airleader Master-4 Bedienungsanleitung
WF STEUERUNGSTECHNIK
Operation manual for Compressor-Management
AIRLEADER Master-4
Zeppelinstr. 7-9, 75446 WIERNSHEIM
Tel. +49 7044 911100, Fax +497044 5717
www.airleader.de info@airleader.de
5460 33rd Street SE
Grand Rapids, MI 49512
Phone 616 828-0716
www.airleader.us info@airleader.us
SUMMARIES
AIRLEADER Master MODUL
Page 2 Summaries
Page 3 Almost the best strategy to sava energy // Program version serial number
Page 4 Funvtional description
Page 5 Main Menu, System information, Symbol Legend
VARIABLE SPEED COMPRESSOR
Page 6 Control and interpretation of regulated compressors
Page 7 Configuration of regulation range and regulation buffer
Page 8 Minimum flow rate and remote pressure supply
Page 9 Station with 2 variable speed compressors
PROGRAMMING COMPRESSOR CONTROL
Page 10 Programming variable speed compressors
Page 11 FU-Control for variable speed compressos
Page 12 Programming load / unload compressors
Page 13 Programming pressure, rank profiles and system parameter
Page 14 Control Parameter
Page 15 Programming of analog inputs of Master Module
Page 16 Programming analog and digital inputs of connection modules (17-24)
REAL TIME CLOCK
Page 17 Programming real time clock
Page 18 Clock programming notes
STATUS DATA and COMMISIONING
Page 19 Status data of compressors and connection modules
Page 20 IP-address and network settings, // Global settings
Page 21 Alarm messages // Data Manager // Diagram
Page 22 Commisioning and switching functions
2
AIRLEADER combines compressors of different sizes to an optimum unit
For program version, serial number and network touch >Status >Control and SD Card
Almost the best strategy to save energy
Pmax
Pmin
25
25
25
13
7
m³/min
Load
Energy
- only program the compressor capacities
- set the common pressure switch points
- mount the pressure transducer
- connect the cables
The compressors will be controlled by the real air consumption
Within only 1 pressure difference for all compressors
Un-load saving
Load energy saving
3
FUNCTIONAL DESCRIPTION
4
AIRLEADER combines compressors of different sizes
to an optimum unit which automatically adapts to the production based on the current compressed air consumption. It is
made sure that it is always the most efficient compressor combination which generates the compressed air necessary for
production, independent of the manufacturer and the performance. The system pressure remains within the smallest
limits. It is seen that the costs are kept as low as possible. The compressor performances and a common pressure
difference are programmed in for all the compressors. Based on this information, AIRLEADER permanently calculates the
current compressed air consumption and the volume of the compressed air system. The self-learning 8-fold calculation
depth makes it possible to adapt the compressors to the changes in consumption in a dynamic way.
Automatic compressor change as per compressed air consumption
If all the compressors are on the same rank, they are working fully automatically and based on real air consumption. The
priority of the compressors is adapted to the production process in real time with a useful hysterisis calculation. It is always
the compressor combination with the lowest cycle rates which is running and thus with the lowest idle times. Big
compressors are only running when needed. The smaller compressors are running under load instead of idling the big
compressors. The compressors auto-regulate the motor start limitations.
The status of the compressors is constantly monitored.
If a running compressor displays a malfunction within the pressure range or is switched off for service, its performance is
taken over by other compressors. If several compressors are needed to do this, addition is made time-delayed. Load and
total running times are stored for the individual compressors. The operating hours are deleted, if required.
Connecting of compressors
is effected using the connecting moduls this being installed in the electrical housing of the compressor on the DIN-rail. The
connection to the Master control is made over the industry us RS 485 bus. The operating voltage of 24 volts AC/DC can
be attached to the tension supply of the compressor. If a power supply of 24V AC or DC is available from the
compressor electric.
Compressor fault
If a compressor goes on fault the display shows a symbolic cross. On fault of reported compressor the performance gets
the compressed air consumption the most favorable compressors combination replaces through this one. The fault report
for the compressors is activated at the AIRLEADER an common fault signal.
Faults from the connection modules will be given out over the digital output „General fault of external equipment.
Compressor motor running
If these inputs get connected, AIRLEADER receives the motor running time. The total hours are also stored as the load
hours. The advertisement of the hours can be retrieved over the display. The running time compensation provides equally
running times of compressors with same capacity.
Compressor ready input
These input must be connected so that compressor management AIRLEADER recognizes the readiness of the
compressors. If these input don't get connected, the compressor cannot be in operation. A fault signal isn't activated.
der Kompressor nicht bereit und kann nicht angewählt werden. Eine Störmeldung wird nicht aktiviert.
If the fault input is not connected
and one of the compressors stops due to a malfunction, the display will show a wrong compressed air consumption (too
high = by the value of the faulty compressor). For this reason it is advisable to connect the malfunction signal inputs, so
that the compressed air consumption is always shown correctly and the capacity is also corrected and immediately after
reaching the P min.
Main Menu, System information, Symbol Legend
5
Touch „Program“ to enter the control settings
Status and Systeminformation -Touch „Status“-
Kompressor Status Symbole
Control and interpretation of regulated compressors
6
The various speed regulated compressor is integrated actively
The VSD compressor send the information about the motor speed over an analog output to AIRLEADER. This parameter must be
programmed to the minimal and maximum capacity of the delivered compressed air. The analog output of the VSD
compressor have to be 4-20 mA. VSD Compressors with an analog output of 0-10 VDC must be changed from 0-10 VDC with a re-
ceiving multicoupler to 4-20 mA.
The pressure Setpoint of the VSD compressor must be centrically programmed between the AIRLEADER switch points.
The right combination of compressor capacities
together with speed regulated and normal compressors with a firm performance is decisive for good results in regulation. Is the various
speed regulated compressor the smallest in combination with only bigger compressors there are only small section regulated by the vari-
ous speed compressor. Big mechanical hurdle cannot be regulated directly.
Example of the right interpretation of the performances:
4 - 20 mA
4536271890
2,5-16 m³/min 10 m³/min 20 m³/min
0
9
18
27
36
45
4536271890
0
9
18
27
36
45
m³/min m³/min
Pmin
Pmax
Pmin
Pmax
2,5-16 m³/min 20 m³/min
20 m³/min
Correct combination Incorrect combination
Configuration of regulation range and regulation buffer
7
Examble with a VSD Compresor with a regaulation range between 2,5 - 16 m³/min -
The free definable regulation range max
switches load/unload compressors ON and OFF within the pressure settings of AIRLEADER. The regulation limits are defined with the
regulation range max and the regulation buffer. Is the regulation range max adjusted lower than the maximum capacity of the VSD, the
regulation range max and the regulation buffer will be activated.
Setting the "regulation range max"
Examble: the regulation range max will be programmed to 15 m of m³/min. If than the compressed air consumption is going higher
than 15 m³/min a time flexible trend calculation watches the compressed air consumption and switches another compressor on (10 m
³/min like example). Within the pressure switch points of AIRLEADER. If the speed's regulated compressor reaches the regulation
range max the second time together with the 10 m ³/min compressor at 25 m ³/min air consumption again, the 10 m ²/min compres-
sor will be replaced with the 20 m ³/min compressor directly.
The 10 m ³/min compressor will be switched on if air consumption reaches the regulation range max of the regulated compressor at 35
m of ³/min together with the 20 m ³/min compressor.
Setting the "regulation buffer"
Examble: the regulation buffer will be programmed to 1,5 m³/min. If the compressed air consumption is getting lower and the regulated
compressor comes to the point "lower than 15 m³/min" together with the 10 and 20 m³/min compressor the regulation buffer of 1,5 m³/
min will be activated. The air consumption get again 1,5 m³/min lower a time flexible trend calculation stops the 10 m³/min compressor
inside the adjusted pressure switch points at the AIRLEADER. The VSD compressor regualtes to the capacity of 13,5 m³/min.
Correct setting of regulation buffer incorrect setting of regulation buffer
Regulation range max = 15,0 m³/min Regulation range max = 15,0 m³/min
Regulation buffer = -1,5 m³/min Regulation buffer = -3,5 m³/min
Min compressor capacity = -2,5 m³/min Min compressor capacity = -2,5 m³/min
Control sum = 11,0 m³/min Control sum = 9,0 m³/min
Note:
- the regulation range max will be activ if the control sum is smaller than the capacity of the load/unload compressor
- the regualtion buffer is active if the controll sum is higher than the capacity of the load/unload compressor
The VSD compressor will be run in his best specific range.
regulation range
0
6,6
Switch off with regulation buffer
4536271890
2,5-16 m³/min
m³/min
Pmin
Pmax
max
18
27
36
09182736
max
10 m³/min 20 m³/min
max
buffer
max max max
buffer
buffer
15
m³/min
Pmin
Regulation range
max
min
minimized
capacity
examble 15 m³/minexamble 4,5 m³/min
0
Pmin
16128
4
0
2,5-16 m³/min
0
4
8
12
Pmin
Pmax
Minimum flow rate and remote pressure supply
8
Settings „minimum flow rate“ of variable speed compressor
By setting the minimum capacity in the menu of the speed regulated compressor
can be determined whether or below the minimum delivery amount of a normal
compressor compressor in load / idle to run mode.
Setting the minimum flow rate of 0 m / min causes:
The speed controlled compressor is running in start / stop operation as long as the
consumption of compressed air is from 0 to 2.5 m³ / min.
Setting the minimum flow rate of 2.5 m³ / min causes:
Below 2.5 m³/min compressed air consumption a normall compressor is running in
a load / unload mode. The downshift is receding in consumption with a hysteresis
This mode is only economic if the air station with a small compressor as 2.5 to 4 m /
min is installed in addition
Pressure differences caused by dryers and filters
cause may be between the pressure transmitter
of the controlled compressor, and the master
control rule up to 0.4 bar difference.
A precise control of pressure within very close
limits is not possible. The pressure difference at
the higher level control must be expanded by
the pressure value can be set. This results in a
pressure differential of 0.7 bar.
(More than at a station without a regulated com-
pressor)
With the remote control actual pressure value
ensure that the regulated compressor can be operated in conjunction with the master control in a narrow pressure limit.
The analog output of the connection module, deliver the current actual pressure of AIRLEADER via 4-20 mA.
If the compressor pressure transmitter has an different range, than the output has to be adjusted accordingly.
Examble:
AIRLEADER 0-16 bar = 4-20 mA
Compressor 1-20 bar = 4-20 mA or Compressor -1-15 bar = 4-20 mA
An offset value setting for remote actual pressure
can be programmed via the menu of regulated compressor to the pressure setpoint of the controlled compressor to adjust the pressure
difference.
This is especially important when more than 1 controlled compressor is installed in the compressed air network and the analog values
do not match the individual compressors
Remote pressure supply through analog output at the RS-485 connection module
0,4 bar
Capacity of regulated compressor
Station with 2 variable speed compressors
9
In a station with 2 regulated compressors
the pressure transducer of regulated compressors in the same place as the pressure transmitter of the AIRLEADER feel, because differ-
ences in pressure of compressed air dryers and filters, the control behavior can influence each other greatly.
The configuration is described on page 4.
Settings „regulation range max“ und regulation buffer
examble 1: 2 variable speed compressors with same capacity
examble 2: 2 variable speed compressors with different capacities
In examble 2
- if compressor 1 reach the regualation range max - it changes to compressor 2
- if compressor 2 reach the regualation range max - compressor 1 start again
- if both compressors reach the regulation gange max - one of th load / unload compressor will be started
- the controller decides, dependent of air consumption tha one of the regulated compressor can be switched off
The regulation range max
ensure that regulated compressors are always in the correct specific area. If an varaiable speed compressor delivers more air than the
setting of the regulation range max, the control started a flexible trend calculation to start the next load/unload compressor. Dependent of
the compressed air consumption.
compressor compressor type m³/min Regulation range max Regulation buffer Min. flow rate
1 Variable speed 5-30 28 m³/min 5 m³/min 0
2 Variable speed 5-30 28 m³/min 5 m³/min 0
3 load / unload 15 - - -
4 load / unload 25 - - -
compressor compressor type m³/min Regulation range max Regulation buffer Min. flow rate
1 Variable speed 1,5-10 9 m³/min 1,5 m³/min 0
2 Variable speed 5-20 18 m³/min 4 m³/min 0
3 load / unload 15 - - -
4 load / unload 25 - - -
max max max max max
regul. buffer
regul. buffer
Regulation range Downshift with regulation buffer
5-30 m³/min 5-30 m³/min
25 m³/min
15 m³/min
max max
regul. buffer
max
regul. buffer
Programming variable speed compressors
10
Touch >Settings >compressor
than
Touch > on compressor symbol
> set min capacity
> set max capacity
> set Imax
> set Imin
> set regulation range max
> set regulation buffer
> compressor min air flow
Attention:
Activate servise for maintenance
the signal "Ready" is deactivated and
the compressor goes into idle when it
is running on load
Install Senor on Analog Input 2
Touch on Analog input 2
> select type of installed sensor
> set min range of sensor at 4 mA
> set max range of sensor at 20 mA
> set min Alarm point
> set max Alarm point
Following sensors are possible:
> Amperé
> Universal sensor
> Power (kW)
>Temperatur
> Bearing monitor
If the sensor value is out of the Alarm
setpoints, you will get an alarm on the
Web-Server Visualisation
Touch on Analog output „AO“
> set min and max range of the
compressor pressure sensor
at 4 mA and 20 mA
> set max range of sensor at 20 mA
> set pressure offset if it is neccessary
Don´t select !Average value output
If average value output is selected
the analog output signal ist the
average between Pmin and Pmax of
Airleader pressure setting
Fault input selection
Standart is C-NC
If neccessary change to
C-NO
Dieses Handbuch passt für folgende Modelle
1
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