Chicago Pneumatic ES 4000 STANDARD User manual

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Controller Instruction
1 General information
ES 4000 STANDARD
Printed Matter Number : 2946 7002 09
Applicable to : MB compressors
Preliminary Operations: : –
Safety Instructions : General
Persons Required : 1
Special Tools : –
Consumables : –
2 Document Overview
This document describes the following:
1General information............................................................................................................................................................1
2Document Overview...........................................................................................................................................................1
3General description............................................................................................................................................................4
3.1 Introduction ..................................................................................................................................................................4
3.2 Automatic control of the compressor............................................................................................................................4
3.3 Protecting the compressor ...........................................................................................................................................4
3.3.1 Shut-down ...........................................................................................................................................................4
3.3.2 Shut-down warning..............................................................................................................................................5
3.4 Service warning............................................................................................................................................................5
3.5 Automatic restart after voltage failure...........................................................................................................................5
4Detailed description of the control panel ............................................................................................................................6
5Icons used..........................................................................................................................................................................7
5.1 Status icons .................................................................................................................................................................7
6Main screen .......................................................................................................................................................................9
7Shut-down warning ..........................................................................................................................................................10
7.1 Description .................................................................................................................................................................10
7.2 Compressor element outlet temperature....................................................................................................................10
7.3 Dewpoint temperature................................................................................................................................................11
8Shut-down........................................................................................................................................................................12
8.1 Description .................................................................................................................................................................12
8.2 Compressor element outlet temperature....................................................................................................................12
8.3 Motor overload ...........................................................................................................................................................13
9Service warning ...............................................................................................................................................................14

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9.1 Description .................................................................................................................................................................14
10 Scrolling through all screens ......................................................................................................................................15
10.1 Description.............................................................................................................................................................15
10.2 Overview of the screens ........................................................................................................................................15
10.2.1 Overview of the Digital input screens ................................................................................................................15
10.2.2 Overview of the Parameter screens ..................................................................................................................15
10.2.3 Overview of the Protections screens .................................................................................................................16
10.2.4 Overview of the Test screens ............................................................................................................................16
10.3 Menu flow ..............................................................................................................................................................17
11 Calling up outlet and dewpoint temperatures .............................................................................................................19
12 Calling up running hours ............................................................................................................................................20
13 Calling up motor starts ...............................................................................................................................................20
14 Calling up module hours ............................................................................................................................................21
15 Calling up loading hours.............................................................................................................................................21
16 Calling up load relay...................................................................................................................................................22
17 Calling up/resetting the service timer .........................................................................................................................23
17.1 Calling up the service timer ...................................................................................................................................23
17.2 Resetting the service timer ....................................................................................................................................23
18 Selection between local, remote or LAN control.........................................................................................................24
19 Calling up/modifying CAN address control.................................................................................................................25
19.1 Calling up...............................................................................................................................................................25
19.2 Modifying the Node ID ...........................................................................................................................................26
20 Calling up/modifying IP, Gateway and Subnetmask...................................................................................................27
20.1 Calling up...............................................................................................................................................................27
20.2 Modification............................................................................................................................................................28
21 Calling up/modifying pressure band settings..............................................................................................................29
21.1Calling up the settings ...........................................................................................................................................29
21.2 Modification............................................................................................................................................................30
22 Modifying the pressure band selection.......................................................................................................................30
23 Calling up/modifying service timer settings ................................................................................................................30
24 Calling up/modifying the unit of temperature..............................................................................................................31
25 Calling up/modifying unit of pressure .........................................................................................................................31
26 Activating automatic restart after voltage failure ........................................................................................................32
27 Selection between Y-D or DOL starting .....................................................................................................................32
28 Calling up modifying load delay time..........................................................................................................................33
29 Calling up modifying minimum stop time....................................................................................................................33
30 Activating password protection...................................................................................................................................34
31 Activate load/unload remote pressure sensing...........................................................................................................35
32 Calling up/modifying protection settings.....................................................................................................................35
32.1 Available protections..............................................................................................................................................35
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32.2 Example of protection screens...............................................................................................................................36
32.3 Changing the settings ............................................................................................................................................36
33 Test screens...............................................................................................................................................................37
33.1 Display test ............................................................................................................................................................37
33.2 Safety valve test ....................................................................................................................................................37
33.3 Production test.......................................................................................................................................................37
34 Programmable settings ..............................................................................................................................................38
34.1 Parameters: unloading/loading pressures .............................................................................................................38
34.2 Parameters fix speed drive ....................................................................................................................................38
34.3 Protections.............................................................................................................................................................38
34.4 Service plan...........................................................................................................................................................38
34.5 Terminology...........................................................................................................................................................39
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3 General description
View of the ES 4000 Standard controller
3.1 Introduction
The electronic controller has following functions:
•Controlling the compressor
•Protecting the compressor
•Monitoring components subject to service
•Automatic restart after voltage failure
3.2 Automatic control of the compressor
The controller maintains the net pressure between programmable limits by automatically loading and unloading the
compressor. A number of programmable settings, e.g. the unloading and loading pressures, the minimum stop time and the
maximum number of motor starts are taken into account.
The controller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when
the net pressure decreases. If the expected unloading period is to short, the compressor is kept running to prevent too short
stand-still periods.
3.3 Protecting the compressor
3.3.1 Shut-down
If the compressor element outlet temperature exceeds the programmed shut-down level, the compressor will be stopped.
This will be indicated on the display of the controller. The compressor will also be stopped in case of overload of the drive
motor.
Air-cooled compressors will also be stopped in the event of overload of the fan motor.
Before remedying, consult the Safety precautions in the Instruction book.
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3.3.2 Shut-down warning
A shut-down warning level is a programmable level below the shut-down level.
If one of the measurements exceeds the programmed shut-down warning level, this will also be indicated to warn the
operator before the shut-down level is reached.
3.4 Service warning
If the service timer exceeds a programmed value, this will be indicated on the display to warn the operator to carry out some
service actions.
3.5 Automatic restart after voltage failure
The controller has a built-in function to automatically restart the compressor when the voltage is restored after voltage
failure.
Provided the controller is in the automatic operation mode, the compressor will automatically restart when
the supply voltage to the module is restored.
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4 Detailed description of the control panel
Function keys of the controller
Ref. Designation Function
1 Display Shows icons and operating conditions.
2 Automatic operation symbol
3 LED, Automatic operation Indicates that the regulator is automatically controlling the compressor: the compressor
is loaded, unloaded, stopped and restarted depending on the air consumption and the
limitations programmed in the regulator.
4 Warning symbol
5 LED, Warning Is lit if a warning condition exists.
6 Voltage symbol
7 LED, Voltage on Indicates that the voltage is switched on.
8 Service symbol
9 LED, Service Is lit when service is needed.
10 Start button This button starts the compressor. Automatic operation LED (3) lights up. The
Elektronikon is operative.
11 Stop button This button is used to stop the compressor. Automatic operation LED (3) goes out.
12 Scroll buttons Use these buttons to scroll through the menu.
13 Enter button Use this button to confirm the last action.
14 Escape button Use this button to go to previous screen or to end the current action.
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5 Icons used
5.1 Status icons
Name Icon Description
Compressor status
When the compressor is stopped, the icon stands still.
When the compressor is running, the icon is rotating.
Motor stopped
Running unloaded
Running loaded
Machine control mode
Remote start / stop
LAN control
Automatic restart after
voltage failure
Automatic restart after voltage failure is active
Timer
Active protection
functions
Emergency stop
Service
Service required
Units
Pressure unit (Mega Pascal)
Pressure unit (pounds per square inch)
Pressure unit (bar)
Temperature unit
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Name Icon Description
Temperature unit
Hours (always shown together with seconds)
Percent
The value shown must be multiplied by 10 to get the actual value
The value shown must be multiplied by 100 to get the actual value
The value shown must be multiplied by 1000 to get the actual value
Motor (overload)
Element outlet temperature
Filter
Drain
Energy saving (dryer)
Ambient temperature
Dewpoint temperature
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6 Main screen
When the voltage is switched on, the first screen is a test screen. The next screen is the Main screen, shown automatically.
The Main screen shows:
•The compressor status by means of pictographs
•The air outlet pressure
Always consult your supplier if the pressure on the display is preceded by a "t".
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7 Shut-down warning
7.1 Description
A shut-down warning will appear in the event of:
•Too high a temperature at the outlet of the compressor element.
•Too high a dewpoint temperature (Full-Feature compressors).
7.2 Compressor element outlet temperature
If the outlet temperature of the compressor element exceeds the shut-down warning level (see section Programmable
settings), warning LED (5) starts blinking.
1. Press the Scroll down button.
The screen shows the temperature at the compressor element outlet.
The screen shows that the temperature at the element outlet is 122 °C
It remains possible to scroll through other screens, using the Scroll buttons up and down (12) to check the actual status
of other parameters.
2. Press button (11) to stop the compressor and wait until the compressor has stopped.
3. Switch off the voltage, inspect the compressor and remedy.
The warning message will disappear as soon if the warning condition disappears.
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7.3 Dewpoint temperature
On compressors with integrated dryer, alarm LED (5) will light up and the related pictograph will appear flashing if the
dewpoint temperature exceeds the warning level (programmable).
Main screen with the dewpoint temperature warning
The related pictograph will appear flashing:
1. Press the Scroll button (12) until the actual dewpoint temperature appears.
Warning screen, dewpoint temperature
The screen shows that the dewpoint temperature is 9˚C.
It remains possible to scroll through other screens (using Scroll buttons 12) to check the actual status of other
parameters.
2. Press button (11) to stop the compressor.
Wait until the compressor has stopped.
3. Switch off the voltage, inspect the compressor and remedy.
The warning message will disappear as soon as the warning condition disappears.
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8 Shut-down
8.1 Description
The compressor will be shut down:
•In case the temperature at the outlet of the compressor element exceeds the shut-down level.
•In case of error of the outlet pressure sensor.
•In case of overload of the drive motor.
•In case of overload of the fan motor on air-cooled compressors.
8.2 Compressor element outlet temperature
If the outlet temperature of the compressor element exceeds the shut-down level (factory setting 120 °C/248 °F,
programmable) the compressor will be shut-down, alarm LED (5) will flash, automatic operation LED (3) will go out and the
following screen will appear.
Main screen with shut-down indication, element outlet temperature
The related pictograph will appear flashing:
1. Press the Scroll button (12) until the actual compressor element temperature appears.
Shut-down screen, element outlet temperature
The screen shows that the temperature at the outlet of the compressor element is 122 °C.
2. Switch off the voltage.
3. Remedy the trouble.
4. After remedying and when the shut-down condition has disappeared, switch on the voltage.
5. Restart the compressor.
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8.3 Motor overload
In the event of motor overload, the compressor will be shut-down, alarm LED (5) will flash, automatic operation LED (3) will
go out and the following screen will appear.
Main screen with shut-down indication, motor overload
1. Switch off the voltage.
2. Remedy the trouble.
3. After remedying and when the shut-down condition has disappeared, switch on the voltage.
4. Restart the compressor.
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9 Service warning
9.1 Description
A service warning will appear when the service timer has reached the programmed time interval.
If the service timer exceeds the programmed time interval, alarm LED (5) will light up.
1. Press Scroll buttons (12) to scroll to <d.6>.
The service symbol is shown.
2. Press button (13).
The actual reading of the service timer appears and is shown in <hrs> or <x1000 hrs> (if the service timer value is
higher than 9999).
Example of service timer screen
The screen shows that the reading of the service timer is 4002.
3. Press Scroll button (12) to scroll to <d.1>.
The running hours symbol is shown.
4. Press button (13).
The actual reading of the service timer appears and is shown in <hrs> or <x1000 hrs> (if the service timer value is
higher than 9999).
Example of running hours screen
The longer interval service actions must also include the shorter interval actions. In the example above,
carry out all service operations belonging to the 8000 running hours interval as well as those belonging to
the 4000 running hours interval.
The setting of the service timer can be changed in function of the operating conditions See section
Preventive maintenance schedule.
5. After servicing, reset the service timer. See section Calling up/resetting the service timer.
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10 Scrolling through all screens
10.1 Description
Scroll buttons (12) can be used to scroll through all screens. The screens are divided into register screens, measured data
screens, digital input screens (numbered as <d.in>, <d.1>, ...), parameter screens (numbered as <P.01>, <P.02>, ...),
protections screens (numbered as <Pr.01>,...) and test screens (numbered as <t.01>,...).
During scrolling, the numbers of the screens appear consecutively. For most screens, the unit of measurement and the
related pictograph are shown together with the screen number.
Example
The screen shows the screen number <d.1>, the unit used <hrs> and the related symbol for running hours.
Press Enter key (13) to call up the actual running hours.
10.2 Overview of the screens
10.2.1 Overview of the Digital input screens
Digital input screens Designation Related topic
<d.in> Digital input status
<d.1> Running hours (hrs or x 1000 hrs) See section Calling up running hours
<d.2> Motor starts (x 1 or x 1000) See section Calling up motor starts
<d.3> Module hours (hrs or x 1000 hrs) See section Calling up module hours
<d.4> Loading hours (hrs or x1000 hrs) See section Calling up loading hours
<d.5> Load relay (x1 or x 1000) See section Calling up load relay
<d.6> Service timer reading (hrs or x 1000 hrs) See section Calling up/resetting the service timer
<d.7> Actual program version
10.2.2 Overview of the Parameter screens
Parameter screens Designation Related topic
<P.01> Selection between local, remote or LAN
control
See section Selection between local, remote or LAN control
<P.02> Setting a node ID for LAN control and the
channels for Mk 4 and Mk 5
See section Calling up/modifying CAN address control
<P.03> Settings for IP, gateway and Subnet mask See section Calling up/modifying IP, Gateway and
Subnetmask
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Parameter screens Designation Related topic
<P.04> Pressure band settings See section Calling up/modifying pressure band settings
<P.05> Setting a pressure band selection See section Modifying the pressure band selection
<P.06> Modifying a service timer See section Calling up/modifying service timer settings
<P.07> Setting of unit for temperature See section Calling up/modifying the unit of temperature
<P.08> Setting of unit for pressure See section Calling up/modifying unit of pressure
<P.09> Selection for function: Automatic restart after
voltage failure
See section Activating automatic restart after voltage failure
<P.10> Selection between Y-D or DOL starting See section Selection between Y-D or DOL starting
<P.11> Setting of load delay time See section Calling up modifying load delay time
<P.12> Setting of minimum stop time See section Calling up modifying minimum stop time
<P.13> Setting a password See section Activating password protection
<P.14> Remote pressure sensing See section Activate load/unload remote pressure sensing
10.2.3 Overview of the Protections screens
Protections screens Designation Related topic
<Pr.01> Protections screens See section Calling up/modifying protection settings
<Pr.02>
<Pr.03>
10.2.4 Overview of the Test screens
Test screens Designation Related topic
<t.01> Display test See section Test screens
<t.02> Safe valve test See section Test screens
<t.03> Production test See section Test screens
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10.3 Menu flow
Simplified menu flow
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(1) Compressor outlet pressure (16) Pressure band setting
(2) Compressor outlet temperature (17) Service timer settings
(3) Dewpoint temperature (18) Temperature unit
(4) Digital input status (19) Unit pressure
(5) Running hours (20) Auto restart
(6) Motor starts (21) Selection Y-D/DOL
(7) Module hours (22) Load delay time
(8) Loading hours (23) Minimum stop time
(9) Load relay (24) Password settings
(10) Service timer reading (25) Remote pressure sensing
(11) Actual program version (26) Protections
(12) LAN selection (27) Display test
(13) Settings node ID (28) Safety valve test
(14) IP settings (29) Production test
(15) Pressure band selection
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11 Calling up outlet and dewpoint temperatures
Starting from the Main screen:
1. Press Scroll button (12).
The outlet temperature will be shown.
The screen shows that the outlet temperature is 82 ˚C.
1. Press Scroll button (12).
For Full-Feature compressors:
The dewpoint temperature will be shown:
The screen shows that the dewpoint temperature is 3 ˚C.
2. Press Scroll button (12) to scroll downwards or upwards through the screens.
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12 Calling up running hours
Starting from the Main screen:
1. Press Scroll button (12) until <d.1> is shown.
2. Press Enter button (13).
The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the compressor are 11250
hours.
13 Calling up motor starts
Starting from the Main screen:
1. Press Scroll button (12) until <d.2> is shown.
2. Press Enter button (13).
A screen similar to the following appears
This screen shows the number of motor starts (x 1 or - if <x1000> lights up - x 1000). In the above example, the
number of motor starts is 10100.
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