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Altronic DE-2500 Installation & Operating Instructions Manual

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ALTRONIC CONTROLLER SYSTEM
MODEL DE-2500
WARNING: DEVIATION FROM THESE OPERATING INSTRUCTIONS MAY LEAD TO
IMPROPER ENGINE/MACHINE OPERATION WHICH COULD CAUSE PERSONAL
INJURY TO OPERATORS OR OTHER NEARBY PERSONNEL.
1.0 OVERVIEW
1.1 For help locating subjects in this document, a section index is provided on page 57. A
glossary of technical terms is also provided which begins on page 52.
1.2 The Altronic DE-2500 controller system is an electronic, microprocessor-based system
designed to sense various analog and digital input points to control and monitor industrial
compressors. The system is field-programmable using a PC (personal computer) and the
supplied DE-2500 terminal program and contains a non-volatile memory to store the setup.
Serial communications provide an interface to PC's, PLC's, modems and satellite uplinks for
remote communication. A backlit 4x20 LCD character display shows system status,
programmed engine/motor and compressor parameters and channel labels. A front mounted
keypad serves as the user interface. The DE-2500 provides for both the safety shutdown
functions needed to prevent unnecessary damage to remote operated equipment and the
closed loop automatic control functions needed to optimize their efficiency of operation.
Additionally, the DE-2500 provides for remote data acquisition and supervisory control in a
compact, low cost package dedicated to industrial compressor applications. The optimization
strategies available for the management of compressor throughput include automatic prime
mover speed setting as well as capacity control. On rotary screw compressors, capacity
control can be done via suction throttling, or using an internal gas bypass technique
employing poppet valves, turn valves or slide valves. On reciprocating compressors, capacity
can be controlled using external gas bypass loops or pressure regulation techniques. A wide
range of output options, including both analog current loops and digital outputs, are provided
to interface with the large variety of actuation systems currently in use. In addition, automatic
load limiting based upon prime mover power capabilities or other application specific
limitations, such as cooling capacity, are readily implemented. There is also an AUTO START
option that is enabled using the terminal program.
1.3 The system consists of three main parts: a panel mounted Display Module DE-2500, a
Power Supply Module 691122-1, and a Terminal Module 691127-1. These components are
interconnected by means of Cable assembly 693115-1.
WARNING: THE CONTROLLER SYSTEM MUST BE CONFIGURED PRIOR TO USE ON A
COMPRESSOR
INSTRUCTIONS, FOR INSTRUCTIONS DESCRIBING HOW TO CONFIGURE THE
CONTROLLER FOR THE SPECIFIC APPLICATION. VERIFY THE PROGRAM IN
NONVOLATILE MEMORY (THE EEPROM) PRIOR TO STARTING THE SYSTEM.
REFER TO SECTION 10.0 ON HOW TO VIEW THE CURRENT CONFIGURATION.
INSTALLATION & OPERATING INSTRUCTIONS
SYSTEM.
REFERENCE
-1-
FORM DE-2500 IOI 3-04
DE-2500
PI
PROGRAMMING

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Summary of Contents for Altronic DE-2500

  • Page 1 There is also an AUTO START option that is enabled using the terminal program. 1.3 The system consists of three main parts: a panel mounted Display Module DE-2500, a Power Supply Module 691122-1, and a Terminal Module 691127-1. These components are interconnected by means of Cable assembly 693115-1.

  • Page 2: Display Module

    2.0 DISPLAY MODULE 2.1 The Display Module serves as the user interface for the DE-2500 system. It is in a 6.5" x 6.5" panel mounted enclosure and consists of an alphanumeric 20-character x 4-line backlit LCD display, a 16-key front-mounted keypad, DB-25 D-Sub and DB-9 D-Sub connectors and three pairs of serial port indicators.
  • Page 3 PLC (programmable logic controller) to perform remote monitoring or control functions if desired. 3.5 Terminals marked IGN IN and PU IN are used by the DE-2500 system to detect either engine rotation or ignition system firings. This input monitors changing signals such as those seen on either the ignition shutdown lead or a magnetic pickup monitoring an engine mounted gear.

  • Page 4: Terminal Module

    4.1 The Terminal Module is made to be rail mounted and is the point of interface between the field sensor wiring and the DE-2500 control system. A removable dual terminal strip is used for the connection of the system to the equipment mounted discrete sensors which may consist of up to 16 normally open or normally closed switches as well as 14 analog transducers.
  • Page 5 5.0 MOUNTING 5.1 DISPLAY MODULE - Mount the Display Module inside a control panel or to a suitable flat surface so that the display is at a convenient viewing height. A drilling template and mounting dimensions are provided. NOTE: Avoid mounting the unit with the LCD display facing direct sunlight.
  • Page 6 20 character label associated with it. The sensor inputs are numbered similar to previous Altronic DA and DD annunciator systems: 10-17, 20-27. The set of terminals labeled R and S are for remote Reset and Stop respectively, with AUTO START disable.
  • Page 7 ANALOG SENSOR WIRING - For each analog monitored point, inputs 30-37 and 40-45, select a transducer - either an Altronic pressure or temperature transducer listed above or one that outputs a signal in the range of 0 to 5 Vdc or 0 to 25 mA. Mount as described above. Use cable assembly 693008-x or similar to wire transducer to the Terminal Module.
  • Page 8 3 connects to the terminals marked “A3", ‘B3" and “S3". Connect to the other communication devices "A" to "A"( ) and "B" to "B"(+). Connect the shield wire to the DE-2500 system ONLY. 6.7 SENSE ROTATION INPUT - Terminals marked IGN IN and PU IN on the Power Supply Module are used by the DE-2500 system to detect either engine rotation or ignition system firings.

  • Page 9: Hazardous Area Operation

    7.0 HAZARDOUS AREA OPERATION 7.1 The DE-2500 system is CSA certified for CLASS I, DIVISION 2, GROUPS C and D areas when mounted in a suitable enclosure. In addition, the following requirements must be met (see NFPA standard no. 493): 1.
  • Page 10 8.11 MENU - The MENU key allows the user to enter the edit menu. The global timers, input class output assignment, output configuration and the time and date may be viewed and adjusted using the MENU key. 8.12 UNITS/TENS - UNITS/ UNITS keys increase or decrease values by one. The TENS/ TENS keys increase or decrease values by ten.
  • Page 11 9.3 If the AUTO START option is selected when programming the system from the PC, the display below will appear when the AUTO START sequence begins. The auto start sequence allows for activation of an electrically controlled pre-lube pump for a programmed time period prior to cranking.
  • Page 12 9.5 Whenever a programmed servicemeter interval has expired, a character will be displayed at the end of the STATUS word on the top line of the HOME screen. If programmed to do so, when using Terminal version 2.0 or above, Digital control output #7 will turn “ON” when any service meter interval has expired.
  • Page 13 There are up to eleven user programmable service messages. The desired messages and service intervals are selected when programming the DE-2500 system. The service intervals can only be changed by using the terminal program and the PC. The servicemeter alert can be reset after the required service is performed by pressing the F2 key with the desired message displayed.
  • Page 14 9.6 (continued) By programming limits on the secondary control channels, further loading of the compressor can be inhibited until the conditions return to the desired range. Additionally, the option of forcing an unloading of the compressor can also be selected. The control home screen will display the override action and the channel number of the responsible input.
  • Page 15 9.7 FOLLOW THIS SECTION FOR DE-2500 UNITS PROGRAMMED FROM TERMINAL VERSION 2.0 OR ABOVE. FOR DE-2500 UNITS PROGRAMMED FROM TERMINAL VERSION 1.8 OR BELOW, SEE SECTION 9.6. DE-2500 UNITS WITH SERIAL NUMBERS ABOVE 1525 MAY BE PROGRAMMED USING EITHER VERSION OF TERMINAL SOFTWARE, VERSION 1.8 OR 2.0.
  • Page 16 9.7 (continued) The current values of the control loop can be viewed at any time, however, to change these values, a specific key sequence must be entered first. To unlock the control loop values, press the keys F2, F1, and ENTER in that order. A small arrow will appear next to the value to be changed.
  • Page 17 1s D:450m AUTO 9.8 In addition to the two 4-20 mA analog control loop outputs, the DE-2500 offers a pulsed digital output control option on Digital outputs #1 and #2 for use with solenoid valves or motor valves. This option is referred to as PULSE CONTROL and allows for closed loop control of the variable measured by the analog voltage measured by input channel 30.
  • Page 18 9.9 On some applications, in addition to all of the standard PID control tuning, it may be desirable to allow for a small controller deadband in order to promote system stability. To set or edit the PID deadband value, select this function from the Menu as shown. EDIT SETPOINTS press to edit PID...
  • Page 19 9.11 If a fault condition occurs, the “FAULT” message for the first faulted channel will appear on the display and will remain there until it is acknowledged. The numbers one through two, after “AL” (alarm), shows the output switch that is faulted. To again view the first fault screen, press the VIEW CHAN key.
  • Page 20 10.0 VIEW PROCESS INFORMATION SCREENS 10.1 The process information screens can be accessed from any of the home screens (except the test home screen) or from the view channel screen by pressing the VIEW key. There are four process screens: screens one and three each display up to four user programmed process variables;...
  • Page 21 VIEW process escape screen Note: On DE-2500 units programmed using Terminal Program 2.0 or above two additional process screens are available, to allow the display of up to 12 process channels. 11.0 VIEW CHANNEL STATUS SCREENS 11.1 Use the VIEW CHAN key to enter the view channels screens. Once in the VIEW CHAN mode, the user can view any channel’s details.
  • Page 22 11.1 (continued) from current press STATUS TIMERS ACTIVE VIEW home screen SPEED 330 RPM CH AN SUCTION 102.3 PSIA DISCHARGE 200 PSIG to see channel press  STATUS TIMERS ACTIVE 20 from channel NOT ARMED TENS CHAN 10 ENGINE OIL PRESSURE to see channel press ...
  • Page 23 11.1 (continued) press then then   UNITS press press  TENS TENS to see channel press  STATUS RUNNING 41 from channel UNITS ARMED CHAN 40 83 PSIG COMP OIL PRESSURE to exit view press STATUS RUNNING channels mode ARMED CHAN 41 10.5 PSIA...
  • Page 24 12.1 (continued) to reset STATUS TIMERS ACTIVE timers & RESET SPEED 330 RPM outp uts SUCTION 102.3 PSIA DISCHARGE 200 PSIG or press or press reset to esc for RESET reset fault home outp uts screen 12.2 When a fault occurs on an analog channel 30-47 monitor, a “HIGH” or “LOW” indication will additionally be displayed as to whether the point faulted on a high or low setpoint.
  • Page 25 13.1 (continued) pres s to Te st sc reen is sho wn w ith STATUS TEST 600 SEC enter test no faulted points. Test TEST SPEED 1000 RPM mode key was pressed from the “R UN NIN G” hom e SUCTION 102 PSIA screen .
  • Page 26 N/C (Normally Closed) - closed in the normal run state and opens upon a fault or loss of 12-24 Vdc input power. IGN (Ignition Shorting and Fuel Valve Trip Module, Altronic P/N 691124) - open in the normal run state and closes upon a fault or loss of 12-24 Vdc.
  • Page 27 14.2 To VIEW the controller configuration from the home screen, press the MENU key. Use the NEXT key to select the group to be viewed and press ENTER. To EDIT the controller configuration, the controller system requires a password key sequence. The password procedure is: Press the MENU key.
  • Page 28 14.5 To edit the setpoint values, point to “EDIT CONTROL VALUES” and press the ENTER key. The edit control values menu is shown. The arrow points to the “EDIT SETPOINTS”. pres s to EDIT SETPOINTS edit se t- ENTER EDIT PRIM. CONTROLS points CHAN LO SP...
  • Page 29 300 SECONDS TIME DELAY ON START-UP Note: On DE-2500 units which are programmed using Terminal Software Version 2.0 and above the Sensor Class may be adjusted from the keypad. The “VIEW INPUT CLASS” display line is replaced by “EDIT INPUT CLASS”. Press NEXT key to access the Class from screen above and use RIGHT/LEFT ARROW keys to select Class A, B, C.
  • Page 30 TENS or TENS key to increase or decrease the channel by ten and press ENTER. Note: On DE-2500 units which are programmed using Terminal Software Version 2.0 and above the Timer value for Class B sensors may be adjusted from the keypad. From the display shown above press the NEXT key until the arrow points to the time in seconds.
  • Page 31 14.10 To edit the output configuration, choose “EDIT SAFETY SHUTDOWN” from the main menu. Select “MORE MENUS” from the following menu. Finally, select “OUTPUT CONFIG.” from the last menu. EDIT SETPOINTS VIEW INPUT CLASS EDIT GLOBAL VALUES MORE MENUS OUTPUT CONFIG. EDIT TIME AND DATE COMMUNICATIONS TO PREVIOUS MENU...
  • Page 32 N/O (normally open), N/C (normally closed), or IGN (ignition module 691124). NOTE: The IGN selection is intended for the Altronic output module 691124 only. The IGN selection can be made for output switch numbers 1 and 2 only.
  • Page 33 14.10 (continued) pres s to pres s to OUTPUT 1 select accept ENTER NEXT DELAY TIME 6 SEC the value change IGN Upon pressing the ENTER key, a diamond will replace the selection arrow. To view or edit the next output number, press the NEXT or TENS or TENS keys until the arrow points to the desired output number and repeat the process.
  • Page 34 14.11 (continued) The date is shown as month-day-year. The month, day and year can be edited separately. With the selection arrow pointing to the month, use the UNITS or UNITS keys to increase or decrease the month. Press ENTER to save the new month setting; the selection arrow will point to the day.
  • Page 35 15.0 VIEWING THE TIME AND DATE OF THE FIRST FAULT 15.1 The DE-2500 controller system “stamps” the time and date occurrence of the first fault. To view the time and date of the first fault, press the F2 key after a fault occurs but before reset is initiated.
  • Page 36 17.0 DATA LOGGING AND COMMUNICATION OPTIONS 17.1 The DE-2500 controller system contains a data logging feature. Data logging collects information from the system and keeps track of, or logs, that information over a period of time. That data is then available through a PC or PLC at port 1, the RS-232 port or port 3, the RS-485 port.
  • Page 37 17.5 The DE-2500 system uses a simple ASCII command to read the data collected. The ASCII command must be transmitted to the controller by the PC or PLC before it can respond. The command is shown below. The hexadecimal values for the characters are shown only for those using low level (assembly language) decoding and will not appear on the communications terminal screen.
  • Page 38 17.6 One record contains the following information: COMP. STATION #01 GIRARD, OHIO User entered data log header describing location 001 10333 HRS Record number and running hours 10-19-1998 9:46 AM Date/time the record information was collected STATUS RUNNING Normal home screen status line SPEED 925 RPM Normal home screen, line two SUCTION 102.3 PSIA...
  • Page 39 NN 17 07 D E - 2 5 0 0 CRC CRC NN = node number, 17 = ID function code, 07 = number of bytes to follow, DE-2500 ( seven byte ASCII ID string ), CRC CRC = two byte Modbus RTU CRC 17.14...
  • Page 40 17.15 REMOTE OPERATOR INTERFACE - The DE-2500 has a feature called the Remote Operator Interface or “ROI” that can be accessed through function code 20. This feature makes it possible for any function normally accessible locally on the keypad to be implemented remotely via Modbus.
  • Page 41 When a fault occurs, the DE-2500 controller system will dial up to four preprogrammed phone numbers stored in an external modem, negotiate communications and send the first fault data log report message (the 999 command) to the Altronic monitor program on a PC or to a customer supplied device.
  • Page 42 Make sure the fuel valve and ignition shutdown lead are wired to power supply terminals FV1 and FV2 for the fuel valve and IGN+ and IGN- for the ignition shutdown lead. Make sure that Altronic output module 691124 is in power supply output slots OUT 1 and OUT 2.
  • Page 43 OUTPUT #3, which would typically be used to control a solenoid valve or power relay connected to the starting device. After cranking begins, the DE-2500 system implements the engine purge cycle. The engine purge cycle consists of a 5 second roll without fuel or ignition, followed by a second 5 second delay with ignition and no fuel while still cranking.
  • Page 44 SEQUENCE CHART FOR AUTO START: EVENT OR COMMAND [---FAULT or STOP--][ AUTO START] ENGINE STATUS [-----STOPPED-------][---WAITING---][--CRANKING--][--RUNNING--] OUTPUTS IGNITION OUT #1 [---OFF-------------------------][5 sec][-----ON-------------] FUEL OUT #2 [---OFF---------------------------------][5 sec][--ON---------] PRE-LUBE OUT #4 [---OFF-----------][------ON---timer 0-999 sec------][--OFF--] CRANKING OUT #3 [---OFF---------------------------][--ON--rpm/timer][--OFF----] RPM OUT [----------------ZERO-SPEED-------------------------][--IDLE--] 4-20 ma CAPACITY [---------UNLOADED--------------------------------------------]...
  • Page 45 1/2 or 1/3 of their rated RPM range. For this reason, it is necessary to select a MINIMUM RPM and a MAXIMUM RPM to define the range in which the DE-2500 will control the speed of an engine/ compressor system. After a startup sequence MANUAL or AUTO START, the speed of the prime mover must reach the MINIMUM LOAD RPM for load control to begin.
  • Page 46 21.1 (continued) The governor input (4-20 ma from the DE-2500 ) will be automatically adjusted within the user programmed MINIMUM RPM to MAXIMUM RPM range to satisfy the PRIMARY CONTROL setpoint. Restating the section above, once the CAPACITY CONTROL OUTPUT reaches 100% the DE- 2500 system will attempt to satisfy the PRIMARY CONTROL setpoint with the CAPACITY OUTPUT held at its maximum value (100%) by adjusting the RPM.
  • Page 47 DE-2500 will regulate only the engine RPM. 22.3 The speed control output of the DE-2500 is a 4-20 ma current loop which can be connected directly to an electronic governor. The RPM values corresponding to 4 ma and 20 ma for the governor are entered during the programming of the DE-2500 so that the control output is prescaled to the correct value for the minimum and maximum RPM setpoints.
  • Page 48 22.6 When programming the DE-2500 system the basic relationship of the PRIMARY CONTROL INPUT, PRIMARY CONTROL OUTPUT and OUTPUT ACTUATOR need to be defined.
  • Page 49 22.7 The DE-2500 controls the compressor throughput based upon the PRIMARY control input; an analog value selected from channels 30, 31, or 32 which would typically be engine manifold pressure, suction pressure or discharge pressure respectively. Additionally, the DE-2500 controller allows for up to 14 additional SECONDARY CONTROL setpoints for compressor throughput control or other supplemental control functions.
  • Page 50 The potential applications of the secondary control setpoints are too numerous to compile here. 22.8 On DE-2500 units programmed using Terminal Program 2.0 or higher, the control setpoint options have been modified to add more flexibility as detailed below.
  • Page 51 23.0 CALIBRATION OF TRANSDUCERS Connect the computer cable from the computer to the DB9 port #1 on the back of DE-2500 display module. Using the DE-2500 software resident on the CDROM, open the DE-2500 program. Then click on the “CALIBRATE” button at the top of the screen.
  • Page 52 ANALOG INPUT An input which accepts voltage signals between 0 and 5 volts. These signals are converted by the DE-2500 to engineering units and compared by the microprocessor to user programmed safety shutdown and control setpoints. Channels 30-37 and 40- 45 are analog inputs.
  • Page 53 GLOSSARY (continued): CURRENT STEP LIMIT The current step limit is a maximum value that the analog output will be allowed to change from one control cycle to another. The current step limit is used to prevent rapid or erratic control action of the actuator even under transient conditions or with a poorly tuned control system.
  • Page 54 GLOSSARY (continued): PROPORTIONAL BAND The proportional band is used to tune the response of the controller to the characteristic behavior of the equipment being controlled. Proportional band is the inverse of gain expressed as a percentage. A proportional band setting of 10% is equal to a gain setting 10, a proportional band setting of 20% is equal to a gain of 5, etc.
  • Page 55 MODBUS ADDRESS LIST: ADDRESS DESCRIPTION OF FUNCTION RANGE 40001 0 to 9999 40002 Hours 0 to 65535 40003 Reserved 0 at all times 40004 Statu s, 00=sta rt up, 01=ru nning, 60=sto p, xx =fau lt no. 00 to 60 40005 Outpu t status 1-4=bits 0-3 in order, 0=fault, 1=inactive 0 to 16...

  • Page 56: Description Of Function

    M OD BU S ADD RES S LIST (continu ed): ADDRESS DESCRIPTION OF FUNCTION RANGE 40085 Optional DSM C han. 11 decimal point position from right 0 to 3 40086 Optional DSM C han. 12 decimal point position from right 0 to 3 40087 Optional DSM C han.

  • Page 57: Troubleshooting

    INDEX BY SECTION: OVERVIEW DISPLAY MOD ULE POW ER SUPP LY MOD ULE TERM INAL MOD ULE MOUNTING W IRING HAZARDOUS AREA OPERATION KEYPAD DESCRIPTION UNDERST ANDING THE HO ME SCREENS 10.0 VIEW PROCESS INFORMATION SCREENS 11.0 VIEW CHANNEL STATUS SCREENS 12.0 SHUTDOW N OF FAULT STATUS SCREENS 13.0 TEST MODE SCREENS 14.0 VIEWING OR EDITING CONFIGURATION...
  • Page 58 DRAWINGS SECTION: DE-2500 SYSTEM DIAGRAM DE-2500 CONTROLLER, MOUNTING DIMENSIONS AND SPECIFICATIONS DE-2500 TERM INAL MOD ULE AND POW ER SUPP LY MOD ULE W IRING DIAGRAM - GENERAL HOOK-UP W IRING DIAGRAM - PERSON AL COMPUT ER W IRING DIAGRAM - RS-485 COMMUNICATION...