Datakom DK-40 User Manual

Datakom DK-40 User Manual

Compressor controller

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DK-40 USER MANUAL
DK-40 COMPRESSOR CONTROLLER
INTRODUCTION
DK-40 is a state of the art unit for the control
of both screw and piston type compressors.
The unit integrates all functions needed in a
compressor system. Thus no extra units are
required in a compressor panel providing
cost reduction and simplicity.
The unit is directly powered from 230/400 volt
mains. It provides power supply for fault
switches and sensors. Thus external
transformer is not required in the panel.
The unit monitors mains phase 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.
K13D01-E
datakom@datakom.com.tr
http://www.datakom.com.tr
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 / Delta startup
Load solenoid control
1 programmable relay output
Optically isolated configurable digital inputs
2 pressure sensor inputs
2 temperature sensor inputs
Additional motor PTC input
Logic level serial port
MODBUS-RTU communication
Password protected front panel programming
Low panel depth, easy installation
Wide operating temperature range
Sealed front panel (IP54)
2 part connector system for easy installation
- 1 -
V2.6 (02.08.2011)
Tel: +90 216 466 84 60
Fax: +90 216 364 65 65
FEATURES

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Summary of Contents for Datakom DK-40

  • Page 1 DK-40 COMPRESSOR CONTROLLER INTRODUCTION FEATURES Pressure driven automatic start and stop DK-40 is a state of the art unit for the control Voltage Protection Relay function of both screw and piston type compressors. Phase Order Protection Relay function The unit integrates all functions needed in a Mains phase voltages display compressor system.
  • Page 2 DK-40 USER MANUAL V2.6 (02.08.2011) SAFETY NOTICE Failure to follow below instructions will result in death or serious injury • Electrical equipment should be installed only by qualified specialist. No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the non-compliance to these instructions.
  • Page 3: Table Of Contents

    DK-40 USER MANUAL V2.6 (02.08.2011) 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.
  • Page 4: Installation

    DK-40 USER MANUAL V2.6 (02.08.2011) 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.
  • Page 5: Front / Rear Panels

    DK-40 USER MANUAL V2.6 (02.08.2011) 1.1 FRONT / REAR PANELS 1.2 MECHANICAL INSTALLATION Panel Cutout Required Panel Depth K13D01-E - 5 -...
  • Page 6: Electrical Installation

    DK-40 USER MANUAL V2.6 (02.08.2011) 1.3 ELECTRICAL INSTALLATION Do not install the unit close to high electromagnetic noise emitting devices like contactors, high current busbars, switchmode power supplies and the like. Although the unit is protected against electromagnetic disturbance, excessive disturbance can affect the operation, measurement precision and data communication quality.
  • Page 7: Connection Diagram

    DK-40 USER MANUAL V2.6 (02.08.2011) 1.4 CONNECTION DIAGRAM K13D01-E - 7 -...
  • Page 8: Pushbutton Functions

    DK-40 USER MANUAL V2.6 (02.08.2011) 2. PUSHBUTTON FUNCTIONS Programming and measurement displays are visualized using below buttons: BUTTON DESCRIPTION FUNCTION Displays next parameter. Resets faults. MENU Saves adjusted value. Run the compressor and reset existing alarms. Increase value. Stop the compressor and reset existing alarms.
  • Page 9: Display Navigation

    DK-40 USER MANUAL V2.6 (02.08.2011) 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.
  • Page 10 DK-40 USER MANUAL V2.6 (02.08.2011) MESSA DESCRIPTION MODE Hours remaining to service E Display / Program / Alarm Total compressor hours Display (ON_LOAD+OFF_LOAD+STOP) Total Run Hours Display (ON_LOAD+OFF_LOAD) Total load time (load contactor active) Display Load hours / Run hours percentage...
  • Page 11: Modes Of Operation

    DK-40 USER MANUAL V2.6 (02.08.2011) 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.
  • Page 12 DK-40 USER MANUAL V2.6 (02.08.2011) 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.
  • Page 13: Alarms And Warnings

    DK-40 USER MANUAL V2.6 (02.08.2011) 5. ALARMS AND WARNINGS Abnormal situations in the compressor are evaluated under 3 different categories as ALARMS, WARNINGS and SERVICE REQUESTS. Warnings are lowest level fault conditions and generate only visual warning, not affecting the compressor operation.
  • Page 14 DK-40 USER MANUAL V2.6 (02.08.2011) FAULT CODES LIST SYMBOL CODE DESCRIPTION Security Pressure Switch Opened ALARM High Pressure ALARM Pressure Sensor Fail ALARM High Temperature ALARM High Temperature WARNING Temperature Sensor Fail ALARM Low Temperature ALARM Fan Motor High Temperature...
  • Page 15: Other Features

    DK-40 USER MANUAL V2.6 (02.08.2011) 6. OTHER FEATURES 6.1. RESETTING SERVICE COUNTERS Service counters can only be reset when the compresssor is in STOP mode. In order to reset service counters: - 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.
  • Page 16: Modifying Hour Counters

    DK-40 USER MANUAL V2.6 (02.08.2011) 6.2. MODIFYING HOUR COUNTERS The unit holds 3 different run hour counters: MESSAGE DESCRIPTION Total compressor hours (ON_LOAD+OFF_LOAD+STOP) This counter increments while the RUN led is on. Total motor run hours (ON_LOAD+OFF_LOAD) This counter increments while the motor runs.
  • Page 17: Selection Of Hour Counting Method

    DK-40 USER MANUAL V2.6 (02.08.2011) 6.3. SELECTION OF HOUR COUNTING METHOD 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.
  • Page 18: Connection Topologies

    DK-40 USER MANUAL V2.6 (02.08.2011) 6.4. CONNECTION TOPOLOGIES 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.
  • Page 19: Preventing Pressure Loss

    DK-40 USER MANUAL V2.6 (02.08.2011) 6.5. PREVENTING PRESSURE LOSS 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.
  • Page 20: Alarm History

    DK-40 USER MANUAL V2.6 (02.08.2011) 6.6. ALARM HISTORY The unit keeps the list of 9 most recent alarm records. A new occurring alarm will appear at the top of the list. The alarm list may be visualized on the screen or read through Modbus.
  • Page 21: Inputs

    DK-40 USER MANUAL V2.6 (02.08.2011) 7. D G TAL 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.
  • Page 22: Relay Outputs

    DK-40 USER MANUAL V2.6 (02.08.2011) 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...
  • Page 23: Programming

    DK-40 USER MANUAL V2.6 (02.08.2011) 9. PROGRAMMING 9.1. INTRODUCTION TO PROGRAMMING The program menu can be entered only when the compressor is in STOP mode. The entry to programming menu is protected by a 2 level password system. The program parameter set and password levels may differ following compressor manufacturers.
  • Page 24: Parameter List

    DK-40 USER MANUAL V2.6 (02.08.2011) 9.2. PARAMETER LIST Some parameters given in this list may not appear on device display. Description Adjustment Range Factory set 0: Analog transducer 1: Pressure Switch Pressure Control If this parameter is set to 1 then P02 ...
  • Page 25 DK-40 USER MANUAL V2.6 (02.08.2011) Description Adjustment Range Factory set 0:Disable (the unit will power-up always in STOP mode) Automatic Restart 1: Enable (the unit will power-up with the same mode as the power-down instant) 0 ... (P09) While the air end temperature is...
  • Page 26 DK-40 USER MANUAL V2.6 (02.08.2011) Description Adjustment Range Factory set 0: Fixed 1: Variable If set to 1: Unload timer fixed or If the stop duration is more than variable the unload run duration, the unload timer is reduced by 1 minute at each run, until an absolute minimum of 2 minutes.
  • Page 27 DK-40 USER MANUAL V2.6 (02.08.2011) Description Adjustment Range Factory set 0: Alarm 1: Fan 2: Load 3: No load RL5 function selection 4: Motor run 5: Motor stopped Refer chapter 8 for more details. 30 ... (P09-2) Fan On Temperature (RL5) 85 °...
  • Page 28 DK-40 USER MANUAL V2.6 (02.08.2011) Description Adjustment Range Factory set High Frequency Alarm 60.0 ... 990.0 Hz 62.0 Hz Value 0: Disable Frequency display 1: Enable 0:Disable Phase L1 voltage display 1:Enable 0:Disable Phase L2 voltage display 1:Enable 0:Disable Phase L3 voltage display...
  • Page 29 DK-40 USER MANUAL V2.6 (02.08.2011) Description Adjustment Range Factory set 0 ... 2047 Input1 configuration register Refer chapter 7 for more details. 0 ... 2047 Input 2 configuration register 28+512=540 Refer chapter 7 for more details. 0 ... 2047 Input 3configuration register 8+512=520 Refer chapter 7 for more details.
  • Page 30 DK-40 USER MANUAL V2.6 (02.08.2011) Description Adjustment Range Factory set Pressure sensor-2 low pressure alarm limit (if 0.. (P79-0.5) adjusted to 0.0 then no alarm is given) Reserved Reserved Reserved Reserved 0: Service request gives warning only Service security selection...
  • Page 31: Modbus Communications

    DK-40 USER MANUAL V2.6 (02.08.2011) 10. MODBUS COMMUNICATION 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.
  • Page 32 DK-40 USER MANUAL V2.6 (02.08.2011) The normal response will be: Byte Description Value Controller address same as in the query Function code Data lenght in bytes (L) number of registers * 2 High byte of 1st register Low byte of 1st register...
  • Page 33 DK-40 USER MANUAL V2.6 (02.08.2011) 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...
  • Page 34 DK-40 USER MANUAL V2.6 (02.08.2011) 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.
  • Page 35: Modbus Register List

    DK-40 USER MANUAL V2.6 (02.08.2011) 10.2. MODBUS REGISTER LIST CONTROLLER REGISTERS ADDR. NAME DESCRIPTION LENG. TYPE MUL. 40001 Frequency 16 BIT unsigned word 40002 Phase L1 Voltage 16 BIT unsigned word 40003 Phase L2 Voltage 16 BIT unsigned word 40004 Phase L3 Voltage...
  • Page 36 DK-40 USER MANUAL V2.6 (02.08.2011) CONTROLLER REGISTERS ADDR. NAME DESCRIPTION LENG. TYPE MUL. Current motor status 0: Compressor in OFF mode 1: Motor star 2: Motor delta (before load) Motor Status 16 BIT unsigned word 3: Motor loaded 40033 4: Motor unloaded...
  • Page 37 DK-40 USER MANUAL V2.6 (02.08.2011) PROGRAM PARAMETERS ADDR. NAME DESCRIPTION LENG. TYPE MUL. 40139 P11 See chapter 9.2 16 BIT signed word 40140 P12 See chapter 9.2 16 BIT signed word 40141 P13 See chapter 9.2 16 BIT signed word 40142 P14 See chapter 9.2...
  • Page 38 DK-40 USER MANUAL V2.6 (02.08.2011) PROGRAM PARAMETERS ADDR. NAME DESCRIPTION LENG. TYPE MUL. 40180 P52 See chapter 9.2 16 BIT unsigned word 40181 P53 See chapter 9.2 16 BIT unsigned word 40182 P54 See chapter 9.2 16 BIT unsigned word 40183 P55 See chapter 9.2...
  • Page 39 DK-40 USER MANUAL V2.6 (02.08.2011) SENSOR GRAPHS 40385 PRESS_SENSOR 32*16 Pressure Sensor (mA - Bar) unsigned word GRAPH [32] 40416 40417 TEMPERATURE Temperature Sensor(Ohm - 32*16 SENSOR GRAPH signed word ° C) 40448 [32] 40449 MOTOR PTC Motor PTC Temperature...
  • Page 40 DK-40 USER MANUAL V2.6 (02.08.2011) COMMANDS 40769 C01 Reserved register 16 BIT unsigned word Return to Factory (value = 40770 C02 16 BIT unsigned word 0xAA55) Reset Counter 40771 C03 16 BIT unsigned word (value = Counter(1-8) LOCK KEY 40772 C04...
  • Page 41 DK-40 USER MANUAL V2.6 (02.08.2011) 10.3. ALARMS-WARNINGS-SERVICE REQUESTS The ALARM record is 32 bits. Each bit indicates the existence of an alarm. DESCRIPTION Low Voltage Alarm High Voltage Alarm Low Frequency Alarm High Frequency Alarm Thermal Motor Switch Open Thermal Fan Switch Open...
  • Page 42 DK-40 USER MANUAL V2.6 (02.08.2011) The service request register is 16 bits. Each bit indicates the existence of a service request. DESCRIPTION Service A requested Service B requested Service C requested Service D requested Service E requested 6-16 - K13D01-E...
  • Page 43: Multiple Controller Operation

    DK-40 USER MANUAL V2.6 (02.08.2011) 11. MULTIPLE CONTROLLER OPERATION The multiple controller operation is designed for installations where more than one compressor have to operate in parallel. The multiple controller operation allows energy efficiency by running only the necessary number of compressors in case of low air consumption. It performs equal aging of compressors as well.
  • Page 44: Declaration Of Conformity

    DK-40 USER MANUAL V2.6 (02.08.2011) 12. DECLARATION OF CONFORMITY The unit conforms to 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: Technical Specifications

    DK-40 USER MANUAL V2.6 (02.08.2011) 13. TECHNICAL SPECIFICATIONS 305 – 460 VAC (between IN-COMM and IN-400V terminals) Supply Voltage: 175 - 275VAC (between IN-COMM and IN-230V terminals) Supply Frequency: 50 - 60Hz nominal (± %10) < 4 VA Power consumption:...

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