DATAKOM DK40 Installation Manual
DATAKOM DK40 Installation Manual
DATAKOM DK40 Installation Manual
2011)
INTRODUCTION FEATURES
Pressure driven automatic start and stop
DK-40 is a state of the art unit for the control
of both screw and piston type compressors. Voltage Protection Relay function
Phase Order Protection Relay function
The unit integrates all functions needed in a
Mains phase voltages display
compressor system. Thus no extra units are
required in a compressor panel providing No need for external transformer
cost reduction and simplicity. Star / Delta startup
Load solenoid control
The unit is directly powered from 230/400 volt
mains. It provides power supply for fault 1 programmable relay output
switches and sensors. Thus external Optically isolated configurable digital inputs
transformer is not required in the panel. 2 pressure sensor inputs
The unit monitors mains phase voltages and 2 temperature sensor inputs
frequency. It features high/low voltage and Additional motor PTC input
phase order protections. Logic level serial port
The standard logic level serial port features MODBUS-RTU communication
MODBUS communication. The unit allows Password protected front panel programming
monitoring and programming through Low panel depth, easy installation
computer. Wide operating temperature range
Sealed front panel (IP54)
2 part connector system for easy installation
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SAFETY NOTICE
Failure to follow below instructions will
result in death or serious injury
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TABLE OF CONTENTS
Section
1. INSTALLATION
1.1. FRONT / REAR PANELS
1.2. MECHANICAL INSTALLATION
1.3. ELECTRICAL INSTALLATION
1.4. CONNECTION DIAGRAM
2. PUSHBUTTON FUNCTIONS
3. DISPLAY NAVIGATION
4. MODES OF OPERATION
5. ALARMS AND WARNINGS
6. OTHER FEATURES
6.1. RESETTING SERVICE COUNTERS
6.2. MODIFYING HOUR COUNTERS
6.3. SELECTION OF HOUR COUNTING METHOD
6.4. CONNECTION TOPOLOGIES
6.5. PREVENTING PRESSURE LOSS
6.6. ALARM HISTORY
7. INPUTS
8. RELAY OUTPUTS
9. PROGRAMMING
9.1. INTRODUCTION TO PROGRAMMING
9.2. PARAMETER LIST
10. MODBUS COMMUNICATIONS
10.1. DESCRIPTION
10.2. MODBUS REGISTER LIST
11. MULTIPLE CONTROLLER OPERATION
12. DECLARATION OF CONFORMITY
13. TECHNICAL SPECIFICATIONS
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1. INSTALLATION
Before installation:
• Read the user manual carefully, determine the correct connection diagram.
• Remove all connectors and mounting brackets from the unit, then pass the unit through
the mounting opening.
• Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure.
• Make electrical connections with plugs removed from sockets, then place plugs to their
sockets.
• Note that the power supply terminal is separated from measurement terminals.
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2. PUSHBUTTON FUNCTIONS
Programming and measurement displays are visualized using below buttons:
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3. DISPLAY NAVIGATION
Usually the upper display shows the pressure-1 value or the pressure switch-1 position.
The lower display shows the temperature-1.
Other values are scrolled by pressing the MENU button. For better clarity, the upper
display will show the parameter name and the lower display will show the parameter value.
Some parameters are longer than 1 display. For these parameters, when MENU button
is presssed the parameter name apeears on the upper display. When MENU button is
released, the parameter value is shown on both displays.
In the occurrence of a fault condition, the fault code will appear on the
upper display.
SHA
SHA Hours remaining to service A Display / Program / Alarm
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MESSA
DESCRIPTION MODE
GE
t-2
t-2 Temperature-2 value or switch position Display
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4. MODES OF OPERATION
Selecting the operating mode:
At power-up, the unit will turn all lights on for 3 seconds in order to allow lamp check. Then
it goes in the STOP mode and the stop led turns on.
The compressor may be run through Remote Start signal (upper display shows rUn for 5
seconds) or by pressing the RUN button.
If P28 Safety Timer has not elapsed, the run led will flash until expiration of the timer. Then
if the pressure is below the limit set by P05 Start Pressure, then the compressor will run.
The compressor may be stopped with Remote Stop signal (upper display shows StP for 5
seconds) or the STOP button.
Stop procedure:
STOP led starts flashing.
If the compressor is loaded, then the LOAD relay will release and the compressor
continues to run during P28 Safety Timer or P26 Unload Timer (whichever is longer).
At this step, operation may be resumed by pressing the RUN button. If STOP
button is pressed during unloaded operation, then the compressor stops immediately.
The stop led flashes until the compressor comes to complete stop.
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Start procedure:
If mains phase voltages and frequency are between preset limits and the phase order is
correct, then the POWER led will turn on. The compressor may run only when the power
led is on. Otherwise it cannot run.
The Run mode of operation is selected by pressing the RUN button or by sending
REMOTE START/STOP signal (if enabled). At this position, when the pressure falls below
P05 Start Pressure (or pressure switch closes) the unit decides to run the compressor.
Befor running the compressor the STAR relay output becomes active. After P15 Delay
between Relays Timer LINE relay will be activated. Thus the motor starts in star mode.
After P23 Star Timer the STAR relay opens and after P24 Star/Delta Transition Timer the
DELTA relay operates.
After P25 Timer before Loading the LOAD relay operates and the compressor starts
producing compressed air.
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Alarms and warnings may be reset by pressing the MENU button. The EMERGENCY
STOP alarm cannot be reset by pressing buttons, the alarm signal must be removed.
TIME REMAINING TO
REACTION
SERVICE
> 100 hours No warning given.
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6. OTHER FEATURES
- Hold MENU and RUN buttons pressed for 3 seconds. If the high level
password is not entered in the last 90 minutes, the unit will ask the password.
- Enter the password.
- In order to reset the hours remaining for SERVICE A, hold pressed MENU button
for 3 seconds.
- The upper display will show the next service counter which is SHB hours remaining for
SERVICE B message.
- Press again the MENU button. The hours remaining for SERVICE B will appear
flashing on the display.
- In order to reset the hours remaining for SERVICE B, hold pressed MENU button
for 3 seconds.
- By pressing the MENU button again, below counters can be scrolled and reset:
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MESSAGE DESCRIPTION
Total compressor hours (ON_LOAD+OFF_LOAD+STOP)
C-H This counter increments while the RUN led is on.
Total motor run hours
R-H (ON_LOAD+OFF_LOAD)
This counter increments while the motor runs.
Total load time (load contactor active)
L-H This counter increments while LOAD led is on.
- Hold pressed together MENU , RUN and STOP buttons for 3 seconds. If
the high level password is not entered in the last 90 minutes, the unit will ask password
(USR
USR).
USR
- Enter password.
- Press MENU button for 3 seconds, the display wil show SEt message and the
counter will be adjusted to the new value. If MENU button is pressed for short
duration, then the value will not be modified and the next hour counter will be displayed.
Same steps are repeated for further modification.
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The unit offers the possibility of incrementing hour counters with a variable coefficient,
depending on air end temperature.
The use of variable coefficient is selected with P89 Variable Hour counting coefficient. If
this parameter is 0, all service and hour counters will increment with a fixed coefficient of
1.00.
If Variable Hour Counting is activated:
Running on load:
below 90 °C, coefficient = 1.00
between 90 and 95 °C, coefficient = 1.50
between 95 and 100 °C, coefficient = 2.00
above 100 °C, coefficient = 3.00
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The unit supports various connection topologies. The topology is selected through
parameter P48.
Different topologies and terminal connections are as below:
P48 = 1
P48 = 3
P48 = 3
P48 = 2
The power supply and measuring terminals
of the unit are isolated. In order to enable
above topology, the unit must be specially
manufactured.
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If the pressure stays above the P05 Start Pressure, during P26 Unload Timer then
the unit will stop the motor. If the pressure falls below P05 Start Pressure then the motor
will run again.
Before the compressor is loaded, a timer equal to P23+P24+P25+P15x3 will be
elapsed.
During this period, depending on the air consumption, the pressure may fall below
P05 Start Pressure.
In most applications, it is required that the pressure never falls below the P05 Start
Pressure limit.
In order to prevent this unwanted situation, the unit offers 3 different operating
modes selected through program parameter P45. The unit calculates dynamically the
restart pressure (Pi)
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In order to visualize the latest alarm in the history press MENU button until
Ah1
Ah1 (alarm history 1) comes to the display.
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7. DİGİTAL INPUTS
The unit offers 4 user configurable digital inputs.
The characteristics of these inputs are configured through parameters P73 to P76.
The configuration record consists on 3 parts. The programmed value is the sum of these
3 parts.
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8. RELAY OUTPUTS
The unit provides 5 relay outputs. 4 of them have fixed function, while RL5 has
selectable function.
Relays with fixed function:
RL1 = LINE relay
RL2 = DELTA relay
RL3 = STAR relay
RL4 = LOAD relay
4 MOTOR RUNNING RL5 operates if the main motor runs, releases otherwise.
RL5 operates if the main motor is stopped, releases
5 MOTOR STOPPED
otherwise.
Released during timer P41
6 FLAŞÖR RÖLE
Active during timer P42 .
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9. PROGRAMMING
- The upper display will show USr . Enter the password using RUN and STOP
buttons and press MENU button. For fast increment/decrement, hold pressed RUN
and STOP buttons.
To exit programming menu:
- Display parameter value by pressing the MENU button. Adjust the parameter with
RUN and STOP buttons and return to parameter number selection by pressing the
MENU button.
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10.1. DESCRIPTION
The unit offers serial data communication port allowing it to be integrated in automation
systems.
The serial port works with logic levels. With special adapters, it can be converted to RS-232
or RS-485 standards.
The MODBUS properties of the unit are:
-Data transfer mode: RTU
-Serial data: 9600 bps, 8 bit data, no parity, 1 bit stop
-Supported functions:
-Function 3 (Read multiple registers, max 120 registers)
-Function 6 (Write single register)
-Function 10 (Write multiple registers, max 32 registers)
-The answer to an incoming message is sent with a minimum of 4.3ms delay after
message reception.
Each register consists of 2 bytes (16 bits). Larger data structure contain multiple registers.
Detailed description about the MODBUS protocol is found in the document “Modicon
Modbus Protocol Reference Guide”. ( http://www.modbus.org/specs.php)
Data Reading
The function 03 (read multiple registers) will be used for data reading. The MODBUS
master will send a query. The answer will be one of the below:
-A response containing the requested data
-An exceptional response indicating a read error.
The maximum number of registers read in one message is 120. If more registers are
requested, the unit will send only the first 120 registers.
The query message specifies the starting register and quantity of registers to be read. The
message structure is below:
Byte Description Value
0 Controller address 1 to 254
1 Function code 3
2 Starting address high See below the description of available
3 Starting address low registers
4 Number of registers high always 0
5 Number of registers low max 78h (120 decimal)
6 CRC low byte See below for the checksum calculation
7 CRC high byte
Here is the sequence to read 16 registers starting from address 20h (32 decimal):
01 03 00 20 00 10 45 CC (each byte is expressed as 2 hexadecimal characters)
The checksum value in the above message may be used for the verification of checksum
calculation algorithm.
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Data Writing
The function 06 (write single register) or function 10 (write multiple registers) is used for
data writing. A maximum of 32 registers can be written at a time.
The MODBUS master will send a query containing data to be written. The answer will be
one of the below:
-A normal response confirming successful write,
-An exceptional response indicating a write error.
Only some of the available registers are authorized to be written. An attempt to write a write
protected register will result to the exceptional response.
The query message specifies the register address and data. The message structure is
below:
Byte Description Value
0 Controller address 1 to 254
1 Function code 6
2 Register address high See below the description of available registers
3 Register address low
4 Data high byte
5 Data low byte
6 CRC low byte See below for the checksum calculation
7 CRC high byte
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Here is the sequence to write the value 0010h to the register 40h (64 decimal):
01 06 00 40 00 10 89 D2 (each byte is expressed as 2 hexadecimal characters)
The checksum value in the above message may be used for the verification of checksum
calculation algorithm
The normal response will be the same as the query:
Byte Description Value
0 Controller address 1 to 254
1 Function code 6
2 Register address high See below the description of available registers
3 Register address low
4 Data high byte
5 Data low byte
6 CRC low byte See below for the checksum calculation
7 CRC high byte
CRC calculation
Here is a procedure for generating a CRC:
1) Load a 16–bit register with FFFF hex (all 1’s). Call this the CRC register.
2) Exclusive OR the first 8–bit byte of the message (the function code byte) with the low–
order byte of the 16–bit CRC register, putting the result in the CRC register.
3) Shift the CRC register one bit to the right (toward the LSB), zero–filling the MSB. Extract
and examine the LSB. The LSB is the least significant bit of the CRC before the shift
operation.
4) If the LSB is 1: Exclusive OR the CRC register with the polynomial value A001 hex.
5) Repeat Steps 3 and 4 until 8 shifts have been performed. Thus, a complete 8–bit byte
will be processed.
6) Repeat Steps 2 through 5 for the next 8–bit byte of the message. Continue doing this
until all bytes have been processed.
7) The final contents of the CRC register is the CRC value.
8) Place the CRC into the message such that the low byte is transmitted first. The algorithm
should give the correct CRC for below messages:
01 03 00 20 00 10 45 CC
01 06 00 40 00 10 89 D2
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Error codes
Only 3 error codes are used:
01: illegal function code
02: illegal address
10: write protection (attempt to write a read_only register)
Data types
Each register consists of 16 bits (2 bytes)
If the data type is a byte, only the low byte will contain valid data. High byte is don’t care.
For data type longer than 16 bits, consecutive registers are used. The least significant
register comes first.
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CONTROLLER REGISTERS
ADDR. NAME DESCRIPTION LENG. R/W TYPE MUL.
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CONTROLLER REGISTERS
ADDR. NAME DESCRIPTION LENG. R/W TYPE MUL.
PROGRAM PARAMETERS
ADDR. NAME DESCRIPTION LENG. R/W TYPE MUL.
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PROGRAM PARAMETERS
ADDR. NAME DESCRIPTION LENG. R/W TYPE MUL.
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PROGRAM PARAMETERS
ADDR. NAME DESCRIPTION LENG. R/W TYPE MUL.
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SENSOR GRAPHS
40385
PRESS_SENSOR 32*16
- Pressure Sensor (mA - Bar) R-O unsigned word 1
GRAPH [32] BIT
40416
40417 TEMPERATURE
Temperature Sensor(Ohm - 32*16
- SENSOR GRAPH R-O signed word 1
°C) BIT
40448 [32]
40449 MOTOR PTC
Motor PTC Temperature 32*16
- SENSOR GRAPH R-O signed word 1
Sensor(Ohm - °C) BIT
40480 [32]
40481 TEMPERATURE 2
Temperature Sensor 2 32*16
- SENSOR GRAPH R-O signed word 1
(Ohm - °C) BIT
40512 [32]
40513 PRESSURE 2
Pressure Sensor 2 Graph 32*16
- SENSOR GRAPH R-O unsigned word 1
(mA - Bar) BIT
40544 [32]
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COMMANDS
40769 C01 Reserved register 16 BIT W-O unsigned word 1
Return to Factory (value =
40770 C02 16 BIT W-O unsigned word 1
0xAA55)
Reset Counter
40771 C03 16 BIT W-O unsigned word 1
(value = Counter(1-8)
LOCK KEY
40772 C04 16 BIT W-O unsigned word 1
(Value = KEY CODE)
40773
- Reserved - 16 BIT W-O unsigned word 1
40800
Time to service A
40801 Set service 1 16 BIT W-O unsigned word 1
(low 2 bytes)
Time to service A
40802 Set service 2 16 BIT W-O unsigned word 1
(high 2 bytes)
Time to service B
40803 Set service 3 16 BIT W-O unsigned word 1
(low 2 bytes)
Time to service B
40804 Set service 4 16 BIT W-O unsigned word 1
(high 2 bytes)
Time to service C
40805 Set service 5 16 BIT W-O unsigned word 1
(low 2 bytes)
Time to service C
40806 Set service 6 16 BIT W-O unsigned word 1
(high 2 bytes)
Time to service D
40807 Set service 7 16 BIT W-O unsigned word 1
(low 2 bytes)
Time to service D
40808 Set service 8 16 BIT W-O unsigned word 1
(high 2 bytes)
Time to service E
40809 Set service 9 16 BIT W-O unsigned word 1
(low 2 bytes)
Time to service E
40810 Set service 10 16 BIT W-O unsigned word 1
(high 2 bytes)
LOADED+UNLOADED+STOP
40811 Set service 11 16 BIT W-O unsigned word 1
time (low 2 bytes)
LOADED+UNLOADED+STOP
40812 Set service 12 16 BIT W-O unsigned word 1
time (high 2 bytes)
Engine run hours
40813 Set Service 13 16 BIT W-O unsigned word 1
(low 2 bytes)
Engine run hours
40814 Set Service 14 16 BIT W-O unsigned word 1
(high 2 bytes)
Load run hours
40815 Set Service 15 16 BIT W-O unsigned word 1
(low 2 bytes)
Load run hours
40816 Set Service 16 16 BIT W-O unsigned word 1
(high 2 bytes)
Alarm history reset
40817 C05 16 BIT W-O unsigned word 1
(Value = 0xAA55 hex)
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The ALARM record is 32 bits. Each bit indicates the existence of an alarm.
BIT
DESCRIPTION
NO:
1 Low Voltage Alarm
2 High Voltage Alarm
3 Low Frequency Alarm
4 High Frequency Alarm
5 Thermal Motor Switch Open
6 Thermal Fan Switch Open
7 High Temperature Alarm
8 Temperature Sensor Fail
9 Low Temperature Alarm
10 Security Pressure Switch Open
11 High Pressure Alarm
12 Pressure Transducer Fail
13 Emergency Stop
14 -
15 Motor PTC Sensor Fail
16 Motor PTC High Temperature Alarm
17 Motor PTC Low Temperature Alarm
18 Phase Sequence Fail Alarm
19 Air Filter Clogged
20 Temperature Sensor 2 Fail
21 High Temperature 2 Alarm
22 Low Temperature 2 Alarm
23 Pressure Transducer 2 Fail
24 High Pressure 2 Alarm
25 Differential Pressure Alarm
26-32 -
The warning register is 16 bits. Each bit indicates the existence of a warning.
BIT
DESCRIPTION
NO:
1 Remote Stop
2 Remote Start
3 Parameter out of limits
4 High Temperature
5 No Stop since 1 Hour
6 Start waits separator pressure drop
7 Differential temperature
8-16 -
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The service request register is 16 bits. Each bit indicates the existence of a service request.
BIT
DESCRIPTION
NO:
1 Service A requested
2 Service B requested
3 Service C requested
4 Service D requested
5 Service E requested
6-16 -
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Operation:
1. If the communication between units is lost, then controllers will operate
independently.
2. The controller with the least engine hours will become the master and operate
following P04-P05 parameters. Other compressors will run and stop following their
engine hours.
3. If any of the compressors has P67 Master Change Period less engine hours than
the master controller, then this one becomes the new master.
4. If an alarm occurs at the master controller, then another controller will become
master.
5. If the pressure falls below P05, the master will run immediately. Other compressors
will run with delays of P66/8.
6. If at the expiration of P66 timer, the pressure is above P05 but below (P04+P05)/2,
then compressors will run with P66/4 delays.
7. When the pressure approaches P04, compressors will stop in their respective order
of run hours.
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The CE mark indicates that this product complies with the European requirements
for safety, health environmental and customer protection.
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