NII Manual 1 1

8/22/2019 NII Manual 1 1

1/35

NEURON II

User Manual

Version 1.1 13 July 2009

8/22/2019 NII Manual 1 1

2/35

INDEX

# Chapter Page1.0 Salient Features 1

2.0 Technical Features 3

3.0 Input Output Description 44.0 Main Screen 6

5.0 Menu Structure 8

5.1 View 8

5.1.1Operator 9

5.1.2 Fault Report 10

5.1.3 Day Report 10

5.1.4 Service Time 10

5.1.5 Cumulative Time 11

5.1.6 VFD 11

5.2 Operator 11

5.2.1 Machine 12

5.2.2 Schedule 13

5.2.3 Maintenance 135.2.4 Language 13

5.2.5 Change Password 14

5.3 Service 14

5.3.1 Calibration 15

5.3.2 Relay 15


5.3.4 Maintenance 16

5.3.5 Clock 16

5.3.6 Self Test 17

5.4 Factory menu 17

5.4.1 Machine 18


5.4.3 Integrator Dryer 195.5 Customer care 19

6.0 Controls 20

6.1 Start Sequence 20

6.2 Stop Sequence 22

6.3 Fan Control 23

6.4 ADV control 24

6.5 Dryer Control 24

7.0 Data Interface 25

7.1 Analog output 25

7.2 DCS Port 25

8.0 Construction & Dimension Drawing 26

9.0 Revision Details 27

10.0 Appendix 28

APPENDIX A: MODBUS Table 28

APPENDIX B: Mimic LED Table 32

APPENDIX C: Short Cut Key Functions 33

8/22/2019 NII Manual 1 1

3/35

1.0 Salient features

Saves Money

The Smart Logic of NEURON II automatically decides the start delay required to ensure minimum wait time

between successive starts of the compressor and dryer thereby increasing their l ifetime.

Start Inhibit till sump pressure is within safe limits to enhance the life of the compressor

Low Voltage & Short time Power Interrupts detection to enhance the life of the contactors

Automatic Display Back-light Control to increase the Display Lifetime

Data validation of critical parameters for protecting the compressor from improper usage.

Saves Energy

Automatic Dryer ON/OFF Control to reduce power wastage

Automatic Fan ON/OFF Control based on temperature to reduce power wastage

Pressure Scheduling to allow user to plan for air requirements and avoid power wastage

Dedicated VFD interface port for synchronized operation of integrated compressor with VFD

8/22/2019 NII Manual 1 1

4/35

Saves Time

Easy User Interface thro 8 line Graphical Display and intuitive menu navigation keys

Multi Language menu & message display: English, Hindi, Selective European Languages

Mimic LED indication for fault diagnosis

Easy to read Fault and Warning message display

Cumulative Hours Display for Load, Unload, Run, Stop, Fault, Standby

Total No of Start/Stop and Load/Unload Cycle Display

Compressor Utilisation Display

Service Remain Hours Display

Dryer or Ambient Temperature (Pt100 sensor) Display

Different Control Modes: Local, Remote & DCS

Unload Mode for Service

Pressure & Temperature Units Selectable PSI or Bar, Centigrade or Fahrenheit

30 Day Report includes Date, Load, Unload, Run, Stop, Standby, Fault hours

99 Fault Report includes Fault Code along with the Date, Time, Pressure, Temperature and Run Status

MODBUS RTU protocol for monitoring the compressor through DCS interface (BAUD 9600 / 19200)

Analog Output for Pressure (Channel1), Temperature/Sump Pressure, Pt100 (Programmable on Channel2)

Programmable Relay for Load, Warn, Trip, Standby, Service, Ready, Remote

Easy Firmware update using a handheld programming device or a laptop

Optional Features

Optional add-on Fault Predictive Device

o Eliminate the need for the customer to call for service or repair

o Compressor life could be increased by regular monitoring for problems

o Production can be maximized due to the minimal downtime

Optional Add-on IO card further extends Input and Output

o 4 nos of Isolated Digital Input

o 4 nos of Relay Output

o 2 nos of Analog Input, 4-20ma

o 2 nos of Analog Input, RTD

8/22/2019 NII Manual 1 1

5/35

2.0 Technical Features

8 nos of Optically Isolated Digital Inputs of 24VDC01 = Emergency Stop02 = Differential Pressure Oil Filter - DPOF03 = Reverse Rotation

04 = Differential Pressure Air Filter - DPAF05 = Remote Start/Stop06 = High Sump Pressure07 = Cooler08 = Main Motor Overload

8 nos of Output Relay (SPDT 250V AC 10A, 1, 00,000 cycle electric life)01 = Main contactor02 = Star contactor03 = Delta contactor04 = Load Valve05 = Fan06 = Auto Drain Valve07 = Dryer (if Dryer is Connected) else Programmable

08 = Programmable [Load, Service, Standby, Warn, Trip, Remote, Ready]4 nos of Analog Input Channels

1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure1 no of RTD (Pt-100) channel, -50 to +85 degree C for Drier or Ambient Temperature

2 nos of Analog Output Channels0 to 5 VDC, One for Discharge Pressure and One Programmable

9 nos of Function keysUp, Down, Left, Right, Enter, Escape, Start, Stop and Reset.

1 no of Display128X64 White Backlight Graphical LCD

11 nos of LEDs for visualization alarm & machine status

AutoAir FilterMain Motor OverloadReverse RotationCoolerPressureTemperatureDifferential Pressure Oil FilterDifferential Pressure Separator ElementStart & Stop

1 no. of Dual led for start/stop indicationGreen for start and Red for stop

1 no. of Non Volatile MemoryFor storage of 30 Day & 99 Fault Reports

1 no. of Real Time ClockWith Battery life of about 10 years

4 nos of Communication Port (RS485, 2 wire)Serial Port 1: MODBUS-RTU or SCADA PortSerial Port 2: Dedicated FPD Port (For future use)Serial Port 3: Add-On I/O Interface Port (For future use)Serial Port 4: VFD Interface Port (For future use)

1 no. of In System Programming (ISP) portPower Supply Input: 24VAC +/- 25%, 50Hz, 1A (In built Protection present for Surge, Over Current)

8/22/2019 NII Manual 1 1

6/35

3.0 Input Output Description

X01: Power supplyConnector type: 3 pole combicon

Pin Function Id Active state1 24V AC Phase 24 VAC P -

2 Earth Earth -

3 24V AC Neutral 24 VAC N -

X02: RelaysConnector type: 10 pole combicon

Pin Function Id Active state

1 Common - Load Relay Common

2 Load Relay L / UL Load when Energised

3 Common - Fan Relay Common

4 Fan Relay Fan Energised

5 Common - Auto Drain Valve Relay Common

6 Auto Drain Valve Relay ADV Energised

7 Common Dryer Relay Common

8 Dryer Relay Dryer / Pr2 Energised

9 Common - Programmable Relay Common

10 Programmable Relay Pr1 Energised

X03: Main Motor RelaysConnector type: 4 pole combicon


1 Common for Main, Star and Delta

contactors

Common -

2 Main Contactor Main Energised

3 Star Contactor Star Energised

4 Delta Contactor Delta Energised

8/22/2019 NII Manual 1 1

7/35

X04: Digital inputsConnector type: 11 pole combicon

X05: Analog InputsConnector type: 8 pole combicon

Pin Function Id Type Range

1 Discharge pressure Dis. Pr 4-20 ma

2 15 to 24VDC 18V

0 to 16 bar

3 Discharge temperature Dis. Tr + KTY10

4 Discharge temperature Dis. Tr -

0 to 150 C

5 Sump Pressure Sump Pr 4-20 ma

6 15 to 24VDC 18V

0 to 16 bar

7 Dryer or Amb temperature Pt100 + Pt100

8 Dryer or Amb temperature Pt100 -

-50 to +85 C

X06: Analog outputs and VFDConnector type: 5 pole combicon

Pin Function Id Type Protocol /Range

1 VFD Interface VFD A RS485 A

2 VFD Interface VFD B RS485 B

FC Protocol

3 Supply Ground For 5V 0VDC - -

4 Dis. Pressure Output AO1 Voltage 0 to 16 bar

5 Programmable Analog

Output

AO2 Voltage Programmable


1 Digital Inputs Common 24VDC 24VDC -

2 Emergency Stop Emergency Fault if open3 Differential Pressure Oil Filter DPOF Fault if open

4 Reverse Rotation Rev. Rot Fault if closed

5 Differential Pressure Air Filter DPAF Fault if open

6 Remote Start Stop Control Remote Stop if open/ start on

Closure

7 High Sump Pressure HSP Fault if open

8 Cooler Fault Input Cooler Fault if open

9 Main Motor Overload MMOL Fault if open

10 24V supply ground GND24 -

11 No Connection - -

8/22/2019 NII Manual 1 1

8/35

X07: CommunicationConnector type: 6 pole combicon

Pin Function Id Type Protocol

1 DCS Interface DCS A RS485 A

2 DCS Interface DCS B RS485 B

Modbus

3 FPD Interface FPD A RS485 A

4 FPD Interface FPD B RS485 B

ASCII

5 Add On Interface Add-On A RS485 A

6 Add On Interface Add-On B RS485 B

Modbus

4.0 Main Screen

Dis. Pr : 6.0 bar

Dis. Tr : 32 C

Message1Message2

Warning

HH:MM:SS DD/MM

Message1: Based on the short cut key pressed (refer APPENDIX C)

Message2: Compressor Status or Fault message- Pressure schedule

- If Blank Pressure Schedule is Disabled

- If PS Pressure Schedule is Enabled

- If PS blinkingWaiting for Pressure Schedule Acknowledgement

- Control Mode

- L Local, ON/OFF Control from Local Keypad

- R Remote, ON/OFF Control from Remote Input

- D DCS, Control is from DCS System

- MManual, Start need to given after Power failure

- A Auto, Compressor will Automatically Restart after power failure

1 2

1

2

8/22/2019 NII Manual 1 1

9/35

Message 2 - Compressor Status or Fault message

Status Description

Ready Ready for Start

Star Motor Running in Star

Run Motor Running in Delta

Run Load Compressor in LoadRun Unload Compressor in Unload

Stop Busy Stop Sequence in Progress

Idle Controller in Idle condition, User interface will not work for this period

(5 Seconds)

Emergency Stop Emergency Stop Push Switch is ON

Start Inhibit xx.x During the Start, if the Sump Pressure is higher than the set start sump

pressure value, you will see this message. XX.X denotes the live sump

pressure value. The Compressor Starts only if the Sump Pressure valuegoes below the set value.

Start Inhibit

seconds

If Sump Pressure is Not used (Disabled) then the controller will ensure

minimum 60 seconds delay between the stop and the start. Count stops ifSTOP key is pressed

Auto Restart

seconds

If Compressor is in Auto Mode,

The controller will ensure minimum delay (user set, e.g. 90 sec) between

stop and start. Count stops if STOP key is pressed

Start ack wait This message is displayed after a fault is cleared and waiting for user

acknowledgement. By pressing RESET key user can acknowledge.

Fault Description

Pr. Probe Failure Discharge Pressure Sensor Probe Failure

Tp. Probe Failure Temperature Sensor Probe Failure

Sump Pr. Probe

Failure

Sump Pressure Sensor Probe Failure

HSP (A) Case 1: Sump Pressure is enabled

If Sump Pressure exceeds the set high sump pressure value.

Case 2: Sump Pressure is disabled

If Discharge Pressure exceeds the set high sump pressure value.

HSP (D) If the HSP Digital Input Opens due to High Sump Pressure

Cooler If the Cooler Digital Input Opens due to Cooler fault

Main Motor Overload IF the MMOL Digital Input Opens due to Main Motor Over Load.

Rev Rot / Ph Fail If the Rev Rot Input Closes when Motor Running due to motorreverse rotation or Phase failure.

Trip Temperature If the Discharge Temperature exceeds the set trip temperature value.

Sump Pressure Not

Developing

After the Start, The Sump Pressure should be at least 1.0 bar in 10

seconds. If this is NOT achieved this Fault occurs

Power failure If the Mains Supply is Interrupted for more than 50 msec

Low Voltage If the Mains Supply Voltage is less than the 67% of rated Voltage.

Compressor is tripped & All Controller Operation is Halted until the

Mains Supply Comes back to normal (at least 75% of the rated)

8/22/2019 NII Manual 1 1

10/35

5.0 Menu Structure

Press any one of the following keys,,and to enter main menu

Main Menu

Dis. Pr : 6.0 bar

Dis. Tr : 32 C

Status

View

Operator

ServiceFactory

Customer Care

5.1 View

View

Operator Fault

Report

DayReport

Service

Time

Cumulative

TimeVFD

8/22/2019 NII Manual 1 1

11/35

5.1.1 Operator

LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4

View Operator Mode Control mode Local / Remote / DCS

Unload Mode Enable / Disable

Auto Restart ON/ OFF

Pressure Unit PSI / Bar

Temperature Unit Fahren / Centi

Pressure Unload pressure X X . X b or p (bar or psi)

Load pressure X X . X b or p

Pr. Schedule ON/ OFF

Start Sump Press X X . X b or p

Max .Diff Pressure X X . X b or p

Delay Warn RST delay X X X s (second)

Star delay X X sDTR delay X X s

RTS delay X X s

Stanby TimeSby X X m(minute)

St/Sp PH X X

DCS port Type Modbus / SCADA

ID X X

Baud 9600/19200

Parity None / Even

Length 8 / 7

Stop Bit 2 / 1

Temperature Trip Temperature X X X C or F

Warn Temp X X X C or F

Fan Temp X X X C or F

Low Dew Pt X X C or F

High Dew Pt X X C or F

8/22/2019 NII Manual 1 1

12/35

5.1.2 Fault Report

Use, to select the Fault Record number (1 to 99).

LEVEL 1 LEVEL 2 LEVEL 3

View Fault report Fault code: XX, Message

Time: HH:MM:SS

Date: DD/MM/YY

Dis.Pr: X X .X

Dis.Tr: X X X

Status: Load/ UnLoad /OFF

Fault Code:

01 & 09 Reserved

02-Main Motor Overload, 03-Cooler, 04-HSP(Analog), 05Trip Temperature, 06-Reverse Rotation, 07-Pressure Probe Failure, 08-Temperature Probe Failure, 0A-

HSP(Digital), 0B-Power Failure( Short Power Interrupt), 0C-Sump Pressure Not

Developing , 0D-Sump Pressure probe Failure.

5.1.3 Day Report

Use, to select the Record number (1 to 30).


View Day report Date: DD/MM/YY

L: X X Hours St: X X Hours

UL: X X Hours F: X X Hours

R: X X Hours Sby: X X Hours

STC: X X X LDC: X X X X X

L- Load, St Stop, UL Unload, F- Fault, R- Run, Sby- Standby, STC Start Count,LDC Load Count

5.1.4 Service Time


View Service time Remaining AFCT: X X X X X X hours

Remaining OFCT: X X X X X X hours

Remaining OSCT: X X X X X X hours

Remaining OCT: X X X X X X hours

Remaining RGT: X X X X X X hours

8/22/2019 NII Manual 1 1

13/35

5.1.5 Cumulative Time


View Cumulative time Load X X X X X X hrs: X X Min

Unload X X X X X X hrs: X X Min

Run X X X X X X hrs: X X MinStop X X X X X X hrs: X X Min

Fault X X X X X X hrs: X X Min

Standby X X X X X X hrs: X X Min

Start Count X X X X X X

Load Count X X X X X X X X X

Utilisation X X %

5.1.6 VFDIf VFD is connected to the compressor and VFD port is connected, user can view the

following parameters of VFD in Neuron II.

1. Voltage in V2. Current in A3. Frequency in Hz4. Power in KW5. Run Hours6. Kilowatt Hour (Multiply the value shown by 100 to get the real KWH)7. Status of the VFD

5.2 OperatorPassword required.

Operator

Machine Schedule Maintenance Language Change

Password

Mode Pressure Set

Delay

DCS

PortAuto Drain

Valve

Set Dew

Point

8/22/2019 NII Manual 1 1

14/35

5.2.1 Machine

# Item Min Max Option Default Unit

Mode

1 Auto Restart - - on / off off -

2 Pr Unit - - bar / psi bar -3 Tr Unit - - cen / fah cen -

4 Control

mode

- - loc/rem/dcs loc -

5 Unload

mode

- - en/dis dis -

6 Analog

output

- - Tmp / Sp /

Pt

Tmp -

Pressure

7 Unload

Pressure

> load

pressure+0.5

(bar)

< max unload

pressure (bar)

- 7.0 bar bar/psi

8 Load

Pressure

4.0 (bar) < unload

pressure-0.5(bar)

- 5.5 bar bar/psi

Set Delay

9 Warn RST 90 300 - 90 second

10 Star 6 10 - 6 second

11 DTR 10 60 - 10 second

12 RTS 5 30 - 10 second

13 Standby 1 99 - 5 minute

14 St/Sp per hr 3 10 - 5 -

DCS Port

15 Type - - Modbus

/SCADA

modbus -

16 ID 01 99 - 01 -

17 Baud - - 9600/19200 9600 bps

18 Parity - - None /Even None -

19 Length - - 8 / 7 8 -

20 Stop Bit - - 2 / 1 2 -

Auto Drain Valve

21 Off time 1 150 - 4 minute

22 On time 1 15 - 5 SecondSet Dew Point

23 Low Dew

point

-6 C +2 C - -2 C C/F

24 High Dew

point

6 C 12 C - 8 C C/F

8/22/2019 NII Manual 1 1

15/35

5.2.2 Schedule

Enable Pressure Schedule, and then use, to select the schedule number (1 to 32).

Then Press Enter to set the following


1 Day - - Sun to Sat /

--- (means noschedule)

--- -

2 Action - - on / off off -

3 Time HH 00 23 - 00 Hour

4 Time MM 00 59 - 00 Minute

5 Unload

Pressure

> Load

Pressure

+ 0.5(bar)

< Max

Unload

Pressure(bar)

- 6.5 bar bar/psi

6 Load Pressure 4.0 bar < UnloadPressure

0.5 (bar)

- 4.5 bar bar/psi

5.2.3 Maintenance


1 AF changed - - no/yes no -2 OF changed - - no/yes no -

3 OS changed - - no/yes no -

4 Oil changed - - no/yes no -

5 Re Grease - - no/yes no -

5.2.4 Language

# Item

1 English2 Hindi

3 Portuguese

Default is English.

8/22/2019 NII Manual 1 1

16/35

5.2.5 Change Password

Procedure for changing the password

1. Enter the old Password

2. If old password is correct, next screen is displayed. If wrong the control comes

out of the change password screen.

3. Enter the New password

4. Enter the New password again

5. If the new password matches both the times then new password is updated. If

mismatch the control goes back to step 3.

Pressing Esc will bring the control to the main menu screen

5.3 ServicePassword required.

Service

Calibration Relay ChangePassword

Maintenance Clock SelfTest

8/22/2019 NII Manual 1 1

17/35

5.3.1 Calibration

Select the parameter need to calibrated using the,keys. Then Press Enter to

calibrate.

Dis Pressure/ Dis Temperature/ Sump Pressure Calibration

Run the Compressor. When the value is stable at some point, measure the actual value

using a standard & recently calibrated meter and enter the meter reading in to the set

value field displayed in Neuron II. Set Value should not exceed +/- 1 bar, +/- 10 C.

Pt 100 Calibration

When the Dew point/ Ambient Temperature is stable at some point, measure the actual

value using a standard & recently calibrated meter and enter the meter reading in to the

set value field displayed in Neuron II. Set Value should not exceed +/- 3 C.

Analog Output 1 & 2Calibration for analog output should be done for two values one at zero and one at 8.0 bar

/ 80 degree C. These values are set by connecting a Variable Resistor (TRIM POT) in the

analog input channel. Measure the Analog output value (can be viewed in the DCS/VFD /

or any master unit where this output is connected). Enter this value in set pr:

Note: Calibration need to be done only when the compressor is in off condition and the

digital outputs (relay terminals) are disconnected from the controller.

Note: Calibration for Pressure will be only in bar and for temperature only in Centigrade.

5.3.2 Relay

Select the Programmable Relay 1 or 2 using the,keys. Then Press Enter to assign

the any one of the following functionality for the relay.

# Item

1 Warn

2 Load

3 Service

4 Standby

5 Trip

6 Remote

7 Ready

Default:Relay 1 = Warn

Relay 2 = Trip

Note: If Dryer is enabled then Programmable

Relay 2 is not user programmable.

It is used for automatic dryer control.

8/22/2019 NII Manual 1 1

18/35











5.3.4 Maintenance


1 Set AFCT 000000 999999 - 002000H Hour

2 Set OFCT 000000 999999 - 002000H Hour

3 Set OSCT 000000 999999 - 004000H Hour

4 Set OCT 000000 999999 - 002000H Hour

5 Set RGT 000000 999999 - 002000H Hour

5.3.5 Clock

# Item Min Max

1 Hour 00 23

2 Minute 00 59

3 Second 00 59

4 Date 01 31

5 Month 01 12

6 Year 00 99

7 Day Sun/Mon/Tue/Wed/Thu/Fri/Sat

8/22/2019 NII Manual 1 1

19/35

5.3.6 Self Test

Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output, Memory &

Communication Ports working.

Follow the instructions displayed in the screen

Warning!!!

Self Test should be conducted only when the compressor wiring is totally disconnected

from the controller. Do NOT perform self test when the controller is connected to the

compressor. Doing so will cause severe damage to the compressor.

5.4 Factory menuPassword required.

Factory

Machine ChangePassword

Dryer

Compressor

Info

DPSE DPOF Max.

PressureSettings

Temperature

Settings

8/22/2019 NII Manual 1 1

20/35

5.4.1 Machine


Compressor Info

1 Rating - - 11 to 315 22 KW

2 Pressure - - LP/ 7.0 to 12.5 LP bar3 Fab no A-Z 00000 A-Z

999999

- A00000 -

4 DPSE - - on/off off -

5 DPOF - - on/off off -

Max. Pressure Settings

6 Max UL

Pressure

> Unload

Pressure

< 13.5 bar - 7.5 bar bar

/psi

7 High Sump

Pressure

> Max

Unloadpressure +1

< Max

Unloadpressure

+3

- 10.5 bar bar

/psi

8 Sump

Pressure

- - enable/disable disable -

9 Start Sump

Pressure

0.0 bar 16.0 bar - 2.2 bar bar

/psi

10 Max.

Differential

Pressure

0.0 bar 2.0 bar - 1.5 bar bar

/psi

Temperature Settings

11 Trip

temperature

110 C 120 C - 110 C C / F

12 Warn

temperature

90 C 110 C - 105 C C / F

13 Fan

temperature

60 80 C - 70 C C / F

8/22/2019 NII Manual 1 1

21/35











5.4.3 Dryer


1 Dryer Mode - - on/off off -

2 Dryer Delay 2 10 - 3 Minute

5.5 Customer care

Dis. Pr : 6.0 barDis. Tr : 32 C

Status

Toll Free No

1800-425-3544

e-mail

[email protected]

8/22/2019 NII Manual 1 1

22/35

6.0 Controls

6.1 Start SequenceExit loop

FAULT?

ON

Command

No

Yes

AUTO

mode

ON?

Dis. Pr.

8/22/2019 NII Manual 1 1

23/35

STAR

ON

MAIN ON

NO. OF. START

INCREMENT

DELTA ON

STAR OFF

Exit loop

Delay for 100msecs

(Fixed)

STAR TO DELTA delay x sec

(Star delay)

Delta to run delay x sec

(DTR delay)

Start Sequence

8/22/2019 NII Manual 1 1

24/35

6.2 Stop Sequence

Is

STAR ON

LOAD OFF

DELTA & MAIN

OFF

(RTS delay)

Run to stop x sec

IDLE delay for 5 secsFixed delay

READY

Yes

No

Stop

8/22/2019 NII Manual 1 1

25/35

6.3 Fan Control

Dis. Temp

> Set FANTemp

FAN ON

No

Yes

FAN

= ON?

Dis. Temp< (Set FAN

Temp 5 C)

FAN OFF

Exit Loop

No

Yes

No

Yes

Exit Loop

State = Run?

No

8/22/2019 NII Manual 1 1

26/35

6.4 ADV control

As per the User set On & Off time the Drain Valve is automatically controlled.

6.5 Dryer Control

Calculate elapsed time from

last stop

IsElapsed time>set

dryer delay ?

Dryer ON

No

Yes

Dryer ON command generates

internally when Compressormotor starts runnin

Dryer OFF when Compressor is stopped

On time

Off time

8/22/2019 NII Manual 1 1

27/35

7.0 Data Interface

Neuron II has two types of Data Interface

Analog output

DCS Port

7.1 Analog output

Two Channels are available as analog output. The First Channel will output the current

Discharge Pressure value 0.0 to16.0 bar, converted into 1 to 4.75V.

The Second channel is programmable. User can select any one of the following in menu

Operator/ Machine/ Mode/ Analog output

a. Dis. Temperature 0 to 150 C, converted into 1 to 4.75V

b. Sump Pressure 0 to 16.0 bar, converted into 1 to 4.75V

c. Pt100 Temperature -50 to 90 C, converted into 1.25 to 4.75V

Note: Analog output will be 0V in case of probe failure.

7.2 DCS Port

DCS port can be of Modbus RTU type to interface to Generic DCS system or SCADA

type to interface to ELGI SCADA software.

User can select the Port type in menu Operator/ Machine/ DCS Port. Also the ID,

Baud Rate, Parity, data Length, Stop Bit are user settable. The Modbus data table is

provided in the Appendix.

8/22/2019 NII Manual 1 1

28/35

8.0 Construction

Corrosion & Dust protected Back Cover

IP65 polyethylene front keypad

Inputs and Outputs through terminal block, board to wires, disconnect able, screw terminals

Front Plate Dimensions 260 x 145mm

Enclosure Dimensions 235 X 120 X 70 mm

Operating Temperature - 0C to +75C

Relative Humidity

8/22/2019 NII Manual 1 1

29/35

9.0 Revision Details

Version Date Changes

1.0 2 April 2009 Initial Draft1.1 8 July 2009 Pilot Batch S/W

Version 1.1

8/22/2019 NII Manual 1 1

30/35

10.0 Appendix

APPENDIX A: MODBUS TABLE [Function Code: 0x03(Read) & 0x10(Write)]

# DataDescription

Address Type Bytes Example / Format Access

Cumulative Time & Count Registers

1 Load Hours 1010 BCD 4 HHHHHH:MM R

2 UnloadHours

1012 BCD 4 HHHHHH:MM R

3 Run Hours 1014 BCD 4 HHHHHH:MM R

4 Stop Hours 1016 BCD 4 HHHHHH:MM R

5 Fault Hours 1018 BCD 4 HHHHHH:MM R

6 Standby

Hours

101A BCD 4 HHHHHH:MM R

7 No of Start 101C BCD 4 NNNNNNNN R8 Load Count 101E BCD 6 NNNNNNNNNNNN R

9 Utilization % 1022 BCD 2 XXXX R

Service Remaining Time Registers

10 Rem AFCT

Hours

1028 Int 2 H8063 = -99

(X10000)

Minutes 1029 ULong 4 H000927BF =

599999

R

11 Rem OFCT

Hours

102B Int 2 H8063 = -99

(X10000)

Minutes 102C ULong 4 H000927BF =599999

R

12 Rem OSCTHours

102E Int 2 H8063 = -99(X10000)

Minutes 102F ULong 4 H000927BF =599999

R

13 Rem OCTHours

1031 Int 2 H8063 = -99(X10000)

Minutes 1032 ULong 4 H000927BF =599999

R

14 Rem RGT

Hours

1034 Int 2 H8063 = -99

(X10000)

Minutes 1035 ULong 4 H000927BF =

599999

R

8/22/2019 NII Manual 1 1

31/35

Mode Registers

15 Control

Mode

1040 BCD 2 0001-DCS

0002-Local

0003-Remote

R/W

16 Unload Mode 1041 BCD 2 0001-Disabled0002-Enabled

R/W

17 Auto Restart

1042 BCD 2 0001-OFF

0002-ON

R/W

18 Pr Unit 1043 BCD 2 0001-BAR0002-PSI

R/W

19 Tr unit 1044 BCD 2 0001-Centi0002-Farhen

R/W

20 Pr.Schdl(on/off)

1045 BCD 2 0001-OFF0002-ON

R

Analog Registers

27 Dis. Pressure

104A BCD 2 1200 (/100) =12.0 bar

R

28 Dis.Temperature

104B BCD 2 1100 (/10) =110 C

R

29 Dew Point /Ambient

Temperature

104C BCD 2 MSB 01 = +MSB 02 = -

LSB = 30

R

30 Sump

Pressure

104D BCD 2 1200 (/100) =

12.0 bar

R

31 Diff Pressure 104E BCD 2 0100 (/100)

=1.0 bar

R

32 Set UnloadPressure

104F BCD 2 0120 (/10) =12.0 bar

R/W

33 Set Load

Pressure

1050 BCD 2 0080 (/10) =

8.0 bar

R/W

34 Set DiffPressure

1051 BCD 2 0010 (/10) =1.0 bar

R/W

35 Trip Temp 1052 BCD 2 0110 = 110 C R

36 Warn Temp 1053 BCD 2 0105 = 105 C R/W

37 Low Dew

Point

1054 BCD 2 MSB 01 = +

MSB 02 = -LSB = 30

R/W

38 High DewPoint

1055 BCD 2 MSB 01 = +MSB 02 = -

LSB = 30

R/W

39 Fan Temp 1056 BCD 2 0070 = 70 C R/W

8/22/2019 NII Manual 1 1

32/35

Delay Registers

21 Auto Restart

Delay (Sec)

1060 BCD 2 0100 R/W

22 Star Delay

(Sec)

1061 BCD 2 0005 R/W

23 DTR Delay

(Sec)

1062 BCD 2 0010 R/W

24 RTS Delay

(Sec)

1063 BCD 2 0010 R/W

25 Standby

Time (Min)

1064 BCD 2 0005 R/W

26 Max. No of

Start per hour

1065 BCD 2 0005 R/W

RTC Registers

40 Hour 106A BCD 2 0023 R

41 Minutes 106B BCD 2 0059 R42 Seconds 106C BCD 2 0059 R

43 Date 106D BCD 2 0031 R

44 Month 106E BCD 2 0012 R

45 Year 106F BCD 2 0009 R

46 Day 1070 BCD 2 0001

Sunday -1

R

Status Registers

47 General

Status

1071 UInt 2 Refer table R

48 Warning

Status

1072 UInt 2 Refer table R

49 Fault Status 1073 UInt 2 Refer table R

Start / StopFunction Code: 05Address : 1074

Value : 0xFF00 Start

0x0000 Stop

8/22/2019 NII Manual 1 1

33/35

Status Register Bit Definition:

Bit Position General Warning Fault

0 Ready DPSE HSP

1 Star DPOF Cooler

2 Run Dryer Probe Failure Main Motor Overload3 Run Load Low Dew Point Reverse Rotation

4 Run Unload High Dew Point Pressure Probe Failure

5 Stop Busy High Differentialpressure

Temperature ProbeFailure

6 Idle Warn Temperature Trip Temperature

7 Emergency Stop Change Air Filter Sump Pressure Not

Developing

8 Start Inhibit Change Oil Filter Sump Pressure probeFailure

9 Start ack wait Change Oil Separator Power failure

10 Standby Change Oil Reserved11 Reserved Change Grease Reserved

12 Reserved Reserved Reserved




8/22/2019 NII Manual 1 1

34/35

APPENDIX B: MIMIC LED TABLE

# LED Description

1 Auto To indicate the machine is in automatic on/off mode. This Led

glows in Amber Colour on these conditions

1. When Pressure Schedule is enabled (or)2. When Auto Restart is enabled2 Air Filter Glows in Amber colour when

1. Air Filter Service is due based on service hours2. Air Filter Digital Input (DPAF) is Open

3 Main Motor

Overload

Glows in Red when the main motor overload Digital Input is

Open.

4 Reverse Rotation Glows in Red when the Reverse Rotation Digital Input isClosed and the machine is in Run state

5 Cooler Glows in Red when the cooler Digital Input is Open

6 Pressure Glows in Red when the

1. HSP Digital Input is Open2. Analog Pressure Input is Open (Probe Failure)3. Dis. Pressure is higher than set HSP

7 Temperature Glows in Red when the

1. Analog Temperature Input is Open (Probe Failure)2. Dis. Temperature is higher than set Trip temp.

8 Differential

Pressure Oil Filter(DPOF)

Glows in Amber when the

1. DPOF Digital Input is Open & DPOF is enabled2. Oil Filter Service is due

9 Differential

Pressure Separator

Element (DPSE)

Glows in Amber when the

1. DPSE Digital Input is Open & DPSE is enabled

2. Oil Separator Filter Service is due10 Start & Stop 1. Glows in Red when machine is stopped / idle

2. Glows in Green when machine is running

8/22/2019 NII Manual 1 1

35/35

APPENDIX C: Short Cut Key Functions

Note1: All shortcut key functions only when the display is in Main Screen.

Note2: On every press of the key NEXT message is displayed.

LEFT Warning messages

Warning Description

DPSE Differential Pressure Separator Element Due For

Service

DPOF Differential Pressure Oil Filter Due For Service

Dryer Probe Failure Pt100 Sensor Probe Failure

Low Dew Point Live Dew Point less than the Set Low Dew Point

High Dew Point Live Dew Point greater than the Set High Dew Point

High Differential pressure Difference Between the Sump & Discharge Pressure is

greater than the set max Differential Pressure value.

Warn Temperature Discharge Temperature exceeds the set Warn valueChange Air Filter Air Filter Due For Service

Change Oil Filter Oil Filter Due For Service

Change Oil Separator Oil Separator Due For Service

Change Oil Oil Change Due For Service

Change Grease Re Grease Due For Service

Start Stop Exceeded No. of Start stop per hour exceeded

RIGHT - Live Analog Values

1. Live Differential Pressure2. Live Sump Pressure

3. Live Pt100 Temperature

UP Set Analog Values

1. Set Load Pressure

2. Set Unload Pressure

3. Set Start Sump Pressure4. Max Differential Pressure

DOWN Today Report

1. Date

2. Load and Stop Hours

3. Unload and Fault Hours4. Run and Standby Hours

5. Start Count and Load Count

Documents

NII Manual 1 1