Monitoring & Control Device Manual

Operator’s Manual

CALMS monitoring and control device

REV.   : 2020.2.1.9

DATE  : May 2020

Online application         : https://app.calms.com

Contact                         : info@calms.com

Before installing, starting or using this unit for the first time, this manual should be studied carefully to obtain a working knowledge of the unit and or the duties to be performedwhile operating and maintaining unit.

PRINT AND RETAIN THIS MANUAL WITH UNIT. This technical manual contains IMPORTANT  SAFETY DATA and should be kept with the unit.

2 — INTRODUCTION

The CALMS PM-X (x stands for 2,4 or 8, where number represents possible number of compressors that can be connected to CALMS PM device) is an advanced Compressed Air Energy Management System with System Controller designed to provide safe, reliable, and energy-efficient management of your compressed air system. The CALMS PM-X is capable of controlling up to eight (8) positive displacement air compressors. The compressors may be fixed speed, variable speed or multi-step and have electro-pneumatic or microprocessor based controls. The CALMS PM-X is uniquely configurable and customizable to meet the specific needs of some of the most complex compressed air systems.As mentioned above there are three (3) different types of PM box. Each type is defined from how many compressors can be connected to it. To PM-2 device two compressors can be connected, to PM-4 device up to four compressors can be connected and to PM-8 we can connect up to eight compressors.Differences between those 3 types can be seen in PLC hardware (see section 12) and HMI hardware and software (see section 8). User manual is generally written and can be used for all PM-X types.

Differences are explicitly explained in sections where types differ.

Benefits

  • Save on energy costs,
  • Improve your energy efficiency,
  • Reducing costly downtime
  • Save your time and improve service provider respond time,
  • Distribute costs in relation to actual consumption,
  • Improve the reliability of your equipment,
  • Improve forecast of energy consumption,
  • Improve your environmental image,
  • Improve the investment process (energy equipment).
  • **ISO 50001:2011, **Energy management systems compliant

3 — SAFETY

WARNING: Risk of Danger

WARNING: Risk of Electric Shock

WARNING: Consult Manual

  • Before installing or operating the CALMS PM-X, take time to carefully read all the instructions contained in this manual, all compressor manuals, and all manuals of any other peripheral devices that may be installed or connected to the unit.
  • Electricity and compressed air have the potential to cause severe personal injury or property damage.
  • The operator should use common sense and good working practices while operating and maintaining this system. All applicable codes should be strictly adhered to.
  • Maintenance must be performed by adequately qualified personnel that are equipped with the proper tools.

INSTALLATION

  • Installation work must only be carried out by a competent person under qualified supervision.
  • A fused isolation switch must be fitted between the main power supply and the CALMS PM-X.
  • The CALMS PM-X should be mounted in such a location as to allow operational and maintenance access without obstruction or hazard and to allow clear visibility of indicators at all times.
  • If raised platforms are required to provide access to the CALMS PM-X they must not interfere with normal operation or obstruct access. Platforms and stairs should be of grid or plate construction with safety rails on all open sides.

OPERATION

  • The CALMS PM-X must only be operated by competent personnel under qualified supervision.
  • Never remove or tamper with safety devices, guards or insulation materials fitted to the CALMS PM-X.
  • The CALMS PM-X must only be operated at the supply voltage and frequency for which it is designed.
  • When main power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the unit.
  • Do not open access panels or touch electrical components while voltage is applied unless it is necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the correct tools and wearing appropriate protection against electrical hazards.
  • All air compressors and/or other equipment connected to the unit should have a warning sign attached stating ‘THIS UNIT MAY START WITHOUT WARNING’ next to the display panel.
  • If an air compressor and/or other equipment connected to the unit is to be started remotely, attach warning signs to the equipment stating ‘THIS UNIT CAN BE STARTED REMOTELY’ in a prominent location, one on the outside of the equipment, the other inside the equipment control compartment.

MAINTENANCE AND REPAIR

  • Maintenance, repairs or modifications must only be carried out by competent personnel under qualified supervision.
  • If replacement parts are required use only genuine parts from the original equipment manufacturer, or an alternative approved source.
  • Carry out the following operations before opening or removing any access panels or carrying out any work on the CALMS PM-X:
    • Isolate the CALMS PM-X from the main electrical power supply.
    • Lock the isolator in the ‘OFF’ position and remove the fuses.
    • Attach a label to the isolator switch and to the unit stating ‘WORK IN PROGRESS - DO NOT APPLY VOLTAGE’. Do not switch on electrical power or attempt to start the CALMS PM-X if such a warning label is attached.
    • Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good working order.
    • The accuracy of sensor devices must be checked on a regular basis. They must be calibrated when acceptable tolerances are exceeded. Always ensure any pressure within the compressed air system is safely vented to atmosphere before attempting to remove or install a sensor device.
    • The CALMS PM-X must only be cleaned with a damp cloth, using mild detergents if necessary. Avoid the use of any substances containing corrosive acids or alkalis.
    • Do not paint the control faceplate or obscure any indicators, controls, instructions or warnings.

4 — CALMS GENERAL CONDITIONS AND POLICY OF DATA PROTECTION

GENERAL CONDITIONAL AGREEMENT

CALMS website server owner (Provider)

The CALMS website server owner and administrator (Provider) of www.calms.com and www.calms.eu is

HPE d.o.o., Dolenjska cesta 83, 1000 Ljubljana, Slovenia Europe E: info@calms.eu

and

CALMS Air Inc, 19 West 34th Street, NY10001 New York, USA, E: info@calms.com

General conditions agreement

By using the CALMS website, the user agrees to the CALMS general conditions agreement and Policy of Protecting of business data and accepts them.

Data accuracy

Provider strives to provide the most precise and current data on its website server, however, the website text is informative, therefore it is not liable for their accuracy. Data provided by CALMS devices and CALMS mobile devices depend on installation and setup from third party and are not responsibility of the provider, as well as reports, alarms generated by those data. Users interpret the contents on their own responsibility.

Limitation of liability

Neither Provider nor any other legal or natural person involved in the creation of this website server is responsible for any temporary disruption to this website, any possible information inaccuracies, or any damages that result in using inaccurate or incomplete information. Provider is not liable for any damage or inconveniences that result from the existence of this website server, from accessing to and/or using and/or inability to use information on this website and/or for any flaws or deficiencies in their contents, regardless of whether they have been notified on the possibility of such damages.

Since the Provider’s website server receives data from external devices and features certain links to websites that are not in any way connected to the Provider  and over which Provider has no control.  Provider cannot guaranty for them nor receive or transmit complaints about the accuracy of the content on any of the data or websites that are linked or referenced and is not responsible for data protection on these websites.

Personal data protection

The administrator may use and process the user’s personal data that are submitted when visiting the Provider website in accordance with the applicable regulations on personal data protection (Personal Data Protection Act ZVOP-1).

In accordance with ZVOP-1, the administrator may process personal data upon the user’s personal consent. Personal consent is the individual’s voluntary statement that their personal data may be processed for a certain purpose and is given based on information provided by the administrator. The individual’s personal consent can be written, oral, a click on a dialog box allowing cookie use, subscription on CALMS / CALMS application , or other applicable user consent forms.

For personal data protection purposes, the administrator will implement organizational, technical, and other appropriate procedures and measures to prevent unauthorized data deletion, change, loss, or unauthorized processing. As the web portal features certain links to other websites that are in no way connected to the provider, the administrator does not assume liability for data protection on these websites. The administrator is also not responsible for any mistakes that result in submitting false data upon registering at the portal website.

Cookies

The cookies we install on your browser enable us to run all the website functions, adapt certain contents to you, and improve our website with page analytics.

You can opt out of using the cookies. In that case, the website will not load any permanent cookies to your browser apart from our own cookies we use for the page analytics. By opting out, you may not be able to view the entire page properly.

The website uses the following elements of other providers that also use cookies:

Facebook button, Tweeter button, and Google  button.

Changes to general conditions

The administrator reserves the right to change or add to the general conditions for the web portal at any time and without prior notice.

The user will be notified on any changes to the general conditions with special pop-ups that will appear when accessing the website.

POLICY OF PROTECTION OF BUSINESS DATA

Provider (CALMS) provides internet based application located on cloud server as a service for Customer (Partner or End-user) for Compressed Air leak management and energy management

Provider and customer want to cooperate, that is why they want to establish confidentially relationship, and they conclude this policy with intention to prevent unauthorized disclosure of confidential information.

All information that customer will put on internet application will be shown only to customer users with password protection.

All data are located on secured web cloud database, with access for users that are confirmed by the customer .

Data related to CALMS or CALMS can be deleted anytime by customer assigned user only without provider notice. When data are deleted they will be completely removed from server database and backup – so no restore possible.

This policy is covering relationship between Provider (CALMS) and his customer only and  does not cover confidentially relationship between Partner and his End-user.

PRIVACY POLICY

This privacy policy manages the collection, storage and processing of personal data which Provider (CALMS)  is collecting from you once you subscribe to contents, such as newsletter, invitations to events, publications, compressed air leak and compressed air energy data collected by CALMS devices and other CALMS products.

The personal data managers as defined by the General Data Protection Regulation (GDPR) of the European Union are:

HPE d.o.o., Dolenjska cesta 83, 1000 Ljubljana, Slovenia Europe E: info@calms.eu

and

CALMS Air Inc, 19 West 34th Street, NY10001 New York, USA, E: info@calms.com

PERSONAL INFORMATION AND THE PURPOSE OF PROCESSING PERSONAL INFORMATION

If you wish to receive contents from Provider (newsletter, invitations to events, publications and other Provider products), please fill out the registration form at the Provider website or purcahse CALMS or CALMS product. By filling out and confirming this the registration form, you will submit the following contact details to Provider:

Name and Surname

E-mail address

Company

Contact details submitted when filling out or submitting the form/order/application/registration are needed for processing your order and for communication regarding specific newsletter, events, publications and other Provider products to which you are subscribed. In case you do not provide the requested contact details, we will not be able to process your order and you will not be able to use the benefit of newsletter, events, publications and other Provider products.

Provider respects your privacy and is committed to being as diligent as possible regarding the collection, storage and processing of your personal data, and to always working in accordance with the current personal data protection regulation.

In order to prevent unauthorised access or disclosure of acquired data, to preserve the correctness of personal data and to assure that they are properly used, we are using suitable technical and organisational procedures for the protection of data we are collecting. Provider cannot exclude potential data abuse because internet is an unpredictable medium, despite all security measures and secure communication protocols.

** CONSENT**

Personal data submitted when registering for the newsletter, events, publications and other Provider products are processed with your clear and unambiguous consent based on Article 6 (1), (a) General Data Protection Regulation (GDPR). We also process information about opened received messages and clicks on links in received messages in order to improve the quality of our products and services, and for statistical purposes regarding e-mails that we send you.

You can withdraw your consent at any time by clicking the “Unsubscribe” link which is located in the footer of each message received from Provider, or via e-mail at the following address: info@calms.com. In case your consent is withdrawn, we will no longer use your personal data for informing you about Provider contents (newsletter, events, publications and other Provider products). Potential withdrawal of the consent does not affect the legality of your personal data processing in the period before the withdrawal was submitted.

** YOUR RIGHTS**

In accordance with the provisions of the General Data Protection Regulation of the European Union, you have the right to access your personal data, the right to modification, deletion, transferability, the right to request limitation of data processing and the right to object.

Please contact our authorised person for data protection regarding all your rights and for additional information, they are available at info@calms.com.  We will process your application and respond in accordance with the GDPR.

PERSONAL DATA RETENTION PERIOD

Provider keeps your personal data as long as it is necessary for the purpose of sending you the content (newsletter, invitations to events and other Provider products) to which you subscribed. In case you no longer wish to receive content from Provider and you decide to unsubscribe or in case you withdraw your consent for processing of personal data for this purpose, we will block your data in the system and will no longer use it for this purpose.

Cookies

WHAT ARE COOKIES?

A cookie is a file that stores website settings. Websites store cookies in devices used by users to access the internet with the purpose of identifying individual devices and settings users used during access. Cookies provide recognition if users already visited this website and advanced applications use them to adapt specific settings to users. Their storage is fully controlled with the browser of the user – they can limit or disable cookies.

WHY ARE COOKIES NECESSARY?

Cookies are essential for providing user-friendly web services; most common e-commerce functions would not be possible without cookies. The interaction between the user of the web and the website is faster and simpler with the use of cookies. The website uses cookies to remember individual preferences and experience, making browsing the websites more efficient and pleasant. There are several reasons to use cookies. They are used for storing data about the situation of an individual website (details on adaptations of individual websites), they facilitate website services (i.e. online stores), they help to collect statistics about users and website visits, about the habits of website users etc. Cookies facilitate the assessment of design efficiency of our website. You can also read the guidelines of the information commissioner on the use of cookies about the recommended and allowed use of cookies on website. They are available here

Cookies used on our website do not collect your personal data which could be used to personally identify you and they cannot harm your computer, tablet or mobile phone. Cookies facilitate the operation of our website and help us understand which information is most useful to visitors.

NOTIFICATION

By using this website, you agree that this website will add cookies to your computer or mobile device.

MANAGEMENT AND DELETION OF COOKIES

If you wish to modify how the cookies are used in the browser, including blocking or deletion, you can do this by suitably modifying browser settings. Most browsers have the option to accept or reject all cookies, you can accept only a certain type of cookies or receive a warning that a website wants to save a cookie. Cookies saved by your browser can also easily be deleted. If you change or delete a cookie file in your browser, if you modify or upgrade your browser or your device, you will also have to disable the cookies again. The procedure for the management and deletion of cookies is different in each browser. If you need assistance, you can check the help files of the browser

CERTIFICATION

Certificates:

  • Low voltage directive 2014/35/EU
  • Electromagnetic compatibility directive 2014/30/EU

Product has applied next standards:

  • EN 61010-1 ed.2:2011
  • EN 61326-1 ed.2:2013
  • EN ISO/IEC 17067:2014

5 — COMPRESSOR CONNECTION AND CONTROL

COMPRESSOR CONNECTION AND CONTROL

Each air compressor in your system must be interfaced to the CALMS PM-X. Interface methods may vary depending on the compressor type and/or local control configuration.

The following are main methods for interfacing compressors to the CALMS PM-X:

1)The CAL-C-ON/OFF Interface module that is designed to interface to any positive displacement air compressor (regardless of make or manufacturer) with an available control voltage of 12-250V (either 50Hz or 60Hz). The CAL-C-ON/OFF Interface module is installed within the compressor control area and connected to the CALMS PM-X using an EtherCAT cable. Each air compressor must be equipped with an online/offline pressure regulation system capable of accepting a remote load/unload signal through a volt-free switching contact or a single electro-mechanical pressure switch. Consult the air compressor manual or your air compressor supplier/specialist for details before installing the CALMS PM-X.

Figure 1 - CALMS PM-C-ON/OFF module

Description

CAL-ON/OFF

Compressor Interface Module kit - ON/OFF Compressor

Coupler

Module Coupler for E-bus terminals with integrated digital I/Os:
– 4 digital inputs 24 V DC, filter 3.0 ms, type 3
– 4 digital outputs 24 V DC, 0.5 A, 1-wire system
– E-bus power supply, current max. 1 A


Bus Interface

2 x RJ 45 switched

EtherCAT module


Power Supply

Power Supply 24Vdc, 1A, 24W


Materials

Enclosure: PBT Polycarbonate, ABS plastic


Mounting

DIN Rail Mounting

Compressor Cabinet

Power analyzer

3-phase power measurement terminal, max. 500V AC 3\~, max. 5 A, via measuring current transformers x A/5A
Accuracy: ANSI 12.20 0.5% accuracy,

IEC 62053-22 Class 0.5S
Compatible with CTs from 5 to 32000A
UL listed, CE,  ANSI C12.20

3 pcs Current Transformer coils 0-500 A / 5A as standard (as Option available also Split core CT and different sizes)

Accuracy

1 % (U/I),
1.5 % calculated value (P)
(at 0°C ... +55°C, of the full scale value)

Build in energy efficiency and power management with the Power & Energy Meter. This cost-effective analyzer is simple to deploy and is standard build in CAL-C-xx modules. Module with Power meter comes on standard DIN Rail and should be installed in each compressor to monitor power:

Measures AC Current, AC Voltage, Amp Hour (Ah), Amps (A), Kilowatt Hours (kWh), Kilowatts (kW) , Power Factor (PF), Volt-Amp Reactive (VAR), Volt-Amp Reactive Hour (VARh), Volt-Amps (VA), Volts (V), Watt Hours (Wh), Watts (W)Range: 90-600VAC – Wye or Delta configurations

2) The PM-C-VSD Interface module is intended to provide a method of system integration for a VSD (Variable Speed Drive) air compressor that is not equipped with any accessible means of remote connectivity (such as IR- Nirvana). The PM-C-VSD will provide required functionality to enable system integration and efficient control using the CALMS PM-X automation system. The CAL-C-VSD connects to the CALMS PM-X controller via an EtherCAT network

Each air compressor in a system, that requires CAL-C-VSD integration, must be equipped with an individual CAL-C-VSD. Multiple VSD Boxes can be connected to the CALMS PM-X as long as the number of compressors does not exceed the maximum number of compressors (4).

Figure 2 - CAEMS CAL-C-VSD module

Description

CAL-C-VSD

Compressor Interface Module kit - VSD Compressor

Coupler

Module Coupler for E-bus terminals with integrated digital I/Os:
– 4 digital inputs 24 V DC, filter 3.0 ms, type 3
– 4 digital outputs 24 V DC, 0.5 A, 1-wire system
– E-bus power supply, current max. 1 A


Bus Interface

2 x RJ 45 switched

EtherCAT module


Analog Outputs

2-channel analog output terminal 4…20 mA, 12 bit


Power Supply

Power Supply 24Vdc, 1A, 24W


Mounting


DIN Rail Mounting

Compressor cabinet

Power analyzer

3-phase power measurement terminal, max. 500V AC 3\~, max. 5 A, via measuring current transformers x A/5A
Accuracy: ANSI 12.20 0.5% accuracy,

IEC 62053-22 Class 0.5S
Compatible with CTs from 5 to 32000A
UL listed, CE,  ANSI C12.20

3 pcs Current Transformer coils 0-500 A / 5A as standard (as Option available also Split core CT and different sizes)


A/5A

Accuracy: ANSI 12.20 0.5% accuracy,

IEC 62053-22 Class 0.5S
Compatible with CTs from 5 to 32000A
UL listed, CE,  ANSI C12.20

3 pcs Current Transformer coils 0-500 A / 5A as standard (as Option available also Split core CT and different sizes)

Accuracy

1 % (U/I),


1.5 % calculated value (P)
(at 0°C ... +55°C, of the full scale value)

Build in energy efficiency and power management with the Power & Energy Meter. This cost-effective analyzer is simple to deploy and is standard build in CAL-C-xx modules. Module with Power meter comes on standard DIN Rail and should be installed in each compressor to monitor power:

Measures AC Current, AC Voltage, Amp Hour (Ah), Amps (A), Kilowatt Hours (kWh), Kilowatts (kW) , Power Factor (PF), Volt-Amp Reactive (VAR), Volt-Amp Reactive Hour (VARh), Volt-Amps (VA), Volts (V), Watt Hours (Wh), Watts (W)Range: 90-600VAC – Wye or Delta configurations

PRESSURE DETECTION AND CONTROL

The CALMS PM-X utilizes the signal from a 4-20 mA pressure sensor that is mounted remotely from the CALMS PM-X in a suitable location in the compressed air system.

The factory default settings for the pressure sensor is 0–232 PSI (16 bar), but the CAEMS PM-X can accept any pressure sensor with a 4–20 mA output and a range of up to 8700 PSI (600 bar), which is changeable through the CALMS PM-X HMI.

6 — INSTALLATION OVERVIEW

INSTALLATION

It is recommended that installation and commissioning be carried out by an authorized and trained product supplier.

UNIT LOCATION

The CALMS PM-X can be mounted on a wall using conventional bolts. The CALMS CS-X can be located remotely from the compressors. The CALMS CS-X must be located within 330 feet (100 meters) of the system pressure transducer.

POWER SUPPLY

A fused switching isolator must be installed to the main incoming power supply, external to the CALMS PM-X. The isolator must be fitted with a properly sized fuse to provide adequate protection to the power supply cable used (in accordance with local electrical and safety regulations.

.Supply voltage is to be connected on the pins L and N. Accepted voltage is AC 100 – 230 V AC.

PRESSURE SENSOR LOCATION

The system pressure sensor (P) must be located where it will see the air pressure that is common to all of the compressors

Dry side pressure will be lower than the system pressure due to pressure differential losses across air treatment equipment. The nominal system pressure will reduce as the air treatment differential pressure increases.

Ensure each compressor is equipped with independent excess pressure shutdown. An increase in pressure differential across air treatment equipment can result in excess compressor discharge pressure.Regular routine monitoring of pressure differential across air treatment equipment is recommended.

PRESSURE SENSOR CONNECTION

The pressure sensor connects to terminal AI1 or AI2 of the CALMS PM-X using a shielded 18 AWG maximum 2-conductor cable no more than 330 feet (100 meters) in length. The transducer threads are BPT. It is the equivalent of ¼” NPT.

                                  
FLOW SENSOR CONNECTION

The flow sensor connects to terminal AI1 or AI2 of the CALMS PM-X terminal PCB using a shielded 18 AWG maximum 4-conductor cable no more than 330 feet (100 meters) in length. The transducer threads are BPT. It is the equivalent of 1/2” NPT.

OPTIONAL ANALOG SENSOR CONNECTION

CALMS PM-X is equipped with 8 analog inputs, of which 6 are free usable as customer desire. Usual use for free analog inputs are any 24V DC supplied, 4…20 mA sensors such as: additional pressure sensor, temperature sensor, dew point meter, sensors for HRS, etc…  Any sensor can be optionally ordered as part of the CALMS PM-X. Ask your CALMS PM-X supplier for additional sensors

.CAL-C-XX INTERFACE MODULE

The CAL-C-XX is designed to interface a compressor with the CALMS PM-X. Each compressor in the system must be assigned a unique identification number from 1 up to the number of compressors in the system. The identification number should be clearly indicated on each compressor for operational reference.The CAL-C-XX is a DIN rail mountable module designed to be installed within the compressor starter enclosure.Each air compressor must be equipped with a load/unload regulation system and, if not regulated with a single electro-mechanical pressure switch, have a facility for a remote load/unload control with the ability to accept a volt-free switching contact input for remote load/unload. Each air compressor must have Auto Restart capability.The CAL-C-XX accepts a 12V to 250V input voltage detection system and utilizes universal relay contact control outputs (250V “CE” / 115V “UL” @ 5A maximum) integrated directly into the circuits of an air compressor. The CAL-C-XX avoids the need for additional relays or remote inputs. The CAL-C-XX also acts as an electrical barrier between the compressor and the CALMS PM-X providing protection and voltage isolation.EtherCAT data communications and other low voltage signals can be subject to electrical interference. This potential can result in intermittent malfunction or anomaly that is difficult to diagnose. To avoid this possibility always use earth shielded cables, securely bonded to a known good earth at one end. In addition, give careful consideration to cable routing during installation.

  • Never route an EtherCAT data communications or low voltage signal cable alongside a high voltage or 3-phase power supply cable. If it is necessary to cross the path of a power supply cable(s), always cross at a right angle.
  • If it is necessary to follow the route of power supply cables for a short distance (for example: from a compressor CALMS PM-X to a wall along a suspended cable tray) attach the EtherCAT or signal cable on the outside of an earthed cable tray such that the cable tray forms an earthed electrical interference shield.
  • Where possible, never route an EtherCAT or signal cable near to equipment or devices that may be a source of electrical interference (for example: 3-phase power supply transformer, high voltage switchgear unit, frequency inverter drive module, radio communications antenna).


INTERNET CONNECTION SETUP

Depending on your order and/or appliance of CALMS, CALMS box can be shipped with a 3G/4G router or a smart LAN ROUTER. Below are the instructions to assure proper connections are established. Please read carefully this part of the manual. Any errors performed in this step of the setup will make log upload impossible to use. ROUTER 3G/4G: To setup a 3G /4G PMrouter you will need a normal SIM card or MicroSIM card with an adapter. Make sure that you disable the PIN number on the SIM card. All routers come with preconfigured settings based on provided mobile provider.SIM card has to be inserted into SIM card slot. Slot is to be opened by unscrew the black screw on the red insert. Once the slot is out, you need to place the SIM card so it fits nicely. After that you can insert the slot back in and restart the GPRS router.

ROUTER X

All ROUTERX shipped with your CALMS box are preconfigured and ready to use. If your CALMSS box is shipped with a ROUTER X that means, that you have a secure and stable internet access nearby the compressor station. All that is needed in this case is to connect your LAN cable with the ROUTERX. For connecting your LAN to the ROUTERX please refer to the table below.

CONNECT YOUR INTERNET CABLE AS IN TABLE BELOW

PORT No.Eth0 / PoE INEth1Eth2Eth3Eth4 / PoE OUT
DEDICATED TO:SERVICE PORTWAN – incoming internet connectionCAEMS BOXSPARE PORTSPARE PORT

7 — PM CONTROL FEATURES AND FUNCTIONS

Each of down described CALMS PM-X Control features are optional and must be purchased in order to become possible to use.

EMCS – ENERGY MANAGEMENT CONTROL SYSTEM

PRESSURE CONTROL

Pressure control is achieved by maintaining the system pressure within an acceptable range, or pressure band, which is defined and programmed by the user. Pressure will rise in the band when system demand is less than the loaded compressor’s output. Pressure will fall when system demand is greater than the loaded compressor’s output.Simply stated, pressure control is achieved by starting/loading and turning off/unloading compressors to closely match compressor output with system demand within a specified pressure band defined by Pressure Tolerance.Variable speed compressors also operate within the pressure band and actively match compressor output with system demand by speeding up and slowing down around a target pressure defined by the exact midpoint of the pressure band defined by Psp + dif (Psp – pressure set point, tol. – pressure tolerance). The EMCS will take no action if (Psp-Ptol < P < Psp+Ptol)

The variable speed compressors in the system will run on their target pressure and smooth out the variations in system pressure. This assumes that system demand does not vary more than the capacity of the variable speed compressor.

ANTI-CYCLING CONTROL

The most efficient way to utilize most air compressors is either fully loaded or off, with the exception of variable speed compressors which can operate efficiently at reduced loading. Compressor cycling (start-load-unload-stop, etc.) is essential to maintain pressure control. Excessive cycling, however, can result in poor compressor efficiency as well as increased maintenance. Anti-cycling control is incorporated to help ensure that only the compressors that are actually required are started and operating while all others are kept off.

SYSTEM VOLUME

System volume defines how fast system pressure will rise or fall in reaction to either increased/decreased demand or increased/decreased supply. The larger the system volume, the slower the pressure changes in relation to increased/decreased demand or supply. Adequate system volume enables effective pressure control and avoids system over-pressurization in response to abrupt pressure fluctuations. Adequate system volume is created by correctly sizing and utilizing air receivers.

The most accurate way to determine the size of air receivers or the additional volume required would be to measure the size and duration of the largest demand event that occurs in the system, then size the volume large enough to ride through the event with an acceptable decrease in system pressure. Sizing the volume for the worst event will ensure system stability and effective control over all other normal operating conditions.If measurement is not available, then estimating the largest event is a reasonable alternative. For example, assume that the largest demand event could be equal to the loss of the largest operating air compressor. System volume would be sized to allow time for a back-up compressor to be started and loaded with an acceptable decrease in pressure.The following formula determines the recommended minimum storage volume for a compressed air system:

V – “Volume of required storage” (Gal, Ft3, m3, L )

T – “ Time of start Back-up Compressor” (Minutes)

C – “Lost Capacity of Compressed Air” (CFM, m3/min)Pa – “Atmospheric pressure” (PSIa, BAR)

ΔP – “Allowable Pressure Drop” (PSI, BAR)

EMCS STANDARD FUNCTIONALITY

Which compressor is next to start/load or stop/unload is specified by PRIORITES. We have two types of priorites: START and STOP PRIORITES. Start priorites are used when next compressor for start or load is required, and stop priorites are used when next compressor for stop or unload is required.

*IMPORTANT:PRIORITY MUST NOT BE SET TO ZERO. TWO COMPRESSORS CAN’T HAVE SAME PRIORITY NUMBER!!!*Compressor with the 1. start priority will be started first, compressor with 8. start priority will be started last. Compressor with 1. stop priority will be stopped first and compressor with 8. stop priority will be stopped last.

EXAMPLE:

PM-4 Each priority consists of 4 digits ( PM-4) or 8 digits (PM-8). First digit represents priority number of first compressor (C.01) in the system, second digit represents second compressor (C.02) in the system, third digit represents third compressor (C.03) in the system, fourth digit represents fourth compressor (C.04) in the system.** Starng priority: 234Stopping priority**: 2143In upper example compressor four (C.04) is first to be started/loaded and compressor three (C.03) is last (fourth) to be started/loaded. When we are unloading/stopping compressor and we refer on upper stopping priority we see that compressor two (C.02) is first to be stopped/unloaded and compressor three (C.03) is last (fourth) to be stopped/unloaded.

CONTROL MODES

EMCS provides three different modes of compressor regulation: Priority Rotation mode, Schedule mode and Energy mode. Control modes or control strategies is a way to control system know which compressors to run or stop. Control system start/load and stop/unload compressors according to what priority they have. If we want to run another compressors we have to change their priorites. According to selected control strategy system gets the right priority configuration and »drives« the CAS according to them. Only one control mode can be enabled at once. System will not allow two enabled control modes at once.

PRIORITY ROTATION MODE

In this mode priorites are cyclicaly rotated. The operator sets »Primary« and »Secondary« priorites, number of days (how often priorites rotate) and »Priority Rotation« enabled or disabled. If »Priority Rotation« is enabled the priorites will rotate otherwise only Primary priorites will be used.By default this mode is selected and »Priority Rotation« is disabled.

SCHEDULE MODE

Schedule mode allows user to define nine different schedules. For each schedule you enter start day, start hour, start min and priority for each compressor. If two schedules have the same start day, start hour and start time the higher numbered schedule will have priority.

ENERGY MODE

You choose energy mode when you want your system works energy efficient. System flow is measured and you can define in which flow zone each compressor is working. Controller calculates average system flow every X (set from HMI) hours and depending how the user sets priorities starts the correct compressors for that demand.

CONTROL FUNCTIONS

PRIORITIES CHANGE FUNCTION

Every time when priorities are changed and new priorites are assigned to compressors function of priorites change is activated. The algorithm is designed that in first 2 minutes of function compressor with start priority 1 and compressor with start priority 2 are started. We can also disable starting 2nd compressor if this is not needed in certain system. If they are already running nothing happens.

AUTO START/STOP COMPRESSOR STATION

Function offers us automatic stop and start of whole compressor station. That can be done manually through HMI interface or we can set schedule on daily base and system wil automatically starts and stops the compressor station. For detailed explanation see Section 8.

SHUT OFF VALVES

System offers us to regulate three ON/OFF shutoff valves through DOR outputs. We can manually OPEN-CLOSE valves through HMI interface or we can adjust schedule on daily base for each valve seperately.For detailed explanation see Section 8.

CALMS CFC-C

CALMS CFC is an advanced Flow Controller which separates supply side (compressors) and demand side(users). It main purpose is to maintain constant system pressure no matter on system demand. Compressor control can be designed to achieve best energy efficiency. Usually this is done by rising pressure on supply side so that we increase air storage so there is no need of activating new compressor in case of quick air demand change.Goal of CFC is lowering pressure on demand side to its lowest acceptable point what leads to maximum energy efficiency. CFC is regulated through PID regulator that has response sensitivity +/- 0.05 bar.

**FLOW CONTROL WITH PI(D) REGULATOR    **

CFC controls the flow to maintain the stable pressure on demand side. To achieve that it uses PI(D) regulator. Proportional-Integral-Derivative (PID) control is the most common control algorithm used in industry and has been universally accepted in industrial control. The popularity of PID controllers can be attributed partly to their robust performance in a wide range of operating conditions and partly to their functional simplicity, which allows engineers to operate them in a simple, straightforward manner. CFC is shipped with some default PID parameters values which must be fine set for each system differently. There are some methods how to tune the system parameters correctly. We recommend that parameters are not changed drastically. How parameters can be changed will be explained in next section.

PROPORTIONAL BAND

Proportional control varies the signal sent to the valves as a linear response to the difference between the actual system pressure and the system pressure setpoint. Valve responsiveness can be adjusted through the CFC Controller with the proportional band (“band”), setpoint. This scaling factor is the amount of change in the input variable (actual minus setpoint pressures) to cause a full scale change in the output variable (valve position).In other words, if the pressure in the air system fluctuates frequently, it would be prudent to set band to a low value to keep up with those system changes. Otherwise, if the system is very stable, a larger value can be used. Band is directly related to valve life and indirectly related to valve cycling; so, as band decreases, valve life decreases and cycling increases. As stated earlier, the CFC Controller uses a proportional plus integral control algorithm. The result of proportional only control is offset from the controlled variable, discharge pressure. Proportional control only functions when a difference or error exists. Design discharge pressure could not be attained in a proportional only control system. Therefore, an integral control algorithm is added to achieve the desired discharge pressure

INTEGRAL TIME

The offset produced by the proportional control algorithm could be eliminated by Integral time. Integral control, also known as reset control, automatically resets the desired system pressure setpoint. For the CFC controller, the rate at which the controller resets the system pressure setting is known as Integral Time (IT), and is expressed in minutes between reset. If precise control of the specified discharge pressure is required, the IT  setpoint should be set for a fast value. It is directly related to valve life and inversely related to valve cycling, therefore, as IT increases, valve life increases and cycling decreases. When band is low and IT is fast, valve activity is significant in both magnitude and frequency to obtain the desired setpoint. The other scenario, band is high and IT is slow, has relatively little valve activity, and may never reach the setpoint position. Proportional Band and Integral Time are variables used internally by the control system to determine valve response and direction for a given compressed air system. Each has an optimum value based upon the system’s characteristics. Determining these optimum values is a trial and error exercise. These setpoints should be re-evaluated any time there is a major change in the compressed air system.CALMS System will send and alarm message in case of system change and must be regularly monitored on CALMS web to be able to  adjust CFC accordingly.

Empty system fill option

CFC controls also the pressure before (upstream) at the delivery point. When the system is empty (upstream pressure is lower then 2 bar) and if this option is selected CFC will close so that compressors can build pressure at the production site, before slowly open with predefined ramp until setpoint pressure is reached. With this option dryers and filters will operate at design pressure and less water will come to the system.

CFC Bypass Valve

Every CFC is equipped with bypass valve which is opened in case of mailfunction or other unpredictable issue. It opens if pressure drops below CFC setpoint for more than defined on HMI.

For detailed explanation see Section 8.

8 – HMI OP OPERATOR PANEL OVERVIEW

PM-2 and PM-4 are using smaller 4,3’’ HMI, PM-8 is using bigger 7’’ HMI.

4,3’’ HUMAN MACHINE INTERFACE (FOR PM-2 AND PM-4)

STATUS SCREENS

CAEMS can be ordered with an optional HMI operator panel.  When powering up the unit the operator panel (OP) will display the HOME screen.

Pressing the  icon will send you to the CAEMS status menu. Here you have an overview of your sistem. The  squares on the right represent ALARM, EMCS, CAEMS and compressors status.

If any of the states in the upper right corner is active the signal lights will lid up. Below is a picture to represent the status light color. Alarm LED is ON when system alarm is active. Which alarm is active you can check in Alarm status page.EMCS light is ON if EMCS Control feature is enabled. CAEMS light is ON if CAEMS is activated in general settings, pressure is beyond critical and at least one compressor is running.

In the right corner below there are 4 status light to indicate single compressor state. Compressor states are:

                                        

STOPPED               RUNNING               LOADED                 ALARM!

Below compressor state light you can see temporary % load of the compressor. If compressor is VSD and it is running loaded this % changes from 0-100%. If compressor is ON/OFF and it is running loaded this % indicates full load (100%). If compressor is running unloaded or is turned off this % indicates no load (0%)
You can navigate the menu by pressing any of the avaliable buttons. To return to home page press the  button.Pressing the button will activate the CAEMS status menu, which is composite by several different pages:On the first status page compressor digital states are visible.

If any state is active, the lights will turn on in color, otherwise the displayed color is gray. Upper light represent the same states as in REVIEW page.

You can jump directly to compressor power analyzer state by pressing the name close to the compressor symbol.  On the PM-X there are 4  compressor power measurement pages. Here are displayed power related measured values.Notice the CAL-C-X text . If the text is colored GREEN a CAEMS compressor module is connected and recognized, otherwise the text color is RED!

If compressor has enabled MODBUS communication an extra button is displayed. By pressing this button you enter to compressor MODBUS parameters pages.

Here are three MODBUS pages. How many parameters is shown depends which controller is selected. (See belowàCompressor settings). On first page you can see first 14 parameters.

On last third page you can se pressure parameters, alarm and warning codes for further analysis

The second page of the CALMS STATUS group represents CALMS PM-X digital input states. Each PM has by default eight digital inputs. If a digital state is active the representing light will light up.

Pressing the up  button from this screen will show the main selection screen, otherwise pressing   will show the next/previous screen. The analog inputs screen displays values that needs to be entered in the SETTINGS menu. When settings are completely filled, the input tags and measurement values will be displayed in real time as in picture above. Here you can also access to TRENDS menu. Moving trough the menu is achieved by pressing the  buttons.

Next page indicates compressors hours. Hours are calculated via running and loaded signals or via MODBUS states if enabled. The hours can be corrected by clicking on fields, but you have to be login as manager.

Next page shows us active alarms. If no alarm is present the fields are empty. Possible alarms are:Critical pressure, AI probe alarm, DI alarm, Voltage Imbalance alarm, Compressor 1-8 alarm, C.01 to C.08 alarm and EMCS Fault Compressor 1-8.

Next page shows energy consumption totalizers. System calculates energy consumption for each compressor and for additional fourAi’s that can be selected in CALMS settings (login as operator required). Total energy consumption is sum up of all compressors and additional 4 AI’s energy consumptions. You can reset each energy consumption by pressing button (press and hold for 1 sec, login as operator required).

Next page shows air consumption totalizers. System calculates air consumption for selected System flow (this can be selected in CALMS settings Meter display settings, login as operator required) on HMi visible as Total air consumption and also calculates totalizers for additional four Ai’s which are calculated independately of total air consumption. (if you have flowmeter installed on one of production lines and you want to know what is the air consumption of this line, you select this AI as additional AI for air consumption totalizer)

Next page will display MODULE C.01 power management, next MODULE C.02 power management and so on ..

Returning to the REVIEW page is done by pressing the up  button.

By clicking on you will enter the Shut Off Valves status menu. NOTE: This feature must be enabled to be possible to enter those status menus.Here you can see statuses of all three SOV. Red or green color of specific valve ( , ) tells us if specific SOV is enabled or disabled. Red color means that this SOV is disabled (its regulation is disabled), green color means that this SOV is enabled (its regulation is enabled).Each SOV is recognized through “SOV Name” which is given in SOV settings (must be logged in as Operator). Each SOV can be in AUTO or MANUAL mode. Manual mode means that valve can be opened or closed via HMI interface by switching the Open-Close switch. If SOV is in AUTO mode means that valve is opening, closing via schedule which is set on daily base.Position of SOV indicates the position of specific SOV.
Returning to the REVIEW page is done by pressing the up  button. By clicking on you will enter the CFC Status page. NOTE: This feature must be enabled to be possible to enter those status menus.

On CFC Status page we can see all the vital system and CFC parameters.(Statuses of compressors, position of CFC valves, Inlet and Outlet pressure, Setpoint value and System flow. On the top of the window is a status bar which indicates if which regulation mode CFC is. Here is in MANUAL mode. That means CFC valves can be regulated manually via HMI interface in CFC Settings (must be logged in as operator).

Returning to the REVIEW page is done by pressing the up  button. By clicking on  you will enter the EMCS Status page. NOTE: This feature must be enabled to be possible to enter those status menus.On first EMCS status page you can see all the compressors states (Compressor stopped, loaded, unloaded, alarm, remote control enabled). You can also see what is the pressure status and what is the ECMS status. EMCS status tells us what EMCS function is doing, for example: loading new compressor, starting new compressor,…On the top right corner we can see what is the enabled control mode (Priority mode, Energy mode or Schedule mode).

You go to next page by clicking  icon. On next page you can see actual compressors stop and start priority.

TREND SCREEN

By pressing the   button it will show the Analog inputs trends screen. Here you will be able to investigate a single  AI values at desired time. Pressing the up  button from this screen will show the main selection screen.

When any AI0X button is pressed the following screen will be shown

:

Pressing the up  button from this screen will show the TRENDS selection screen. Buttons  will move to previews/next analog input trends.  In the upper left corner you will find a camera icon  . Pressing it will save a print screen of the opened page. Right to the forward button is displayed the analog input number/name . Pressing it will open a history window from witch you will be able to safe a csv file of the input values by pressing the  save icon ( save to USB if present ).

Returning to the main selection screen is performed by repetedly pressing the up   button.

ALARM SCREEN

By pressing the  button will show the ALARM screen

Here you will be able see any alarm that has been recorded by the CALMS system. Alarms must be acknowledged by pressing on the alarm text (text color with turn to green). Pressing the up  button from this screen will show the main selection screen

SETUP

Next on the main window is the SETUP icon . Pressing it will show the SETUP page.

LOGIN SCREEN

Before you can actually enter or enable any setting a operator login is mandatory. This is done by the following procedure.By pressing the   button in the main manu you will be showed the login screen. Here you can see which functions are purchased and enabled.

Operator is to be select by a dropdown menu,

Password is to be inputed by user. Prior to that any change is uneditable.
After succcesfull login additional options can be enabled. Enabling the option will be seen by activity light and text change. Please notice that not all option are avaliable. Which options will be avaliable is determined by the option your CALMS is shipped. In the picture below CFC,EMCS and SHUTOFF VALVE options are purchased therefore are all avaliable to use.

Pressing the up button from this screen will show the SETUP screen. After enabling additional options the SETUP page menu looks different:

CALMS SETTINGS SCREEN

By pressing the  button will show the SETTINGS screen. There are several screens where you can input system settings.

CALMS PM-X ANALOG STATES SETUP

Here you MUST input Analog inputs name, min values, max values and measuring units. Pressing on an empty box under Analog input name or AI Units opens a keyboard.

After entering desired text press the Enter button to confirm input and hide keyboard, or ESC to cancel inputs and hide keyboard. Pressing the gray button under the Minimum or Maximum AI range will open a numerical keyboard for entering numerical data.

CURRENT TRANSFORMER RANGE

Current transfomer range must be entered here for each CAL-C module (Compressor). Buttons in the lower left corner  still have the same functionality as on other screens.

COMPRESSOR NAMES

Compressor names can be given names through this input page.

DIGITAL INPUT AS ALARM

Here you can choose which DI`s you will use as ALARM inputs. If specific DI is used as ALARM means that after 5s of active state alarm output DO4 will be activated and also CALMS Alarm will be triggered.

DIGITAL INPUT TYPE SELECTOR

Depending on what type of digital input you need (NO, NC) different inputs states and logic can be selected here. Here you can set for all DI’s that are available in your device.

METER DISPLAY SETTINGS

Here you can choose, depending on which AI is your system pressure, the correct AI. Same for system flow. In case system flow is on multiple AI`s you select “Multiple AI`s” and choose correct analog inputs. Sum of all AI`s is your system flow from which Specific power is calculated.
If you don’t have connected flowmeter to any of AI’s you can choose “Calc Flow” and system will calculate the flow. In this case nominal flow of compressors must be set correctly, otherwise calculation of flow will not be correct. Here you can also check what is the MAX RANGE of calculated flow. Default value is 300 m3/min. If necessary it can be changed, but you have to be login as Manager. This MAX Range value is value which is set on CALMS WEB interface as MAX Range of AI21. (AI21 is reserved for calculated flow)

ALARM SETTINGS

Here you can choose which analog inputs are connected to 4-20mA sensors. System will than constantly checking those inputs. In case of under or over current of the analog input alarm will be triggered.

UNIT SELECTION

On unit selection page you can adjust units for pressure, flow, specific, temperature and volume. This settings must be set correctly and same units must be used on analog input settings page, because system is doing some calculations based on those settings.

TOTALIZERS

On this page you can adjust four additional analog inputs for totalizer calculation. Adjust four additional AI’s for energy consumption which will be added to total energy consumption ( compressors energy consumption + additional AI’s energy consumptions = total energy consumption). Adjust four additional AI’s for air consumption, which are independently calculated and have no relation with total air consumption which is based on system flow measurement. If none is selected means that system will not calculate certain additional TOTALIZER. 

GENERAL SETTINGS

Here you can acess the HMI setting page and enable or disable the PM-X functionality.Minimal critical pressure is used to automatically set PM-X ENABLE/DISABLE button to off if pressure is under that value and all compressors are shutdown. Line voltage setting is used for power calculation ( see below). You can also choose energy specific display or power specific display.

On this page users can select HMI display language by language selector :

Depending on user location and expected language the selection can be upgraded. After finishing the setting up of the input return to SETUP page by pressing the  button.

EMCS SETTINGS

If EMCS is purchased and enabled in login page you can acess EMCS SETTINGS by pressing the EMCS SETTINGS button   and a setup screen for the control system will be displayed. Here you can input EMSC options such as control pressure, timers and control mode.Navigate the pages with the navigation buttons as usual.

PRESSURE SETTINGS

On this page user setups EMCS pressure parameters.PRESSURE SETPOINT: is the desired pressure of the systemCRITICAL PRESSURE: is the minimum pressure of the system. If pressure goes below that point an alarm will be issued and additional compressors will be started.PRESSURE SETPOINT OFFSET: is the below and under Pressure Setpoint setting. If pressure reaches (Pressure Setpoint + Pressure Setpoint Offset) next compressor will be unloaded and if pressure falls below (Pressure Setpoint - Pressure Setpoint Offset) next compressor will be loaded.MAX. CRITICAL PRESSURE: If pressure reaches this set value emergency stopping of compressors is followed.On this page you can also select on which AI is connected pressure sensor for EMCS regulation.

If pressure settings are setup as above the EMCS will try to maintain a system pressure between 7,5 and 6,5 bar. If pressure goes higher compressor will be unloaded, if pressure falls below next compressor is loaded.

TIMERS

On this page user setups EMCS TIMER settings:NORMAL START: time that EMCS will wait before starting compressor in the system if system pressure falls below (Pressure Setpoint - Pressure Setpoint Offset).CRITICAL START: time that EMCS will wait before starting another compressor if system pressure falls below critical pressure set pointLoad/Unload: time that EMCS will wait before loading or unloading next compressor.Unload Stop(long): time in which next unloaded compressor will be stoppedUnload Stop(short): time in which next unloaded compressor will be stoppedDifference between long/short timer is in the number of unloaded compressor. If only two or less compressors are unloaded than long timer is used, otherwise short timer is used.Delay between starting: time that EMCS will wait unit starting next compressor (normal and critical conditions)

IMPORTANT! PRIORITY MUST NOT BE SET AS ZERO. TWO COMPRESSOR CAN’T HAVE SAME PRIORITY NUMBER!!!Compressor with the HIGHEST starting priority number will be started FIRST, compressor with LOWEST starting priority number will be started last.Compressor with the HIGHEST stopping priority number will be stopped FIRST, compressor with LOWEST stopping priority number will be stopped last.
EXAMPLE: PM-4 Each priority consists of 4 digits ( PM-4) or 8 digits (CS-8). First digit represents priority number of first compressor (C.01) in the system, second digit represents second compressor (C.02) in the system, third digit represents third compressor (C.03) in the system, fourth digit represents fourth compressor (C.04) in the system.** Starng priority: 234Stopping priority**: 2143In upper example compressor four (C.04) is first to be started/loaded and compressor three (C.03) is last (fourth) to be started/loaded. When we are unloading/stopping compressor and we refer on upper stopping priority we see that compressor two (C.02) is first to be stopped/unloaded and compressor three (C.03) is last (fourth) to be stopped/unloaded.

CONTROL MODE

Here you select desire control mode. Only one mode can be selected. You can adjust settings of control mode by clicking on specific icon. You can click the icon before enabling specific control mode.

PRIORITIES

In this control mode you have two possible options. One option is to adjust only Primary Starting Priorities and Primary Stopping Priorities. You can also enable Switching Prio option and system will then change the compressors priorites every defined hours.The LED shows us which priorities are used at the momentàPrimary or secondary.

ENERGY MODE SETTINGS

Input your flow values and priorities will be acceppted if system flow is in determined range. Determine the flow average time calculation.

SCHEDULES

You can input nine different schedules. When specific schedule is active the correct priorities will be accepted. Operator can set the start day, hour, min, starting priorites and optional stopping priorites. With enabling certain schedule the system will start using those settings.** START DAY:** Operator can choose from Monday, Tuesday, Wednesday, Thursday, Friday, Saturday, Sunday, Daily, Week Day (Monday-Friday), Week End (Saturday, Sunday).HOUR: 0-23 (can only be sleected by )MIN: 0-59 (can only be selected by )If two schedules have the same start day,  hour  and min the higher numbered schedule will have priority.

Compressor System Stop-Start FUNCTION

On this page user can stop and start whole COMPRESSOR SYSTEM (CS). By activating this function system will calculate how many compressors are needed to fill the system in prefill time specified by operator. So, when “Auto Start CS” button is pressed, system starts compressors ( how many is calculated from “Pressure tank capacity” and “Prefill time”). When pressing “Auto Stop CS” all compressors will be stopped and system will wait for next command to start CS.

If Start/Stop schedule is enabled, operator has option to adjust schedule when CS will start and when stop. On picture below we see that schedule for Monday is disabledàRed LED (If hour for start and stop is 24 then schedule for this day is disabled). For Tuesday we see that schedule is enabledàGreen LED and time is set. Compressor station will start at 5.30 and stop at 15.00.Here you can adjust schedule for each day.

After finishing setup return to the SP page by pressing the UP button.

CFC SETTINGS

From the SETUP PAGE, if the option is purchased and enabled pressing the  button enters the CFC menu.Here is the main setting page for CALMS Flowcontroller (CFC). Operation mode can be Manual or Auto. In Manual mode we can manually open MRV1 valve from 0-100% in order to test its functionality.

In Auto mode we set the Setpoint value of Pressure that we want to maintain after Flowcontroller. We have Default setpoint which is used if there is no other CFC Function selected, otherwise other Setpoints are used.Also for BRV1 valve we have Manual or Auto mode. In Manual mode we can also manually open BRV1 valve from 0-100% in order to test its functionality. In Auto mode we adjust the CFC Pressure Diference. If pressure falls below Setpoint-CFC Press. Diference CFC opens in order to raise outlet pressure

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With clicking on icon you are redirected to CFC status page, which is described in upper pages

System offers to set the Setpoint for CFC from two different functions. If none function is selected Default Setpoint is used.

DI Setpoint Function

Here we can set Setpoint via three digital inputs which are predefined (DI6, DI7, DI8). When certain DI is activated it turns green and at the bottom on right side you can see which Setpoint is used at the moment.

Only one DI can be activated at once otherwise DI Setpoint Alarm is triggered and Default Setpoint is used.

CFC Schedule Function

Here you can adjust schedule for CFC. For each day you can adjust two different setpointsà SP1 and SP2. When specific Setpoint is used it turns green. If time adjustments are not OK (if hour setting is 24, or both SP of the same day have set same time) the setting for Setpoint disappears and system will not use this SP.

IMOP

Pressing the button enters the IMOP menu. A readings reset button per compressor is available.  IMOP is a function that monitors and writes values of all AIP variables (all voltages, all currents, all CosFi-s, reactive power, real power,…) in CSV format and uploads it. If compressor is ON/OFF type it writes and uploads both states in difference from VSD compressors for which writes and uploads only one state à RUNNING. By resetting IMOP readings will be performed and uploaded again

SHUTOFF VALVE SETTINGS

Pressing the  button enters the SHUT OFF VALVES menu. If this option is purchased, operator can set three different shut off valves. They can be regulated manually ( open-close ) or automatically through schedule setup. We also can set the name of each valve for easier recognization.

If we want to set the schedule, we click on  and then adjust schedule settings for specific Shut off valve. When is green it means that second SOV is enabled, otherwise its regulation is disabled.

VOLTAGE IMBALANCE

Pressing the  button enters the specific menu. Here you can view function status, activate readings and reset all voltage imbalance readings. Voltage imbalance is a function that uploads an alarm log file when supply voltage varies for more than 3% from rated voltage. When first event happens, a timer of 300 s starts and after the expiry function waits for next voltage imbalance. After third event of imbalance the function locks and waits for manual reset on HMI. If the LOCKED icon  is active a reading has already been uploaded. Press and hold the reset button to reactivate reading and uploading data.

ANALISYS LOG FUNCTION

Pressing the  button enters the LOG menu. When you activate this function, system uploads all values of all variables from 1 minute before and 1 minute after the function has been activated.

INFO & HELP SCREEN

The remaining buttons on the main selection screen display Info and Help for the CALMS – CAL interface.

EVENT LOG

From main menu go to event log page by pressing the icon. Event log is self-explanatory.

ALARM LOG

From main menu go to alarm log page by pressing the icon. Alarm log is self-explanatory.

9 HUMAN MACHINE INTERFACE (FOR PM-8)

STATUS SCREENS

CALMS can be ordered with an optional HMI operator panel.  When powering up the unit the operator panel (OP) will display the HOME screen.

Pressing the  icon will send you to the CALMS status menu. Here you have an overview of your sistem. The  squares on the right represent ALARM, EMCS, CALMS and compressors status.

If any of the states in the upper right corner is active the signal lights will lid up. Below is a picture to represent the status light color. Alarm LED is ON when system alarm is active. That means if pressure is below critical value, if any of compressors is in alarm or one of auxilliary CAL-C modules is disconnected.EMCS light is ON if EMCS Control feature is enabled. CALMS light is ON if CALMS is activated in general settings, pressure is beyond critical and at least one compressor is running.

In the right corner below there are 8 status light to indicate single compressor state. Compressor states are:

STOPPED               RUNNING               LOADED                 ALARM

                                 

You can navigate the menu by pressing any of the avaliable buttons. To return to home page press the  button.Pressing the button will activate the CALMS status menu, wich is composite by several different pages:On the first status page compressor digital states are visible.

If any state is active, the lights will turn on in color, otherwise the displayed color is gray. Upper light represent the same states as in REVIEW page. On the top you can also see name of the compressor.

You can jump directly to compressor power measurement by pressing the  On the PM-8 there are 8  compressor power measurement pages. Here are displayed power related measured values.Notice the CAL-C-0X text . If the text is colored GREEN a CALMS module is connected and recognized, otherwise the text color is RED!

If compressor has enabled MODBUS communication an extra button is displayed. By pressing this button you enter to compressor MODBUS parameter pages.
In MODBUS parameter page you can see detailed compressor performance. How many parameters is shown depends what is  the type of the compressor controller.

The second page of the CALMS STATUS group represents CALMS PM-8 analog and digital input states. Each PM has by default eight digital and eight analog inputs. If a digital state is active the representing light will light up.The analog inputs screen displays measured values. When settings are completely filled, the input tags and measurement values will be displayed in real time.You can also check AI Probe alarm. This light will become red if any of connected sensors is faulty. (it must be set in settings)

Pressing the up  button from this screen will show the main selection screen, otherwise pressing   will show the next/previous screen. On next 4 status pages you can see power analyzer values for each compressor.Next status page is compressors hour status page. Hours are calculated via running and loaded signals or via MODBUS if enabled. The hours can be corrected by clicking on fields, but you have to be login as manager.

Returning to the REVIEW page is done by pressing the up  button.

By clicking on you will enter the Shut Off Valves status menu. NOTE: This feature must be enabled to enter those status menus.Here you can see statuses of all three SOV. Red or green color of specific valve ( , ) tells us if specific SOV is enabled or disabled. Red color means that this SOV is disabled (its regulation is disabled), green color means that this SOV is enabled (its regulation is enabled).Each SOV is recognized through “SOV Name” which is given in SOV settings (must be logged in as Operator). Each SOV can be in AUTO or MANUAL mode. Manual mode means that valve can be opened or closed via HMI interface by switching the Open-Close switch. If SOV is in AUTO mode means that valve is opening, closing via schedule which is set on daily base.Position of SOV indicates the position of specific SOV.

Returning to the REVIEW page is done by pressing the up  button. By clicking on you will enter the CFC Status page. NOTE: This feature must be enabled to be possible to enter those status menus.On CFC Status page we can see all the vital system and CFC parameters.(Statuses of compressors, position of CFC valves, Inlet and Outlet pressure, Setpoint value and System flow. On the top of the window is a status bar which indicates if which regulation mode CFC is. Here is in MANUAL mode. That means CFC valves can be regulated manually via HMI interface in CFC Settings (must be logged in as operator)

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Returning to the REVIEW page is done by pressing the up  button. By clicking on  you will enter the EMCS Status page. NOTE: This feature must be enabled to be possible to enter those status menus.On first EMCS status page you can see all the compressors signals, system pressure and system flow.

You go to next page by clicking  icon. On next page you can see compressors priorities and which compressor is next to start and stop. Number 9 means that there is none compressor to regulate.

TREND SCREEN

By pressing the   button from system overview page it will show the Analog inputs trends screen. Here you will be able to investigate a single  AI values at desired time.

When any AI0X button is pressed the following screen will be shown:

Pressing the up  button from this screen will show the TRENDS selection screen. Buttons  will move to previews/next analog input trendsReturning to the main selection screen is performed by repetedly pressing the up   button.

ALARM SCREEN

By pressing the  button will show the ALARM screen.

Here you will be able see any alarm that has been recorded by the CALMS system. Alarms must be acknowledged by pressing on the alarm text (text color with turn to green). Pressing the up  button from this screen will show the main selection screen.

SETUP

Next on the main window is the SETUP icon . Pressing it will show the SETUP page.

LOGIN SCREEN

Before you can actually enter or enable any setting a operator login is mandatory. This is done by the following procedure.By pressing the   button in the main manu you will be showed the login screen. Here you can see which functions are purchased and enabled.

Password is to be inputed by user. Prior to that any change is uneditable.

After succcesfull login additional options can be enabled. Enabling the option will be seen by activity light and text change. Please notice that not all option are avaliable. Which options will be avaliable is determined by the option your CALMS is shipped. In the picture below CFC,EMCS and SHUTOFF VALVE options are purchased therefore are all avaliable to use.

Pressing the up  button from this screen will show the SETUP screen. After enabling additional options the SETUP page menu looks different:

CALMS SETTINGS SCREEN

By pressing the  button will show the SETTINGS screen. There are several screens where you can input system settings.

CALMS CS-8 ANALOG INPUT  AND CURRENT TRANSFORMERS RANGE SETUP

Here you MUST input Analog inputs name, min values, max values and measuring units. Current transfomer range must be entered here for each CAL-C module (Compressor). Pressing on an empty box under Analog input name or AI Units opens a keyboard.

COMPRESSOR NAMES AND METER DISPLAY SETTINGS

Compressor names can be given names trought this input page. Here you can choose, depending on which AI is your system pressure, the correct AI. Same for system flow. In case system flow is on multiple AI`s you select “Multiple AI`s” and choose correct analog inputs. Sum of all AI`s is your system flow from which Specific power is calculated.

If you don’t have connected flowmeter to any of AI’s you can choose “Calc Flow” and system will calculate the flow. In this case nominal flow of compressors must be set correctly, otherwise calculation of flow will not be ok. Here you can also check what is the MAX RANGE of calculated flow. Default value is 200 m3/min. If necessary it can be changed, but you have to be logined as Manager. This MAX Range value is value which is set on CALMS WEB interface as MAX Range of AI21. (AI21 is reserved for calculated flow)

DIGITAL INPUT TYPE SELECTOR AND DI AS ALARM SETTINGS

Here you can choose which DI`s you will use as ALARM inputs. If specific DI as ALARM is used it means that after 60s of active state alarm output DO4 will be activated and also CALMS Alarm will be triggered.Depending on what type of digital input you need different inputs states and logic can be selected here. Here you can set for all DI’s that are available in your device.

ALARM SETTINGS

Here you can choose which analog inputs are connected to 4-20mA sensors. System will than constantly checking those inputs. In case of under or over current of the input alarm will be triggered. NOTE: Default there are only eight AI’s.

GENERAL SETTINGS

Here you can acess the HMI setting page and enable or disable the PM-8 functionality. Minimal critical pressure is used to automatically set PM-8 ENABLE/DISABLE button to off if pressure is under that value and all compressors are shutdown. Line voltage setting is used for power calculation ( see below). You can also choose energy specific display or power specific display.

On this page users can select HMI display language by language selector :

Depending on user location and expected language the selection can be upgraded. After finishing the setting up of the input return to SETUP page by pressing the  button.

EMCS SETTINGS

If EMCS is purchased and enabled in login page you can acess EMCS SETTINGS by pressing the EMCS SETTINGS button   and a setup screen for the control system will be displayed. Here you can input EMCS options such as control pressure, timers and control mode.
the pages with the navigation buttons as usual.

PRESSURE SETTINGS

On this page user setups EMCS pressure parameters.PRESSURE SETPIONT: is the desired pressure of the systemCRITICAL PRESSURE: is the minimum pressure of the system. If pressure goes below that point an alarm will be issued and additional compressors will be started.PRESSURE SETPOINT OFFSET: is the below and under Pressure Setpoint setting. If pressure reaches (Pressure Setpoint + Pressure Setpoint Offset) next compressor will be unloaded and if pressure falls below (Pressure Setpoint - Pressure Setpoint Offset) next compressor will be loaded.MAX. CRITICAL PRESSURE: If pressure reaches this set value emergency stopping of compressors is programmed.If pressure settings are setup as above the EMCS will try to maintain a system pressure between 7,5 and 6,5 bar. If pressure goes higher compressor will be unloaded, if pressure falls below next compressor is loaded.

TIMERS

On this page user setups EMCS TIMER settings:NORMAL START: time that EMCS will wait before starting another compressor in the system if system pressure falls below (Pressure Setpoint - Pressure Setpoint Offset).CRITICAL START: time that EMCS will wait before starting another compressor if system pressure falls below critical pressure set pointLoad/Unload: time that EMCS will wait before loading or unloading next compressor.Unload Stop(long): time in which next unloaded compressor will be stoppedUnload Stop(short): time in which next unloaded compressor will be stoppedDifference between long/short timer is in the number of unloaded compressor. If only two or less compressors are unloaded than long timer is used, otherwise long timer is used.
IMPORTANT! PRIORITY MUST NOT BE SET AS ZERO. TWO COMPRESSOR CAN’T HAVE SAME PRIORITY NUMBER!!!Compressor with the HIGHEST starting priority number will be started FIRST, compressor with LOWEST starting priority number will be started last.Compressor with the HIGHEST stopping priority number will be stopped FIRST, compressor with LOWEST stopping priority number will be stopped last.

CONTROL MODE

Here you select desire control mode. Only one mode can be selected. You can adjust settings of control mode by clicking on specific icon. You can click the icon before enabling specific control mode.

PRIORITIES

In this control mode you have two possible options. One option is to adjust only Primary Starting Priorities and Primary Stopping Priorities. You can also enable Switching Prio option and system will then change the compressors priorites every defined days.The LED shows us which priorities are used at the momentàPrimary or secondary.

ENERGY MODE SETTINGS

Input your flow values and priorities will be acceppted if system flow is in determined range. Determine the flow average time calculation.

SCHEDULES

You can input three different schedules that must cover whole week. When next schedule is started previous is aborted. When schedule is active the correct priorities will be accepted.

Compressor System (CS) Stop-Start FUNCTION

On this page user can stop and start whole compressor system ( CS). By activating this function system will calculate how many compressors are needed to fill the system in prefill time specified by operator. So, when “Auto Start CS” button is pressed, system starts compressors ( how many is calculated from “Pressure tank capacity” and “Prefill time”). When pressing “Auto Stop CS” all compressors will be stopped and system will wait for next command to start CS.

If Start/Stop schedule is enabled, operator has option to adjust schedule when CS will start and when stop. On picture below we see that schedule for Monday is disabledàRed LED (If hour for start and stop is 24 then schedule for this day is disabled). For Tuesday we see that schedule is enabledàGreen LED and time is set. Compressor station will start at 5.30 and stop at 15.00.Here you can adjust schedule for each day.

After finishing setup return to the SP page by pressing the UP button.

CFC SETTINGS

From the SETUP PAGE, if the option is purchased and enabled pressing the  button enters the CFC menu.Here is the main setting page for CALMS Flowcontroller (CFC). Operation mode can be Manual or Auto. In Manual mode we can manually open MRV1 valve from 0-100% in order to test its functionality

In Auto mode we set the Setpoint value of Pressure that we want to maintain after Flowcontroller. We have Default setpoint which is used if there is no other CFC Function selected, otherwise other Setpoints are used.Also for BRV1 valve we have Manual or Auto mode. In Manual mode we can also manually open BRV1 valve from 0-100% in order to test its functionality. In Auto mode we adjust the CFC Pressure Diference. If pressure falls below Setpoint-CFC Press. Diference CFC opens in order to raise outlet pressure.

With clicking on icon you are redirected to CFC status page, which is described in upper pages.
System offers to set the Setpoint for CFC from two different functions. If none function is selected Default Setpoint is used.

DI Setpoint Function

Here we can set Setpoint via three digital inputs which are predefined (DI6, DI7, DI8). When certain DI is activated it turns green and at the bottom on right side you can see which Setpoint is used at the moment.

Only one DI can be activated at once otherwise DI Setpoint Alarm is triggered and Default Setpoint is used.

CFC Schedule Function

Here you can adjust schedule for CFC. For each day you can adjust two different setpointsà SP1 and SP2. When specific Setpoint is used it turns green. If time adjustments are not OK (if hour setting is 24, or both SP of the same day have set same time) the setting for Setpoint disappears and system will not use this SP.

IMOP

Pressing the button enters the IMOP menu. A readings reset button per compressor is available.  IMOP is a function that monitors and writes values of all AIP variables (all voltages, all currents, all CosFi-s, reactive power, real power,…) in CSV format and uploads it. If compressor is ON/OFF type it writes and uploads both states in difference from VSD compressors for which writes and uploads only one state à RUNNING. By resetting IMOP readings will be performed and uploaded again.

SHUTOFF VALVE SETTINGS

Pressing the  button enters the SHUT OFF VALVES menu. If this option is purchased, operator can set three different shut off valves. They can be regulated manually ( open-close ) or automatically through schedule setup. We also can set the name of each valve for easier recognization.

If we want to set the schedule, we click on  and then adjust schedule settings for specific Shut off valve. When is green it means that second SOV is enabled, otherwise its regulation is disabled.

VOLTAGE IMBALANCE

Pressing the  button enters the specific menu. Here you can view function status, activate readings and reset all voltage imbalance readings. Voltage imbalance is a function that uploads an alarm log file when supply voltage varies for more than 3% from rated voltage. When first event happens, a timer of 300 s starts and after the expiry function waits for next voltage imbalance. After third event of imbalance the function locks and waits for manual reset on HMI. If the LOCKED icon  is active a reading has already been uploaded. Press and hold the reset button to reactivate reading and uploading data.

ANALISYS LOG FUNCTION

Pressing the  button enters the LOG menu. When you activate this function, system uploads all values of all variables from 1 minute before and 1 minute after the function has been activated.

10 — COMMISSIONING

When commissioning the CALMS PM-X, carry out the following procedures before attempting to start.

It is recommended that an authorized and trained service technician perform the commissioning.

PHYSICAL CHECKS

  1. Before applying power to the CALMS PM-X, ensure the power supply connections are correct and secure and the operating voltage selector is set correctly for the power supply voltage in use (115Vac or 230Vac (+-10%), 50/60Hz).
  2. Open the front panel of the CALMS PM-X and check the location of the link wire(s) connected to the “Voltage Selection” terminals of the power supply PCB. If necessary, change the link wire locations to those illustrated for the voltage in use.

See the section on Installation for more information.

  1. Switch on the power supply to the CALMS PMX.
  2. The control program identification will be displayed for a short period followed by the normal operational user display.

PRESSURE DISPLAY

Check the displayed system pressure. If the pressure is incorrect, or inaccurate, check the type and range of the sensor and carry out the pressure sensor commissioning and calibration procedure. If the display shows an error, this will need to be corrected before continuing. See the Operator’s Manual for troubleshooting and correcting the fault/error condition.

CALMS PM-X QUICK SET-UP CONFIGURATION

Before successful basic operation can be established specific parameters must be entered prior to startup. Please refer to the CALMS PM-X Quick Setup Manual for instruction to accomplish this.

OPTIONAL FEATURES AND FUNCTIONS

Installation requirements may involve the implementation of additional or optional functions and features. Please refer to the appropriate Guide or Manual as required. Below is a list of available features and functions.

Accessories

 

PN

Description

SML-10

Pressure Transducer 0-10 bar / 0-100PSI , NTP200PSI, 0.5%, 12bit with connector and cable 10m

DPT-3070-(16,100,1000)

Differential Pressure Transducer 0-16KpA - 0,25%FS, 0-100 kPa - 0,5%FS, o-1000kpa, Pmax static 1MPa,  4-20 mA

FS10A

Flow meter CALMS OEM FCI FS10A Flow monitor, 4-20mA, calibration 0-122 Nm/s, pipe DN 25-152 mm, 1/2" Male NPT, 12 bit, 2%

CAB-FS10A

Cable with connector 10m for FCI FS10A

VP-FS50

Flow meter VPFlowscope, 4-20mA, calibration 0-122 Nm/s, pipe DN50, 12 bit, 5%

C-PT-PS

Temperature sensor PT100 (ambient) C-PT-PS/I-30-50, -30 - +50C, 4-20 mA (wall mount design)

MWT200

Temperature sensor 0-200C, 4-20 mA, PT100, class.A, G1/2NPT, L=120mm

UT-750

Ultrasonic mechanical noise and vibration detector  with 4 -20 mA output
Sense ultrasonic amplitude changes and guards against unplanned downtime because of mechanical failure on compressor air end or motor
•  output ultrasonic  frequency of 40 kHz
• Detection range up to 120 dB
Mounting kit

DVT-408

Dew Point transmitter with -40 - +50degC, 4-20 mA, +-3degC with pressure chamber and XJZ display, power supply 24Vdc or 220Vac

TDS100R-M2-H

The TDS100RM2-H is a fixed ultrasonic Heat Meter for continuous
measurement of volumetric flow and heat energy.
Accuracy: <1% of reading above 0.6ft/sec ( 0.2 m/sec)
Repeatability: 0.2% fixed installation
Temperature: 2x PT100
Pipe size: DN50 - DN700
Output: 1xRS485, 1x 4-20 mA, 2x DO
Temperature: -40  - +160 C

OP-HMI4.3 Eth

Operator panel HMI 4.3 inch 480x272 Touch-  Ethernet with
Resolution (W x H) 480 x 272
Remote VNC , local scada

CAL-OPTICS :

Optics connection kit add-on for one compressor:
1-port EtherCAT multi-mode fiber optic junction, distance max.2 km
EtherCAT Coupler with ID switch, multimode fiber optic for E-bus terminals
Connectors, without optic cable

CS-3G-LAN

Cellular GSM modem   3G Router Wireless Radio:  Tri-band: 900/1800/1900 Hz, UMTS (up to) DL: 384Kbps, UL: 384Kbps, Dual SIM slots
• SMA female connectors (50 Ω) for external antenna 
• 1x Ethernet interface 10/100 Base-T (LAN)

CS-X85

Expansion for RS422-RS485 Modbus communication

CS-C-ETH

Remote module Ethernet - for standard LAN connection with Expansion module option or remote connection via LAN. Ethernet LAN EtherCAT Master
LAN controlled EtherCAT Master for DIN rail

CT 300/20mA

Current transformer Split coil 300/20mA,  5VA cl:1 , 1 phase pcs

CT 500/20mA

Current transformer Split coil 300/20mA,  5VA cl:1 , 1 phase pcs

CT 500/5A

Current Transformer, split coil, 500/5A 5VA cl:1 , 3 pcs kit

CT 1000/5A

Current Transformer, split coil 1000/5A 5VA cl:1 , 3 pcs kit

CT RS 1000/20mA

Current Transformer Rogowski Split coil, 1000/20mA 5VA cl:1 , 1 pcs

CS-AI4

Expansion 4-channel analog input terminal 4…20 mA, 12 bit, 4 x 2-wire system

CS-AI8

Expansion 8-channel analog input terminal 4…20 mA, 12 bit, 8 x 1-wire system

CS-DI8

8-channel digital input terminal 24 V DC, filter 3.0 ms, 2-wire system

CS-AO4

Expansion 4-channel analog output terminal 4…20 mA, 12 bit, 4 x 2-wire system

CS-AO8

Expansion 8-channel analog output terminal 4…20 mA, 12 bit, 8 x 1-wire system

CS-EMCS -2

Control System EMCS  for 2 compressors

  • Capable of controlling up to 2 Compressors
  • Energy Control Mode - Auto Sequence Selection
  • Multiple Pressure Profiles
  • Anti-Cycling control

CAL-EMCS -4

Control System EMCS  for 4 compressors

  • Capable of controlling up to 4 Compressors
  • Energy Control Mode - Auto Sequence Selection
  • Multiple Pressure Profiles
  • Anti-Cycling control

    • CAL-EMCS -8

    Control System EMCS  for 8 compressors

  • Capable of controlling up to 8 Compressors
  • Energy Control Mode - Auto Sequence Selection
  • Multiple Pressure Profiles
  • Anti-Cycling control

    • CAL-EMCS -16

    Control System EMCS  for 16 compressors

  • Capable of controlling up to 16 Compressors
  • Energy Control Mode - Auto Sequence Selection
  • Multiple Pressure Profiles
  • Anti-Cycling control

    • CAL-VIS-2

    SCADA - Local System Visualization for 2 Compressor station via LAN Ethernet

    CS-VIS-4

    SCADA - Local System Visualization for up to 4 Compressor Station via LAN Ethernet

    CS-VIS-8

    SCADA - Local System Visualization for up to 8 Compressor Station via LAN Ethernet

    CS-VIS-16

    SCADA - Local System Visualization for up to 16 Compressor Station via LAN Ethernet

    CFC-50

    CALMS Flow Controller Valve DN50, Regulation range 2-10 bar, resolution 0.05 bar, range 2-25 m3/min, with on-off bypass valve, CALMS connection

    CFC-65

    CALMS Flow Controller Valve DN65, Regulation range 2-10 bar, resolution 0.05 bar, range 3-34 m3/min, with on-off bypass valve, CALMS connection

    CFC-80

    CALMS Flow Controller Valve DN80, Regulation range 2-10 bar, resolution 0.05 bar, range 5-45 m3/min, with on-off bypass valve, CALMS connection

    CFC-100

    CALMS Flow Controller Valve DN100, Regulation range 2-10 bar, resolution 0.05 bar, range 11-89 m3/min, with on-off bypass valve, CALMS connection

    11 — DIAGRAMS

    WIRING DIAGRAMS

    CALMS PM-2

    CALMS PM-4

    CALMS PM-8

    CAL-C-ON/OFF

    CAL-C-VSD

    CONNECTION DIAGRAMS FOR CAL-C-XX ON/OFF OR CAL-C-XX VSD MODULES

    PM-2

    PM-4

    PM-8

    12 — CALMS FIELD INSTALLATION SETUP


    FIELD INSTALLATION REPORT

    Compressed Air Solution provider:

    Company :


    Location name:

    Location address:



    Contact person (Technical person)

    DATE:****__****

    CALMS DATA

    CALMS CS Type, SN:
    CALMS CS MAC Address:
    Electricity Cost* / kWh
    Compressed Air Cost* / m3

    * use your currency

    COMPRESSED AIR SYSTEM DETAIL

    Target specific Power☐kWh/m3 ☐kW/m3/min ☐kWh/ft3 ☐kW/ft3/min
    Pressure SETPOINT☐ barg ☐ kPa ☐ PSI
    Pressure MAX ( unload point )☐ barg ☐ kPa ☐ PSI
    Pressure MIN ( load point )☐ barg ☐ kPa ☐ PSI
    Pressure MIN – Critical pressure☐ barg ☐ kPa ☐ PSI

    COMPRESSOR DATA

    C.01C.02C.03C.04C.05C.06C.07C.08
    TYPE ( on/offVSD )
    Nominal Capacity
    Nominal Pressure
    Nominal Power
    Motor SF
    Working hours

    COMPRESSED AIR STATION DATA

    SHIFTWorking compressorsNm3/minHoursShift timingLunch timingTea brake
    1st
    2nd
    3rd

    Product manufactured:

    Describe Compressed Air point of use:

    Working Days/Year: **_**        Week holiday on:

    Main Header Size: ****_**** mm Φ                Length: ****__**** m

    Receiver Capacity: **____** m3

    **Dryer: ** ☐ YES / ☐ **NO     Dryer Type: ** ☐ Refrigeration / ☐ Ads.Heatless  / ☐ Ads. Heated  / ☐ HOC

    • Do you have any specific problem at your compressed air station that needs solution?

    Please draw a single line schematics diagram of your Compressed Air system along with this data sheet:

    ** **

    PROCESS DIAGRAM of compressed air system (production – distribution - users)

    TAGS

    Analog INPUTSElectrical terminalCompressor linkLabel TypeLabelUnitDescriptionRange
    Analog INPUTSPLC.Input.TerminalSignal linked to compressor C.01,C.02,C.03,C.04 or all compressorsFlow, pressure, Power, Vibration, Ultrasound, Temperature, etc.Total Flow,Total Pressure,Total Power,Custom …Barg, kPa, m3/min, cfm, kW, etc…4-20 mA
    AI1AI1.I1.1
    AI2AI1.I2.5
    AI3AI1.I3.3
    AI4AI1.I4.7
    AI5AI2.I1.1
    AI6AI2.I2.5
    AI7AI2.I3.3
    AI8AI2.I4.7
    Analog INPUTSElectrical terminalCompressor linkLabel TypeLabelUnitDescriptionRange
    POWERPLC.Input.TerminalSignal linked to compressor C.01,C.02,C.03,C.04 or all compressorsPowerTotal PowerkWCT X/x
    AIP1CS-C-XX-01-AIP
    AIP2CS-C-XX-02-AIP
    AIP3CS-C-XX-03-AIP
    AIP4CS-C-XX-04-AIP
    AIP5CS-C-XX-05-AIP
    AIP6CS-C-XX-06-AIP
    AIP7CS-C-XX-07-AIP
    AIP8CS-C-XX-08-AIP

    DIGITAL INPUTS

    Digital INPUTSElectrical terminalCompressor linkLabel TypeLabelDescriptionInverted
    Digital INPUTSPLC.Input.TerminalSignal linked to compressor C.01,C.02,C.03,C.04Flow, pressure, Power, Vibration, Ultrasound, Temperature, etc.Total Flow,Total Pressure,Total Power,Custom …True=1 / False=0
    DI1DI1.I1.1CS-BASEInternally used
    DI2DI1.I2.5CS-BASEInternally used
    DI3DI1.I3.4CS-BASEInternally used
    DI4DI1.I4.8CS-BASEInternally used
    DI5BC1.I1.2RUNNING
    DI6BC1.I2.3LOADED
    DI7BC1.I3.10ALARM
    DI8BC1.I4.11LOCAL / REMOTE
    DI9BC1.I1.2RUNNING
    DI10BC1.I2.3LOADED
    DI11BC1.I3.10ALARM
    DI12BC1.I4.11LOCAL / REMOTE
    DI13BC1.I1.2RUNNING
    DI14BC1.I2.3LOADED
    DI15BC1.I3.10ALARM
    DI16BC1.I4.11LOCAL / REMOTE
    DI17BC1.I1.2RUNNING
    DI18BC1.I2.3LOADED
    DI19BC1.I3.10ALARM
    DI20BC1.I4.11LOCAL / REMOTE

    CALCULATIONS

    Compressor linkLabel TypeLabelFORMULAUnit
    CALCULATIONSignal linked to compressor C.01,C.02,C.03,C.04Flow, pressure, Power, Vibration, Ultrasound, Temperature, etc.Total Flow, Total Pressure, Total Power, Custom …Barg, kPa, m3/min, cfm, kW, etc…
    C.01
    C.02
    C.03
    C.04
    COMPRESSOR INSTALLATION SPECIFIC
    How old is this compressor? How many hours will the compressor run?
    What is the average air consumption?
    What is your electrical unit cost?
    Does it change for day shift / night shift?
    What is the plant minimum pressure?
    What is the existing pressure band Minimum / Maximum / Useful Differential?
    Are there several compressors running together?
    How are they controlled?
    What ancillaries are fitted (dryers, filters)?
    What is the pressure drop Initial & at element change?
    What is the size of their pipe work?
    What is the pressure drop they have?
    COMPRESSED AIR SPECIFICS
    What do you think the min pressure is?
    Is there a piece of production equipment that needs a higher pressure than the majority of the plant?
    Do you have pressure drop?
    Do you know size of piping distribution?
    Are you happy with current service supplier who is currently doing this work?
    Do you have production problems?
    How reliable is your existing system?
    Do you have air quality issues and if yes what happens?
    How much do you pay for electricity?
    Do you know how efficient your compressed air system is?
    Working hours of air end?
    Are you proactive in fixing leaks?
    Do you have any unregulated air users?
    What is your shift rotation and does demand change?
    Do you isolate supply to non-production areas?
    Do you have a LP or HP air system?
    Do you have a high failure rate of production equipment?
    What happens when the pressure is too low?
    Quality of air need and is this different for different air users?
    Is there any large volume demand events but short duration?
    Do you have sufficient back up machines?
    What is the cost of lost production?
    When was the last time you audited the air system?
    Are you or are you working to ISO 14001?
    Would you consider total air responsibility outsourcing?
    Pay as you use?
    Air over the fence
    Why do you value your existing service / compressor provider?
    Do you use hot water in your production process?
    Do you have problems with corrosion in your pipe work,
    Is there any product spoilage?
    How much money does it cost per hour in lost production if your air fails?
    How much are you spending on equipment repairs due to moisture contamination?
    How much are your air leaks costing you?
    What do you think the min pressure is?
    Is there a piece of production equipment that needs a higher pressure than the majority of the plant?
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