3)

Max presband 1

to program the maximum setting forpressure band 1

(3) 8.0 (3) bar(e)

Min presband 2

to program the minimum setting forpressure band 2

4.0 (3) 7.0 (3) bar(e)

Max presband 2

to program the maximum setting forpressure band 2

(3) 8.0 (3) bar(e)

C1 starts/day to program the number of starts per day forcompressor 1 (Node 1)

3 240 720 -


3 240 720 -


3 240 720 -


3 240 720 -

Forced time to program the interval at which, if activatedby parameter system forced, the masterstarts a new compressor in case nosequence change has occured during theinterval

1(2) 7 (4) 60(2) days (2)

Rem to loc T to program the time interval betweenremote to local commands from the masterregulator to the slave regulators

5(2) 20(4) 600 (2) s

Starts react T to program the time interval between whichthe start commands from the master shouldresult in loaded running of compressors

10 15 60 s

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Parameter Function minvalue

exfactorysetting

maxvalue

unit Note

Start time to program the time interval between thedifferent start and load commands frommaster regulator to slave regulators

5 20 600 s

Delta time to program the difference in running hoursto allow the master to decide starting /loading another compressor

10(2) 168 (4) 672 (2) hrs

Stop react T to program the time interval between whichthe stop command from the master shouldresult in stopping the compressor

5 (2) 35 (4) 120 (2) s

Unload time to program the time interval betweendifferent unload commands from themaster to the slave regulators

2 (2) 5 (4) 60 (2) s

Notes:

(1): can only be modified via the display of the regulator

(2): can only be modified via FSP software

(3): can only be modified via FSP (full access required)

(4): can be modified via the display and via FSP

To change the settings in FSP, use the following path:

Standard settings \ MCC Settings:

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5 Operation

5.1 Remarks

Local start/stop function

All local start and stop functions on the control panels of the compressors are disabled, except for theemergency stop buttons which remain active.

Clock functions

In case time-based automatic start/stop commands were programmed in the regulators of the participatingcompressors (via menu Clock function), these commands will not be taken into account.

Variable Speed Driven Compressors

In case a VSD compressor is participating, it will start first and the set point and stop levels will change asfollows:

• The set point will be in the middle of the net pressure band.• The Indirect stop level will equal the maximum level of the net pressure band.• The Direct stop level will equal the sum of the new Set point and the programmed direct stop level of the

VSD compressor; the direct stop level must be higher than the Indirect stop level.

Example:

Pressure band levels programmed in the master regulator: max. 8.0 bar(e) - min. 7.0 bar(e) and Direct stoplevel programmed in the regulator of the variable speed compressor: 1 bar

In LAN configuration, the VSD compressor will have a Set point of 7.5 bar(e), an Indirect stop level of 8.0bar(e) and a Direct stop level of 8.5 bar(e).

5.2 Before starting

Type III controller

When switching on the voltage (or if no key is pressed during 4 minutes), the Main screen will be shown onthe master regulator. Press the F2 button to show the MCC screen, of which an example is shown here:

The screen in above example shows:

• The master (compressor 1) runs load

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• Compressor 2 is stopped• Compressor 3 shows no communication between the master regulator and the related slave regulator• Compressor 4: the related compressor is shut down• The maximum pressure is 8.0 bar• The minimum pressure is 7.0 bar

The related compressor runs load

The related compressor runs unload

The related compressor is stoppedThe related compressor is shut down

!!

The related compressor is not reacting on a command from the master regulator

??

No communication between master regulator and the related slave regulator

XX

The related compressor is not recognized

If one of the compressors is a VSD compressor, a speed bar indicator will be shown.

If one of the compressors is not reacting on a command from the master regulator, ‘Rset’ will be shown inthe main screen:

‘Rset’ (reset) can be used to reset the communication between master and slave regulators, e.g. after integratinga compressor. See Isolation and re-integration of a compressor.

5.3 Starting

After pressing the start button, the master regulator with the activated ES 4i (MCC) functionality will start,load, unload and stop the compressors in the network as needed to keep the net pressure between theprogrammed pressure bands, while taking into account the programmed parameters.

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5.4 During operation

Type III controller

If the master regulator is a type III controller, the MCC main screen will be similar to the one below:

The screen in above example shows:

• Compressor 1 (master regulator) runs loaded• Compressor 2 is stopped• Compressor 3: no communication between regulator and related slave• Compressor 4: the related compressor is not reacting• The maximum pressure is 8.0 bar• The minimum pressure is 7.0 bar

After pressing the arrow down button the following screen will be shown:

This screen shows:

• The net pressure is 8.0 bar• The master regulator is regulating the compressors connected to the LAN

The Stop key (F2) can be used to stop all compressors

The Loc key (F3) can be used to switch the compressors back to local control

Use the arrow up button to go back to the previous screen.

After pressing the Main key in the MCC main screen the screen below will be shown:

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The compressor main screen shows:

• The compressor outlet pressure is 7.5 bar• The compressor is running loaded and is connected to a LAN• The Menu key (F1) can be used to scroll through the menus of the master compressor, e.g. to call up data

of the compressor• The MCC key (F2) can be used to return to the MCC main screen

5.5 Isolation and re-integration of a compressor

Isolation of a compressor

It is possible to isolate a compressor from the regulation by the master regulator.

1. On the regulator of the compressor to be isolated, press the key Menu and scroll to menu Configuration.2. Scroll to option CCM (compressor control mode), press the key Mod and use the arrow up or arrow down

keys to select Local; press the ‘Prog’ key to program it. The compressor will be isolated; the correspondingcompressor number will blink on the control panel of the master regulator.

Re-integration of a compressor

To re-integrate an isolated compressor:

1. On the regulator of the compressor to be re-integrated, press the key ‘Menu’ and scroll to menuConfiguration.

2. Scroll to option CCM (Compressor Control Mode), press key F2 and use the arrow up or arrow down keysto select LAN. Press the Prog key (F1) to program it.

3. Press the key ‘Rset’ on the MCC screen of the master regulator. The master regulator will take over thepressure regulation of the integrated compressor.

5.6 Stopping

Type III controller

If the master regulator is a type III controller, press Function key F2 (‘Stop’) in following screen to stop allcompressors connected to the LAN:

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See During operation for more details.

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Documents

Instruction Book ES4i