CMC Airmaster Q1 Manual

CMC NV –Airmaster Q1 Installation Guide –V1.0 –MANY1032A.EN.00
CMC NV, Industriezone Klein Frankrijk, Klein Frankrijkstraat 40, 9600 Ronse, Belgium
MANY1032A.EN.00
Airmaster Q1 hardware Installation Guide
Version 1.0
SAFETY WARNING
Do not operate the Airmaster Q1 until you and all personnel concerned have read
and understood this installation guide. Failure to follow instructions could result
in death or serious injury.
Important notes
This document serves as installation guide for all Airmaster Q1 products of CMC NV.
Installation and startup may only be done by trained personnel according to safe
engineering practices and with the observance of all relevant local health and safety
requirements and regulations.
A requirement of fault-free operation and fulfillment of any rights to claim under
guarantee is that the documentation is observed. In case of doubt please contact CMC.
This document could be subject to changes. Please contact our factory in case of doubt
in order to ensure that you have received the latest version.
The Airmaster Q1 is further referred to as the “controller”.
This document serves as a manual for the installation of the controller. Remark that the
controller always acts as a component of a complete system in which it is integrated. As
such other documentation for the installation related to the integration of the controller in
the complete system will have to be consulted as well. Reference to such other
documentation is not possible from within the scope of this document. Regardless of the
content of any other documentation, the content of this documentation needs to be fully
respected.

CMC NV –Airmaster Q1 Installation Guide –V1.0 –MANY1032A.EN.00
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Illustration of Airmaster Q1. Remark the layout of the front panel can be different from
the above picture.

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Limit of Liability
The publisher and the author make no representation or
warranties with respect to the accuracy or completeness
of the contents of this work and specifically disclaim all
warranties, including without limitation warranties of fitness
for a particular purpose. No warranty may be created or
extended by sales or promotional materials. Neither the
publisher nor the author shall be liable for damages arising
here from. The fact that an organization or website is
referred to in this work as a citation and/or a potential
source of further information does not mean that the
author or the publisher endorses the information the
organization or website may provide or recommendations
it may make. Further, readers should be aware that
internet websites listed in this work may have changed or
disappeared between when this work was written and
when it is read.
Trademarks
The Airmaster logo is a trademark or registered trademark
of CMC NV. All other trademarks are the property of their
respective owners.
Copyright © 2015 CMC NV.
All rights reserved.
CMC NV, Industriezone Klein Frankrijk, Klein
Frankrijkstraat 40, 9600 Ronse, Belgium

CMC NV –Airmaster Q1 Installation Guide –V1.0 –MANY1032A.EN
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Installation guide
Table of Contents
Section 1: Situation of the product...........................................................................................................................................4
Section 2: Safety.....................................................................................................................................................................5
Section 2.1: Safety warning.................................................................................................................................................5
Section 2.3: Operation.........................................................................................................................................................6
Section 2.4: Maintenance ....................................................................................................................................................6
Section 2.5: Batteries...........................................................................................................................................................6
Section 3: Ratings...................................................................................................................................................................7
Section 4: Connections and Protection....................................................................................................................................8
Section 4.1 Earth.................................................................................................................................................................8
Section 4.2. Power ..............................................................................................................................................................9
Section 4.3 Digital................................................................................................................................................................9
Section 4.4 Relays.............................................................................................................................................................10
Section 4.5 Analog input....................................................................................................................................................10
Section 4.6 Analog output..................................................................................................................................................12
Section 4.7 Communication...............................................................................................................................................13
Section 4.8 1-Phase Current sensor..................................................................................................................................14
Section 4.9 3-Phase Current sensor..................................................................................................................................15
Section 4.10 3-Phase monitoring inputs.............................................................................................................................16
Section 5: Mounting ..............................................................................................................................................................17

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Section 1: Situation of the product
The controller is an industrial controller.
This hardware installation guide is a guide for the
hardware related items. Refer to the software
specifications file for information on how to work with the
unit.
The application area is restricted to components used in
machines that comply with the European machine EMC
directive EMC 2014/30/EU and LVD 2014/35/EU. The
application area is located in electrical driven compressors
and dryers in an industrial environment. Please contact
CMC for appliance in other machines.
The controller does not need to comply to the European
Pressure Equipment Directive 2014/68/EU, because no
parts are under pressure, and the controller is not a safety
component.
The controller is a component, which can’t operate without
other components. However, it is not a safety component,
and it is not a machine.
The controller is to be used in a standard industrial
environment.
The controller may only be used in places without an
explosion risk. So it may never be used where explosion-
proof equipment is required.
This controller may not be used for maritime purposes. It
may also not be used in any way as part of an assembly
that could be used for military or terrorist use.
The controller without additional protection is to be used in
areas of pollution degree 1 or 2. Of course the user can
add additional protection for higher pollution degrees.
The installation of the controller must be made in
accordance with the applicable national and international
standards and regulations.

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Section 2: Safety
Section 2.1: Safety warning
Symbols used (not necessarily all symbols are used on
the controller)
Protective Earth Terminal
The connection referred to by this symbol is to be used as
protective earth terminal
Emergency Stop
The connections referred to by this symbol are to be used
for the connection of an emergency stop switch
Danger –High Voltage.
Connections referred to by this symbol can carry a high
and dangerous voltage.
Manual sign
Indication warning the operators the manual must first be
consulted before any actions are taking place.
Warning: Risk of danger
Warning: Risk of electric shock
Warning: Risk of high pressure
Warning: Consult manual
Warning: Risk of burn
Warning risk of fire or electrical shock:
Do not install or operate the controller until you and all
personnel concerned have read and established a working
understanding of the controller inclusive of duties to be
performed while installing, operating and maintaining the
controller.
Improper use of the product may compromise the safety
and protection of the controller and its environment.
Never use the product in explosive environments.
No serviceable parts inside, return to manufacturer for
servicing or dispose according to local regulations.
Do not expose this controller to heat, fire or direct sunlight
When installing, commissioning, operating or carrying out
service or maintenance on the controller, personnel must
use relevant safe working practice and observe all
relevant local health and safety requirements and
regulations.
Lethal voltages are used within the controller and the
installation it is used in. Electricity has the potential to
cause severe personal injury or death. Isolate the source
of power to the controller when required to do so. Use
extreme caution when carrying out electrical checks.
Never remove or tamper with safety devices, guards or
insulation materials fitted to the controller or the
compressed air installation.
Compressed air has the potential to cause severe
personal injury or death. Use extreme caution when
carrying out compressed air related checks.
Hot and cold surfaces of the machinery may be exposed.
Use caution when carrying out temperature or dew point
sensor related checks.
A requirement of fault-free operation and fulfillment of any
right to claim under guarantee is that documentation is
observed.
This document is subject to changes without notice, if in
doubt, do not proceed!
It is not possible to anticipate every circumstance that
might represent a potential hazard. If the operator
employs an operating procedure, an item of equipment or
a method of working which is not specifically
recommended the user must ensure the product will not
be damaged or made unsafe and that there is no risk to
persons or property. Failure to observe safety precautions
or implement safe working practices may be considered
dangerous practice or misuse of the product.
Section 2.2: Installation
Installation work must only be carried out by a competent
person under qualified supervision. Equipped with the
correct tools and appropriate protection against electrical
hazards.
Disconnect the power before connecting the controller,
never assume power is off but always check the circuit. Be
aware that other nearby circuits can still be powered.
Do not open access panels or approach electrical
components while voltage is applied.
When hazardous live parts are exposed, use individual
protective equipment to prevent risk of shock. Use
protective gloves, fire resistant clothes and face protection
when working with live conductors. Keep fingers behind
protective barriers.
Do not use in environments where vibration or shocks are
likely to disrupt the function or compromise the safety of
the controller.
Do not wear loose clothes or jewellery like chains or
bracelets which could make contact with electrical
components.
Allow the compressor installation to cool or heat to
acceptable temperatures before attempting to install a
pressure, temperature, humidity or other type of sensor.
Always ensure any pressure within a compressed air
system is safely vented to atmosphere before attempting
to remove or install a sensor device, never assume the
compressed air system is vented but always check the air
gauge. Be aware that other nearby parts can still be hot,
cold or pressurized.
The controller should be installed in such a location as to
allow operational and maintenance access to the
installation without obstruction or hazard and to allow clear

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visibility of indicators at all times.
As this product is installed on and integrated with other
machine(s), do read, understand and respect all safety
instructions provided by the supplier of these machine(s).
A switch or circuit-breaker shall be installed as means of
supply disconnection. This switch or circuit-breaker shall
be easy to reach and shall be marked as disconnection
device. When the supply is disconnected, all current
carrying conductors shall be disconnected.
Over-current protection needs to be fitted according to the
specified ratings.
Protective earthing; the controller shall always be earthed.
This is done according to the local legislation. Connection
of earth shall always be done before any other connection
is made. Disconnection of earth is only allowed after all
other connections are disconnected. Connector(s) and
their connection used for earth connection shall at all
times be capable of withstanding at least 30 N traction.
The protective earth conductor shall have at least the
current rating of the maximum rated terminal on the
controller.
All connections made to the product need to be made
according to the specifications. All electrical cabling need
to be compliant with applied maximum voltage and
currents. Maximum Temperature rating of the cables
needs to be at least 75 °C (unless otherwise noticed in the
Connections section). Always use bootlace ferrule with
stranded wiring.
All cabling shall be labeled such that, after disconnection
of cabling, reconnection of it is possible without any
confusion or mistakes. Labeling shall preserve its
readability over the lifetime of the installation in the
conditions the installation is operated.
Colors of cables and connectors shall be done according
to local legislation.
Section 2.3: Operation
Correct operation of the controller may only be checked by
trained personnel according to safe practices equipped
with appropriate protection against electrical hazards.
The controller must only be operated at the ratings: supply
voltage, frequency, pressure, temperature, altitude,
humidity and environmental rating for which it is designed.
Do not operate this controller in high humidity
environments or with wet hands
Do not open access panels or expose electrical
components while controller is operating.
Section 2.4: Maintenance
Maintenance 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.
Before competent personnel under qualified supervision
remove any access panels or carry out work on the
controller, they have to isolate it from the source of supply
power and any other electrical connections interfacing with
the environment in which the product is operating using
relevant and local safe isolation procedures.
After any intervention, the controller shall be completely
re-assembled, all connections need to be verified for their
correctness and all applicable checks need to be carried
out with success before re-powering the equipment.
Ensure that all instructions concerning operation and
maintenance are strictly followed and that the complete
controller, 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 renewed when acceptable
tolerances are exceeded. Always ensure any pressure
within a compressed air system is safely vented to
atmosphere before attempting to remove or install a
sensor device.
The product shall only be cleaned with a soft cloth
dampened with water or a solution of 50% water & 50%
alcohol. Use of any substances containing corrosive acids
or alkalis is strictly prohibited. Remove all sources of
supply before cleaning the product.
Do not paint the control facial or obscure any indications,
controls, instructions or warnings
Section 2.5: Batteries
Remark: not all types of controllers are equipped with a
battery.
Do not use other types of batteries than type supplied, do
not use in other equipment. Replace only by same type
batteries.
Use supplied batteries only in controller as intended. Pay
attention on the polarization when fitting batteries.
Keep batteries out of the reach of children and animals.
Get medical help in case a battery has been swallowed
Never attempt to charge batteries
Do not remove the batteries from their packaging until this
is required for use
Do not store batteries in environments with loose metal
parts or exposed to moisture, heat, fire or direct sunlight
Do no expose batteries to vibration, impacts or
deformation.
Fire, Explosion and sever burn hazard. Do not recharge,
crush, disassemble, heat above 100°C, incinerate
batteries or expose contents to water.
Consult IATI guidelines describing safe air transport of Li-
ion batteries.
Dispose of batteries according to local regulation. A
recycle program might be applicable.

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Section 3: Ratings
Max operating ratings:
Temperature:
Operating: 0 °C –55 °C
Storage: -25 °C –75 °C
Humidity: < 95 % R.H. @ 40 °C without
condensation
Power supply:
AC: 24V AC +/- 15%
DC: 24V DC +/- 15%
Consumption: 30VA
External fuse: Slow 1.6 A
Frequency: 50 / 60 Hz
Altitude: 0 –2000 m
Construction: IP65 (front face only after proper
installation)
Pollution degree: II
Overvoltage
Power supply: CAT II 24V ac/dc
Relays:
Overvoltage X09, X08, X07
All Relays: CAT III 250 V
Current Transformers:
Only use Current Transformers supplied by CMC which
have adequate overvoltage rating suitable for CAT III
600Vac.
3-phase monitoring input:
Overvoltage X12:
L1, L2, L3: CAT III 600V ac
Battery: CR1032 3V primary lithium cell only. Use of
another battery may present a risk of fire or explosion.

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Section 4: Connections and Protection
Remarks:
It remains the responsibility of the integrator of this controller (being a component in the total system) to assure that
the integration of the controller (in terms of wiring and use of other components) is done according to all applicable
regulations. In this context we remind that the controller is not a safety device and that care must be taken that other
components fulfill required safety functionalities.
The printing of text and symbols might differ slightly from the product you have.
Overview:
Section 4.1 Earth
Earthing is done using a “Faston” connection on following connection:

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Section 4.2. Power
Indication: 24Vac
24Vac shall be supplied by transformer in which the primary windings are separated from the secondary windings by reinforced
insulation, double insulation or a screen connected to the positive conductor terminal. Do not connect any of the leads of the
secondary winding to earth as this can result in severe damage of the controller.
Connector reference: X13
Section 4.3 Digital
Indication: DI1 ... DI8 and C-DI
C-DI is a voltage output to be used for the external contacts (relay, switch, …) addressing the DI input connections. C-DI is
approximately 24V dc. Only use this output for its dedicated functionality.

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The digital inputs are addressed via external contacts between C-I and the DI1 .. DI8 connections.
Connector reference: X02
Section 4.4 Relays
R1 .. R8 shall be protected against over-current. Absolute maximum current is 8A (resistive).
C-R on X08 and X09 shall be protected against over-current. Absolute maximum current is 10A (resistive).
Maximum Temperature rating of the cables for relays needs to be at least 100 °C
Connector reference: X07, X08 and X09
Section 4.5 Analog input
4.5.1 Standard analog inputs

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Three fixed analog inputs are available. All three have 2 dedicated connections:
Analog input 1: Connections C-ANA1 and AN1
current input: 4 .. 20 mA
Analog input 2: Connections C-ANA2 and AN2
current input: 4 .. 20 mA
Analog input 3: Connections C-ANA3 and AN3
Selectable by software configuration: current (4 .. 20 mA),voltage (0 .. 10V) or external resistor (acting as
temperature sensor)
For Analog input 1 and Analog input 2, the C connections (C-ANA1 and C-ANA2) are voltage outputs (referenced to the GND of
the controller). The maximum current rating per output is 50mA. The voltage level is approximately 24 V dc.
These voltage outputs (C-ANA1 and C-ANA2) shall only be used with devices that provide the current for respectively AN1 and
AN2. Only connect external components to this input that comply with this specified current range.
Analog input 3 can function in three ways (selected by configuration software):
Current input (4 .. 20 mA). In this case this input behaves as analog input 1 and 2. All remarks related to analog
inputs 1 and 2 apply to analog input 3.
Voltage input (0 .. 10V). In this case C-ANA3 is connected to the GND of the controller. Hence the voltage source can
be connected on C-ANA3 en AN3 with the positive connection of the voltage signal to AN3. Protect this input against
any voltage outside of this specified range.
oRemark: Power (+) can be drawn from for instance C-ANA1 provided total current sourcing remains
according to maximum of 50mA.
Resistor input (used with temperature sensor such as PT100, PT1000, KTY, NTC). The resistor shall be connected
between C-ANA3 and AN3.
Functional earthing
In case the external components demand for a GND connection (such as for functional earthing, It is recommended to use
shielded cabling for analog signals), it is advised to use the faston connections:
Connector reference: X03
4.5.2 Optional Analog input

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In X15 or X16 it is possible that one optional analog input is available.
Such input can be recognized by having 3 connection pins in its connector. If a connector with 2 connection pins is installed, it
is a RS485 connector (see further).
Note: on these 3 pin connectors a GND connection is provided.
In case an optional analog input is present, it behaves as Analog input 3. Hence all remarks related to Analog input 3 apply to
this input.
Connector reference: X15 or X16
Section 4.6 Analog output
The analog output provides a current ranging between 0 and 20 mA. The current leaves the controller through ANA-OUT to go
to the external device and shall return via AGND. For proper functionality the impedance of the external device shall be 500 Ω
resistive maximum.

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Functional earthing
In case the external components demand for a GND connection (such as for functional earthing, It is recommended to use
shielded cabling for analog signals), it is advised to use the faston connection:
Connector reference: X01
Section 4.7 Communication
4.7.1 Fixed RS485 Communication Connection
This connection shall only be used for connecting the controller with another component’s RS485 connection or a RS485 bus.
Connector reference: X04
4.7.2 Optional RS485 Communication Connection(s)
Up to 2 extra (optional) RS485 connections can be installed in the controller.
These can be located in the following positions:

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Such input can be recognized by having 2 connection pins in its connector. If a connector with 3 connection pins is installed, it
is an analog input connector (see above).
In case such optional connection(s) are installed, these connection(s) shall only be used for connecting the controller with
another component’s RS485 connection or a RS485 bus.
Connector reference: X05 and/or X06
4.7.3 Optional Ethernet Connection
Connections only to be done to standard Ethernet using RJ45 connector and at lease cat-5e rated cabling.
Connector reference: X14
Section 4.8 1-Phase Current sensor

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This input is only to be connected to a Current Transformer (CT) supplied by CMC. The selection of CT is done in accordance
with the installation and is as such not covered by this manual. Assure the maximum C.T. rating is 20 mA. Do not connect a
C.T. with a rating greater than 20 mA to this CT input.
For the installation, take into account the safety precautions that apply to Current Transformers.
Connector reference: X10
Section 4.9 3-Phase Current sensor
This input is only to be connected to Current Transformers (CT) supplied by CMC. The selection of CT(s) is done in accordance
with the installation and is as such not covered by this manual.. Assure the maximum CTs rating is 100 mA. Do not connect a
C.T. with a rating greater than 100 mA to this CT input.
For the installation, take into account the safety precautions that apply to Current Transformers.
Connector reference: X11

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Section 4.10 3-Phase monitoring inputs
In operation, high lethal voltages apply on these connections. Assure all power is switched off at the moment of
installation. Never assume power is off but always check the circuit.
The signals applied to the 3-Phase monitoring inputs of the controller must be protected by fuses as illustrated:
Fuses used must be Fast-Acting, High-Interrupting Capacity, Current-Limiting Type Fuses.
Specifications:
Voltage rating: 600Vac
Amperage rating: 100mA
Interrupting rating: AC: 100kA
CE approved
According to local regulation
Wiring:
Cable cross sectional area solid: min: 1.5 mm2; max: 6 mm2.
Cable cross sectional area stranded: min: 1.5 mm2; max: 6 mm2.
Always use bootlace ferrule with stranded wiring.
L1, L2, L3: CAT III 600V ac
Frequency: 50/60Hz
Connector reference: X12

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Section 5: Mounting
The Airmaster Q1 must be mounted in a front panel, enclosure or housing, which must have a suitable protection degree for the
electronics.
Components required (not delivered with the controller)
4 x serrated lock washer M4
4 x nut M4
Dimensions of mounting hole:

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Mounting of the controller (do respect the recommended torque setting):
Illustration of a well mounted controller: