Atlas Copco Elektronikon User Manual
Contents
1. Hour meters e total running hours e total loaded hours e service timer Service requirements indications e service timer alr filter oil filter alr oll separator element oil lifetime Compressor warning indications e high compressor element outlet temperature e high dewpoint temperature e service timer Digital input commands e start stop e emergency stop Main screen display e operating status e delivery air pressure Pressure numerical read out e delivery air Compressor controls e start stop load unload e emergency stop e reset e transition between local remote compressor control Compressor shutdown indications e high compressor element outlet temperature e drive fan motor overload e emergency stop Digital output compressor status e general shutdown Elektronikon a control regulation and monitoring system for GA11 90C WorkPlace and GA VSD compressors CONTROL AND Compressor status indications e voltage on e automatic operation e compressor loaded e compressor unloaded e maximum allowed unload pressure Hour meters e total running hours e total loaded hours e regulator hours Timer e programmable start stop timer e programmable time based switch over between pressure sets Temperature numerical read out e compressor element outlet e dewpoint e energy recovery water e cooling water in e cooling water out SERVICE AND Service requirements indicat2. Management System forms an integral part of each business process Never use compressed air as breathing air without prior purification in accordance with local legislation and standards Atlas Copco The face of Innovation What sets Atlas Copco apart as a company is our con viction 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 flexibil ity to adapt to the diverse demands of the people we cater for It s 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 customer s 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 www atlascopco com 2935 0835 44 Printed in Belgium Subject to alteration without prior notice
3. Atlas Copco Elektronikon system state of the art electronic monitoring and control capability THE BENEFITS OF ADVANCED TECHNOLOGY cn ita Efficient compressor operation In order to derive full benefit from your compressed air system you need to be assured that your compressor is inherently dependable The comprehensive line of Atlas Copco compressors truly matches all your needs These compressors represent the state of the art in reliability featuring Atlas Copco s patented Elektronikon system an advanced electronic monitoring and control capability Elektronikan Simple One technology for all your Atlas Copco equipment to e control e monitor e protect Comprehensive Many years of compressor regulation experience culmi nated in the ultimate regulator platform e one hardware platform for Atlas Copco compressors and many dryer types optimized for compressed air equipment monitoring and control e robust hardware for demanding compressor conditions e LAN port is standard for easy networking of compressor room equipment no interface required Expandable The Atlas Copco Elektronikon system can easily be expanded with extra sensors digital inputs or Fieldbus communication tailored to your specific application e analogue input modules e digital input output module e internet communication e fieldbus communication not on Elektronikon Turning technology into profit Besides easy to
4. applying one of our protocol conversion modules Through a single fieldbus cable all data observable on the Elektronikon can instantly be added to your plant s DCS Distributed Control System We support the standard commercial protocols Modbus Profibus and Ethernet Only one protocol conversion module called ComBox is required per installation Peace of mind through professional care Participate in one of Atlas Copco s varied Service agree ments and you can be assured of an efficiently operating compressed air system 24 7 The truly unique AIRmonitor system allows our service organisation to supervise your com pressed air system warn you and take preventive action to avoid costly process downtime Pre emptive attention through using the AIRmonitor system will increase the overall efficiency of your compressed air system expand the expected lifetime of the Atlas Copco equipment and most importantly save you money You can tailor specific plans to address your plant s needs from simple monitoring and preventive mainte nance to complete responsibility over your entire com pressed air system by highly trained Atlas Copco service engineers Contact your local Atlas Copco representative today to learn more about how we can serve you better ISO 9001 From design to production and delivery of compressors Atlas Copco adheres to the ISO 9001 management system ISO 14001 Atlas Copco s Environmental
5. drastically reduced Typical overall pressure band 1 5 bar Average pressure Min system pressure The Elektronikon MCC offers a significant opportu nity to reduce the overall system pressure band in comparison with traditional cascaded compressor control Every 1 bar reduction of the average system pressure stands for 7 energy savings Losses of compressed air due to system leakage are reduced with 13 These two factors can account for overall energy savings of 10 over the lifetime of your compressors The Elektronikon MCC stabilises the air supply through coordinating the control of individual compressor regulators By lowering the overall system pressure band and offering the sophistication of electronic decision making the MCC offers an inherently more stable and coordinated control algorithm for multiple compressor installations The Elektronikon MCC also allows optimised maintenance scheduling in a multiple compressor installation The MCC ensures that the installed compressors wear evenly so that necessary mainte nance can easily be planned and executed in this way preventing costly downtime of your process Regular service at correct intervals will actually save you money over the lifetime of the compressor installation simple flexible and comprehensive networking Plant management system integration The Elektronikon regulator integrates easily into your existing plant management system by
6. e automatic operation e compressor loaded e compressor unloaded e maximum allowed unload pressure Hour meters e total running hours e total loaded hours e regulator hours Timer e programmable start stop timer e programmable time based switch over between pressure sets Main screen display e operating status e delivery air pressure e IGV open BOV closed e drive motor rpm e accumulated volume Temperature numerical read out e delivery air e element out e HP elementin oj 7 e cooling water e cooling medium Service requirements indications e service plan notification air filter oil filter oil demister oil lifetime regreasing of drive motor e air oil separator element e sensor error Compressor warning indications e high compressor element outlet temperature e high dewpoint temperature e high air oil separator DP e service plan timer e high cooling water temperature e vibration cooler Digital input commands e start stop e emergency stop eload unload e pressure set selection e dew point e regeneration wet air in IMD Pressure numerical read out e delivery air e oil separator DP e air filter DP e oil filter DP e inter cooler oil e DP shroud DP element e Element 2 3 out Compressor controls e start stop e load unload e emergency stop e reset e transition between local remote compressor control e transition between press
7. hutdown due to a protection setting Notifies an operator that service is required or needs to be planned Pe emptive actions can be taken to prevent breakdown Easy troubleshooting and rectification of faults Increases the operating efficiency of the compressor Insuring maintenance Is done properly Remote control standard Digital remote control Centralised compressor control Relay monitoring standard Digital remote monitoring Remote indication of status Automatic restart Programmable restart after voltage failure Maximum availability of your compressor No loss of compressed air MCC optional Multiple Compressor Control Function can be configured in one com pressor in an installation Allows one regulator to act as a master controller to sequence compressors In an installation Remote monitoring optional Modbus and Profibus are among the stand ard communication protocols supported for the Elektronikon Remote monitoring using your plant s DCS allows you to incorporate the compressor into your plant management system Elektronikon Eleeittontlkea a control regulation and monitoring system for GA Pack and GA5 11C compressors Compressor status indications e voltage on e automatic operation e compressor loaded unloaded e maximum allowed unload pressure compressor Temperature read out e compressor element outlet e dewpoint
8. ions e service plan notification air filter oil filter air oil separator element oil lifetime regreasing of drive motor e air oil separator element e sensor error Compressor warning indications e high compressor element outlet temperature e high dewpoint temperature REMOTE CONTROL Digital input commands e start stop e emergency stop eload unload e pressure set selection full feature units full feature units only optional water cooled units 6 air cooled units Elektronikon lll Elektrontkor i a control regulation and monitoring system for Z GA gt 90C GR and ZH compressors MONITORING FUNCTIONS Main screen display e operating status e delivery alr pressure e drive motor rpm Pressure numerical read out e delivery air e oil separator DP Compressor controls e start stop eload unload e emergency stop e reset e transition between local remote compressor control e transition between pressure sets e multiple compressor control 2 STATUS INDICATIONS e high air oil separator DP e service plan timer e high cooling water outlet temperature Compressor shutdown indications e high compressor element outlet temperature e drive motor overload e fan motor overload e emergency stop AND MONITORING Digital output compressor status e automatic operation e general shutdown e general warning Compressor status indications e voltage on
9. ure sets e multiple compressor control e auto dual CPC control Vibration numerical read out e vibration 1 2 3 Current numerical read out e motor current e high elementinlettemperature e high oil temperature e low oil pressure e high inlet filter DP Compressor shutdown indications e high compressor element outlet temperature e vibration e high elment inlet temperature e high oil temperature e low oil pressure e drive motor overload e fan motor overload e emergency stop Digital output compressor status e automatic operation e general shutdown e general warning load unload VSD compressors GA gt 55 and VSD Z compressors only only for VSD only for GA GR air cooled units water cooled units 9 full feature units not on Z lt 55 kW option 9 ZH compressors only not on ZH compressors 1 not on ZE ZA compressors Multiple Compressor Control built in Each Elektronikon has the unique MCC Multiple Compressor Control built in MCC efficiently coordinates individual regulators in a multiple compressor installation in this way reducing the overall system operating pressure increasing system pressure stability and optimising maintenance scheduling All this results in considerable savings on the operation of your compressed air plant Traditional cascade control MCC Net pressure With MCC overall system pressure can be
10. use start stop buttons activating optimal procedures to start or stop your compressor the Elektronikon offers many additional features with a few keystrokes CHARACTERISTIC Pressure regulation FEATURES Fast easy and accurate programming of the required pressure band BENEFITS Narrow pressure band for optimum energy use Programming start stop of the compressor or pressure bands Start and stop of the compressor can be programmed for various times during the week No unplanned running periods easy switch of bands Delayed second stop Electronically controlled load no load stop regulation Saves energy Reduces compressor run time to an absolute minimum Electronic monitoring Sensors at all key locations on the compressor Provides optimized information on operat ing conditon Registration of running conditions Records the load and no load run time as well as the function of the compressor Complete information of the operating sta tus of the compressor Retrieving of data Monitoring of service intervals Stores all available data at emergency stop or shut down Efficient maintenance scheduling Fast detection of causes of faults to sim plify correction Pre warning Indication Shutdown indication Service warning Notifies an operator in advance of machine conditions deviating from specification Notifies an operator that the machine has been s
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