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Datakom DK-40, User Manual

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DK-40 USER MANUAL                                                                       V2.6 (02.08.2011)  

 

K13D01-E                                                        - 4 - 

 

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.

 

 

Below conditions may damage the device: 

•

 Incorrect connections. 

•

 Incorrect power supply voltage. 

•

 Voltage at measuring terminals beyond specified range. 

•

 Connecting or removing data terminals when the unit is powered-up. 

•

 Overload or short circuit at relay outputs 

•

 Voltage applied to digital inputs over specified range. 

•

 High voltage applied to communication port. 

 

Below conditions may cause abnormal operation: 

•

 Power supply voltage below minimum acceptable level. 

•

 Power supply frequency out of specified limits 

 

 

Summary of Contents for DK-40

Page 1: ...se voltages and frequency It features high low voltage and phase order protections The standard logic level serial port features MODBUS communication The unit allows monitoring and programming through computer FEATURES Pressure driven automatic start and stop Voltage Protection Relay function Phase Order Protection Relay function Mains phase voltages display No need for external transformer Star D...

Page 2: ... install damaged equipment Do not open the unit There is no serviceable parts inside Fuses must be connected to the power supply and phase voltage inputs in close proximity of the unit Fuses must be of fast type FF with a maximum rating of 6A Disconnect all power before working on equipment When the unit is connected to the network do not touch terminals Any electrical parameter applied to the dev...

Page 3: ... 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 1...

Page 4: ...then place plugs to their sockets Note that the power supply terminal is separated from measurement terminals Below conditions may damage the device Incorrect connections Incorrect power supply voltage Voltage at measuring terminals beyond specified range Connecting or removing data terminals when the unit is powered up Overload or short circuit at relay outputs Voltage applied to digital inputs o...

Page 5: ...DK 40 USER MANUAL V2 6 02 08 2011 K13D01 E 5 1 1 FRONT REAR PANELS 1 2 MECHANICAL INSTALLATION Panel Cutout Required Panel Depth ...

Page 6: ...n affect the operation measurement precision and data communication quality ALWAYS remove plug connectors when inserting wires with a screwdriver Fuses must be connected to the power supply and phase voltage inputs in close proximity of the unit Fuses must be of fast type FF with a maximum rating of 6A Use cables of appropriate temperature range Use adequate cable section at least 0 75mm2 AWG18 Fo...

Page 7: ...DK 40 USER MANUAL V2 6 02 08 2011 K13D01 E 7 1 4 CONNECTION DIAGRAM ...

Page 8: ...and measurement displays are visualized using below buttons BUTTON DESCRIPTION FUNCTION MENU Displays next parameter Resets faults Saves adjusted value RUN Run the compressor and reset existing alarms Increase value STOP Stop the compressor and reset existing alarms Decrease value ...

Page 9: ...parameters and may differ following compressor manufacturers In the occurrence of a fault condition the fault code will appear on the upper display Below is a list of messages shown on the upper display in normal operation programming and alarm display modes MESSA GE DESCRIPTION MODE bar bar bar bar set set set set Start pressure and stop pressure set values Display FrQ FrQ FrQ FrQ Mains frequency...

Page 10: ... 2 2 Temperature 2 value or switch position Display d p d p d p d p Differential Pressure Display n n n n Remaining starts for the last hour Display rEL rEL rEL rEL Software version Display Ah1 Ah1 Ah1 Ah1 Alarm history 1 Display n C n C n C n C Switch closed Display N O N O N O N O Switch open Display SEP SEP SEP SEP Waiting for separator filter pressure drop Display STP STP STP STP Remote Stop m...

Page 11: ...isplay shows the alarm code A comprehensive list of alarm codes is given in chapter 5 The compressor may be stopped with Remote Stop signal upper display shows StP StP StP 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 ...

Page 12: ... DELTA relay operates After P25 Timer before Loading the LOAD relay operates and the compressor starts producing compressed air Unloading and reloading When the pressure reaches P04 Stop Pressure or pressure switch opens then the LOAD relay opens and the compressor runs unloaded during P26 Unload Timer If the pressure falls below P05 Start Pressure before the expiration of the timer then the LOAD ...

Page 13: ...essor operation depending on the amount exceeding the service period TIME REMAINING TO SERVICE REACTION 100 hours No warning given 100hours Service warning is given and SERVICE led turns on The compressor continues normal operation 0 hour The compressor stops Service warning is given and SERVICE led turns on The compressor resumes normal operation when RUN button is pressed 100 hours The compresso...

Page 14: ...5 15 Phase Squence Fail ALARM A16 16 Air Filter Clogged WARNING A17 17 Maximum starts per hour exceeded WARNING A18 18 Emergency Stop ALARM A19 19 Internal Warning WARNING A20 20 Pressure Difference ALARM A21 21 High Pressure 2 ALARM A22 22 Pressure 2 Sensor Fail ALARM A23 23 High Temperature 2 Delta tS2 tS1 ALARM A24 24 Temperature 2 Sensor Fail ALARM A25 25 Low Temperature 2 ALARM A26 26 Air In ...

Page 15: ...ear flashing on the display 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 SHB SHB 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 ME...

Page 16: ...STOP mode In order to modify hour counters 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 USR Enter password The upper display will show C H C H C H C Hmessage Adjust required hour counter value with RUN and STOP buttons Press MENU button for 3 seconds the display wil show SEt mes...

Page 17: ...is 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 Running off load below 90 C coefficient 0 50 between 90 and 95 C coefficient 0 75 between 95 and 100 C coefficient 1 ...

Page 18: ...ous connection topologies The topology is selected through parameter P48 Different topologies and terminal connections are as below P48 3 P48 1 P48 2 P48 3 The power supply and measuring terminals of the unit are isolated In order to enable above topology the unit must be specially manufactured ...

Page 19: ...unit offers 3 different operating modes selected through program parameter P45 The unit calculates dynamically the restart pressure Pi P45 0 No special care taken Pi P05 P45 1 When the compressor is loaded if the pressure is below P05 Start Pressure then the Restart Pressure Pi is incremented by 0 1 bar When the compressor is loaded if the pressure is above P05 Start Pressure then the Restart Pres...

Page 20: ...ist only if it is different from the previous alarm or the motor has run at least 6 minutes after its previous occurrence In order to visualize the latest alarm in the history press MENU button until Ah Ah Ah Ah1 1 1 1 alarm history 1 comes to the display To visualize previous alarms use RUN and STOP pushbuttons When the alarm history is scrolled the STOP button is always active and stops the comp...

Page 21: ...this input The complete fault code list is given in chapter 5 Part_2 input switch type NO or NC NO normally open 256 NC normally closed 0 Part_3 input detection delay 0 1sec delay 0 0 5sec delay 512 2 0sec delay 1024 5 0sec delay 1536 Example 1 In order to adjust input 2 as EMERGENCY STOP NC switch and 0 1sec delay Part_1 18 refer chapter 5 Part_2 0 NC switch Part_3 0 0 1 sec P74 Input_2 configura...

Page 22: ...gh parameter P40 RELAY FUNCTION DESCRIPTION 0 ALARM RL5 operates if alarm exists releases otherwise 1 FAN If the air end temperature equals or greater than P41 then RL5 is on If the air end temperature is lower than P41 P42 then RL5 is off 2 LOAD RL5 RL4 3 NO LOAD RL5 opposite of RL4 4 MOTOR RUNNING RL5 operates if the main motor runs releases otherwise 5 MOTOR STOPPED RL5 operates if the main mot...

Page 23: ...sed MENU and STOP buttons for 3 seconds The upper display will show USr USr USr 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 Hold pressed the MENU button for 3 seconds 7Modifying program parameters When programming menu is entered the upper display will show the program number and the...

Page 24: ... 5 P04 0 5 8 5 bar P04 Stop Pressure P03 0 2 P05 0 2 7 3 bar P05 Start Pressure 3 P04 0 2 6 5 bar P06 Offset Pressure Transducer 2 2 0 bar P07 Top range temperature probe P08 2 130 130 C P08 High air end temperature Alarm P09 2 P07 2 108 C P09 High air end temperature Warning P10 2 P08 2 103 C P10 Low air end temperature Alarm 10 P09 2 0 C P11 Offset value air end temperature 10 10 0 C P12 Motor P...

Page 25: ... 20 250 200ms P16 Voltage Unbalance Ratio 0 20 5 P17 Temp 2 Sensor operation mode 0 Disable 1 Absolute temperature 2 Differential temperature If this parameter is set to 0 the P18 P19 P20 and P22 parameters will not be displayed 0 P18 Top range Temp 2 Sensor P19 2 200 130 C P19 Temp 2 Sensor High Limit Delta Alarm Limit P20 2 P18 2 Temperature differential alarm Limit 110 C P20 Low Alarm Delta War...

Page 26: ...7 If this parameter is set to 0 then no service B warning is given 4000 hours P31 Service C Period 0 32767 If this parameter is set to 0 then no service C warning is given 6000 hours P32 Service D Period 0 32767 If this parameter is set to 0 then no service D warning is given 14000 hours P33 Service E Period 0 32767 If this parameter is set to 0 then no service E warning is given 20000 hours P34 D...

Page 27: ...Pressure loss preventing method 0 standard operation 1 step increase decrease 2 dynamic calculation 0 P46 Reserved 0 P47 Reserved 0 P48 Connection topology 1 1 phase 2 2 phases 3 3 phases 3 P49 Phase L1 calibration 1 32767 1186 P50 Phase L2 calibration 1 32767 1186 P51 Phase L3 calibration 1 32767 1186 P52 Low Frequency Alarm Enable 0 Disable 1 Enable If this parameter is set to 0 the P53 paramete...

Page 28: ...P62 Phase L3 L1 voltage display 0 Disable 1 Enable 1 P63 MODBUS enable 0 Disable 1 Enable 1 P64 Master Slave MODBUS 0 Slave 1 Master 0 P65 MODBUS node address 1 Starts multiple controller opr 2 254 Modbus address 240 P66 Slave Start Timer Multiple controller operation 1 999 sec 180 sec P67 Master Change Period Multiple operation 1 999 hours 100 hours P68 Serial Number Low Word 0 65535 10 P69 Seria...

Page 29: ... 520 P76 Input 4configuration register 0 2047 Refer chapter 7 for more details 16 256 1808 P77 Pressure 2 Input Configuration 0 Disabled 1 Pressure switch 2 Analog transducer If this parameter is set to 0 or 1 parameters P78 P82 will not be displayed 0 P78 Top range pressure 2 transducer 4 2 99 9 Bar 15 0 bar P79 High Pressure Sensor 2 Alarm Limit 3 7 P78 0 5 8 8 bar P80 Differential pressure alar...

Page 30: ...es warning only 1 Service request stops the compressor as explained in chapter_5 0 P88 Reserved 0 P89 Variable Hour counting method 0 Fixed hour counting coefficient 1 Variable hour counting method Refer chapter 6 3 for more details 0 P90 Pressure Dot Display 0 Enable 1 Disable If this parameter is set to 0 the pressure is displayed in xx x format This format is useful for display in bars If this ...

Page 31: ... 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 qu...

Page 32: ...C high byte 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 availab...

Page 33: ...m calculation 4 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 t...

Page 34: ...l 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 ...

Page 35: ...nsigned word 0 1 40013 Service A Counter remaining time to service A 32 BIT R O signed long 0 1 40014 40015 Service B Counter remaining time to service B 32 BIT R O signed long 0 1 40016 40017 Service C Counter remaining time to service C 32 BIT R O signed long 0 1 40018 40019 Service D Counter remaining time to service D 32 BIT R O signed long 0 1 40020 40021 Service E Counter remaining time to s...

Page 36: ...ord 1 40041 Alarm 5 Alarm 5 in alarm history 16 BIT R O unsigned word 1 40042 Alarm 6 Alarm 6 in alarm history 16 BIT R O unsigned word 1 40043 Alarm 7 Alarm 7 in alarm history 16 BIT R O unsigned word 1 40044 Alarm 8 Alarm 8 in alarm history 16 BIT R O unsigned word 1 40045 Alarm 9 Alarm 9 in alarm history 16 BIT R O unsigned word 1 40046 Connection topology 1 Single phase 2 bi phase 3 three phas...

Page 37: ...word 1 40157 P29 See chapter 9 2 16 BIT R W unsigned word 1 40158 P30 See chapter 9 2 16 BIT R W unsigned word 1 40159 P31 See chapter 9 2 16 BIT R W unsigned word 1 40160 P32 See chapter 9 2 16 BIT R W unsigned word 1 40161 P33 See chapter 9 2 16 BIT R W unsigned word 1 40162 P34 See chapter 9 2 16 BIT R W unsigned word 1 40163 P35 See chapter 9 2 16 BIT R W unsigned word 1 40164 P36 See chapter ...

Page 38: ...er 9 2 16 BIT R W unsigned word 1 40198 P70 See chapter 9 2 16 BIT R W unsigned word 1 40199 P71 See chapter 9 2 16 BIT R W unsigned word 1 40200 P72 See chapter 9 2 16 BIT R W unsigned word 1 40201 P73 See chapter 9 2 16 BIT R W unsigned word 1 40202 P74 See chapter 9 2 16 BIT R W unsigned word 1 40203 P75 See chapter 9 2 16 BIT R W unsigned word 1 40204 P76 See chapter 9 2 16 BIT R W unsigned wo...

Page 39: ...RE SENSOR GRAPH 32 Temperature Sensor Ohm C 32 16 BIT R O signed word 1 40449 40480 MOTOR PTC SENSOR GRAPH 32 Motor PTC Temperature Sensor Ohm C 32 16 BIT R O signed word 1 40481 40512 TEMPERATURE 2 SENSOR GRAPH 32 Temperature Sensor 2 Ohm C 32 16 BIT R O signed word 1 40513 40544 PRESSURE 2 SENSOR GRAPH 32 Pressure Sensor 2 Graph mA Bar 32 16 BIT R O unsigned word 1 ...

Page 40: ...1 40806 Set service 6 Time to service C high 2 bytes 16 BIT W O unsigned word 1 40807 Set service 7 Time to service D low 2 bytes 16 BIT W O unsigned word 1 40808 Set service 8 Time to service D high 2 bytes 16 BIT W O unsigned word 1 40809 Set service 9 Time to service E low 2 bytes 16 BIT W O unsigned word 1 40810 Set service 10 Time to service E high 2 bytes 16 BIT W O unsigned word 1 40811 Set...

Page 41: ... 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 ...

Page 42: ...3D01 E 42 The service request register is 16 bits Each bit indicates the existence of a service request BIT NO DESCRIPTION 1 Service A requested 2 Service B requested 3 Service C requested 4 Service D requested 5 Service E requested 6 16 ...

Page 43: ...ontrollers in the same group No gap is allowed If a gap exists controllers coming after the gap will operate independently 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...

Page 44: ...o the EU directives 2006 95 EC low voltage 2004 108 EC electro magnetic compatibility Norms of reference EN 61010 safety requirements EN 61326 EMC requirements The CE mark indicates that this product complies with the European requirements for safety health environmental and customer protection ...

Page 45: ... Pressure Inputs 4 20mA pressure transducer optional 0 10V transducer Temperature Inputs 1000 5000 ohms KTY or NTC or PTC sensor Heating current 0 3mA Motor PTC input gives alarm above 2000 ohms Serial Port Signal type logic levels 0 5V Communication Modbus RTU Data Rate 9600 baud Operating Temperature 30 C 80 C 22 176 F Storage Temperature 40 C 80 C 40 176 F Maximum Humidity 95 non condensing Deg...

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