CMC Airmaster R1 Manual

C.M.C. n.v. - Airmaster R1 installation guide – base unit – V1.1 – MANY0317A.00
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MANY0317A.00
Airmaster R1 hardware installation guide
for the base unit
Version 1.1
© Compressor & Machine Controls n.v. 2001-2003
safety warning!
Do not operate the Airmaster R1 until you and all personnel concerned have read and
understood this installation guide.
Important notes
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.
Signs:
Hazardous or harmful situation
Possible consequences: Slight or minor injuries.
Possible damage to the unit and the environment.
Electrical hazard:
Possible consequences: Severe or fatal injuries
Specific for the American (US) market
UL

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Table of contents
1. Introduction...................................................................................................................... 4
2. Models ............................................................................................................................. 5
2.1 Basic versions............................................................................................................. 5
2.2 Analog conditioning modules ..................................................................................... 6
2.3 Option modules .......................................................................................................... 7
3. Technical specifications.................................................................................................... 8
3.1 General technical data................................................................................................. 8
3.2 Temperature range...................................................................................................... 8
3.3 Resistance to vibration and shock ............................................................................... 9
3.4 Protection degree ........................................................................................................ 9
4. Safety............................................................................................................................... 9
5. Electromagnetic compatibility ........................................................................................ 10
6. Installation...................................................................................................................... 12
6.1 Cable connector types............................................................................................... 12
6.2 Power supply and fusing........................................................................................... 12
General....................................................................................................................... 13
For the American market (UL).................................................................................... 13
For the European market (CE) .................................................................................... 14
6.3 Analogue inputs........................................................................................................ 15
6.3.1 ACM type 1: digital input on analogue connector............................................... 15
6.3.2 ACM type 2: 0-10Vdc voltage input .................................................................. 15
6.3.3 ACM type 3: 4-20mA input (standard)............................................................... 16
6.3.4 ACM type 4: 4-20mA earth referenced (special type)......................................... 16
6.3.5 ACM type 5: KTY temperature sensor (-10…+132 deg C)................................ 17
6.3.6 ACM type 6: PT100 temperature sensor (-50…+250 deg C) .............................. 17
6.3.7 ACM type 7: PT1000 temperature sensor (-50…+250 deg C) ............................ 18
6.4 Digital inputs............................................................................................................ 19
6.4.1 The emergency stop contact input ...................................................................... 20
6.4.2 The contact inputs.............................................................................................. 20
6.4.3 The PTC inputs.................................................................................................. 20
6.5 Relay outputs............................................................................................................ 21
6.6 analog outputs........................................................................................................... 23
6.7 Communication ........................................................................................................ 23
6.7.1 RS485 port1 (standard) ...................................................................................... 23
6.7.2 RS485 port2 (option) ......................................................................................... 23
6.7.3 CAN™ Port (option).......................................................................................... 24
6.7.4 RS232 port (option) ........................................................................................... 24
6.7.5 RS-485 Communication with a standard HMI.................................................... 25
7. Mounting of the base unit ............................................................................................... 27
8. Putting into operation ..................................................................................................... 28
9. Configuration ................................................................................................................. 28
10. Trouble shouting........................................................................................................... 28
Appendix 1: Dimensions and mounting of base unit........................................................... 29
Appendix 2 : connectors for machine wiring....................................................................... 35
Connector X01: HMI + analogue inputs + analogue outputs ........................................... 36

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Connector X02: relays.................................................................................................... 36
Connector X03: digital inputs......................................................................................... 37
Connector X04: RS232 (optional)................................................................................... 38
Connector X05: CAN (optional)..................................................................................... 38
Connectors X06 and X07: RS485 (1).............................................................................. 38
Connector X08: RS485 (2) (optional) ............................................................................. 38
Connector X10: Supply .................................................................................................. 39
Appendix 3 : UL508 RATINGS / CONDITIONS............................................................... 40

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1. Introduction
The Airmaster R1 is an industrial controller consisting of two parts: a base unit and an HMI
(Human Machine Interface). The base unit is the real control unit and the HMI is the unit for
interaction with the user.
This hardware installation guide is a guide for the hardware related items. Please read the
software specficiations file for information on how to work with the unit.
The application area is restricted to machines that comply with the European machine
directive 89/37/EEC and the EMC directive 89/336/EEC. The application area is located in
electrical driven compressors and dryers in an industrial environment. Please contact CMC
for appliance in other machines.
The Airmaster R1 does not need to comply to the European Pressure Equipment Directive
97/23/EC, because no parts are under pressure, and the Airmaster R1 is not a safety
component.
The Airmaster R1 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 Airmaster R1 base unit 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.
For the American market UL508 is applicable, in accordance with the NFPA.
HMI
Base unit

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National and international directives and standards can change in time.
Please check them at a regular basis, and make modifications to your
equipment where this should be necessary.
2. Models
2.1 Basic versions
There are 7 basic versions available of the Airmaster R1 base unit. The following table
indicates the differences. The analogue conditioning modules (see further) must be added to
the basic version. The separate RS-485 communication channel to a standard HMI is not
indicated in the table below.
256K 512K 2 x
4-20mA
6 x
Relay
8 x
Digital
4 x
Analogue RS485(1) RS485(2) RS232 CAN
Real
Time
Clock
Memory Communications
Inputs Outputs
Flash
R1 - 10
R1 - 20
R1 - 25
R1 - 30
R1 - 35
R1 - 40
R1 - 45
R1

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2.2 Analog conditioning modules
1
black
Digital
2
red
Voltage
0-10Vdc
3
green
4-20mA
Loop Powered
4
blue
4-20mA
Earth Referenced
5
copper
KTY Temperature
-10°C to +132°C
6
red
PT100 Temperature
-50°C to +250°C
7
green
PT1000 Temperature
-50°C to +250°C
3
green
4-20mA
Self Powered
AI
C
AI
C
+V
+V
AI
C
signal
+24Vdc
AI
A GND
10-32Vdc
signal
AI
C
signal
GND
AI
C
AI
C
AI
C
X01-16
+
-
+
-
+
-
A GND
A GND
A GND
A GND
A GND

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2.3 Option modules
The R1 unit can accommodate one option card. Analogue Input types are defined by ACM’s
1
3
2
4
X21
X20
12 3 4
87 6 5
ACM's
ACM's
1
1
1
2
3
X20
X30
43 2 1
ACM's
1
1
X31
1
X30
6
1
6
1
6
R7
R8
R8
R9
R10
R7
8 x Analogue Inputs
8 x ACM Input Selection
reference number: Aabcdefgh
a = AI 1 ACM (0 to 7)
b = AI 2 ACM (0 to 7)
c = AI 3 ACM (0 to 7)
d = AI 4 ACM (0 to 7)
e = AI 5 ACM (0 to 7)
f = AI 6 ACM (0 to 7)
g = AI 7 ACM (0 to 7)
h = AI 8 ACM (0 to 7)
example: A33552700
4 x Analogue Inputs
4 x ACM Input Selection
2 x Relay Outputs
240Vac@8A resistive
24Vdc@5A resistive
reference number: Babcd
a = AI 1 ACM (0 to 7)
b = AI 2 ACM (0 to 7)
c = AI 3 ACM (0 to 7)
d = AI 4 ACM (0 to 7)
example: B3552
4 x Relay Outputs
240Vac@8A resistive
24Vdc@5A resistive
reference number: C
C
B
A

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3. Technical specifications
3.1 General technical data
Processor 16bit ST ST10R272
Flash EPROM 256 Kbytes (512 Kbytes maximum)
Non Volatile RAM 256 Kbytes (512 Kbytes maximum)
I/O processor AduC814BRU (8051 compatible)
A to D Resolution 12bit (1/4096)
D to A Resolution 12bit (1/4096)
RTC Device Real Time Calendar Clock (option)
Supply input 24Vac (+-20%) 50VA
or 24Vdc (20 – 36 Vdc) 40W
Analogue Inputs 4 standard 12 maximum
Digital Inputs 8 standard 16 maximum
Analogue Outputs 2 standard - -
Relay Outputs 6 standard 10 maximum
(consult CMC for combination availability)
Construction steel casing, zinc anti-corrosion
Mounting 35mm Rail, DIN 46277-3
Dimensions 115mm x 166mm x 88mm
Connections PCB mounted, Phoenix compatible
Conformity
3.2 Temperature range
Operating temperature 0°C to +55°C
Storage temperature -25°C to +75°C
Relative humidity at 40°C(non condensing) <95%
According to:
Operating tests at -10°C and +65°C
IEC 68-2-2 B Dry heat, 4 days
IEC 68-2-14 Nb Cyclic, 6hrs/cycle, 5 days
IEC 68-2-3 Ca Damp heat steady, 40°C, tbd R.H., 10 days
IEC 68-2-30 Db Damp heat cyclic, +50°C, variant 1, 2 cycles
IEC 68-2-1 A Cold, 4 days
Storage tests at -25°C and +75°C
IEC 68-2-1 A Cold 6 days
IEC 68-2-14 Na Change of temperature, 3hrs/temp, 2 cycles
IEC 68-2-2 B Dry heat 6 days
US
C

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3.3 Resistance to vibration and shock
operating
IEC 68-2-6 Fc Vibrating, 10-150Hz, 2g, 10sweeps/axis
not operating (storage and handling)
IEC 68-2-6 Fc Vibrating, 10-150Hz, 1g, 5sweeps/axis
IEC 68-2-27 Ea Shock, 15g, 11ms, 3 shocks/axis
IEC 68-2-29 Bump, 10g, 6ms, 500 bumps / axis
3.4 Protection degree
The protection degree is IP00.
The R1 unit must be mounted within an enclosure or housing
with suitable protection rating.
4. Safety
The Airmaster R1 is a class I equipment in which protection against electric shock does not
rely on basic insulation only, but which includes an additional safety precaution in that
accessible conductive parts are connected to the protective earthing conductor in the fixed
wiring of the installation in such a way that they cannot become live in the event of a failure
of the basic insulation.
The Airmaster R1 base unit must be earthed. See drawing below (indicated with the
yellow/green wire)

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In the event that the Airmaster R1 is used to switch circuits
with a voltage of 42,4V peak or more, the danger of
electrocution exists and therefore protection measurements
have to be made for avoiding this situation.
If only low voltage limited energy circuits are connected to the Airmaster R1 it is still
necessary to earth the unit to fulfill the electromagnetic compatibility demands.
The enclosure must be earthed at all times.
Low voltage (low current, limited energy) wires must be separated from the power wires.
CMC disclaims any warranty in case the Airmaster R1 has been opened or repaired by an
unauthorized person.
5. Electromagnetic compatibility
The enclosure is an important part of the protection of the electronics against
electromagnetic interference. Also the radiation of electromagnetic energy is shielded by the
enclosure. Therefore it is necessary to earth the enclosure with a very short wire to the
nearest earthed metal part. We advise a maximum length of 20cm. Use a stranded wire with
at least a section of 1.0mm2.
The electromagnetic compatibility of the unit can not be guaranteed when the unit is opened.

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The use of shielded cables, especially for analog inputs and digital communication is highly
recommended in order to have a correct EMC installation.
It is the responsibility of the user to design the machine or installation to which this
equipment is to be fitted according to the rules of a good EMC installation.
Susceptibility IEC 801-2, EN61000-4-2 level 4, 8kV discharge
IEC 801-3, EN61000-4-3 level 3, 10V/m electric field
IEC 801-4, EN61000-4-4 level 4, 4kV transient on supply
IEC 801-5, EN61000-4-5 level 4, 2kV surge on supply (L-PE)
Emissions CISPR 22, EN55022 class A industrial radiated
CISPR 22, EN55022 class A industrial conducted

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6. Installation
This part is necessary for the designer willing to use the Airmaster R1. It shows how an R1
can be integrated into an electrical circuit. Chapter 8 “Putting into operation” gives some
directions that should be known in production. We strongly advise to use these assembly
instructions.
6.1 Cable connector types
The cable connector must match with the connectors populated on the Airmaster R1. Please
refer to appendix 3 for more information.
6.2 Power supply and fusing
Power supply and fusing is an important part of the installation. The supply can be with an
AC voltage or with a DC voltage. The maximum variation on the 24V ac is +-20%. The
nominal DC voltage is 24V dc. The variation on the DC voltage is 20Vdc to 36Vdc.
The input voltage ratings for UL are: 24 Vac or 24 Vdc
(Limited Voltage/Current).
“The devices shall be supplied by an isolating device such that
the maximum open circuit voltage potential available to the
circuit is not more than 24Vdc/ac and the current is limited to a
value not exceeding 8 amperes measured after 1 minute of
operation. A secondary fuse or other such secondary circuit
protection rated 4A in accordance with the UL248 series shall
be used to limit the available current.”
F1: 4A T (Timelag, slow blow) fuse
Connector X10
Pin Name function
1 SUPPLY(+) Supply input: AC or positive (+) DC
2 SUPPLY(-) Supply input: AC or negative (-) DC
min typ max dim
AC input voltage
+V
24V
50VA
F1 (T)
L1
L3
T1 0V
V2
0V
X10
1
2
UL

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AC input voltage 19.2 24 28.8 Vac
AC input frequency 50 60 Hz
Recommended 24Vac transformer 50 500 VA
Dropout at input 10 ms
DC input voltage
DC input voltage with ripplevoltage at full
load < 2 Vpp. Use a stabilized supply if
input voltage <=23Vdc.
20(*) 24 36 Vdc
Input power 40 W
Recommended DC power supply 40 500 W
Dropout at input 10 ms
(*) The DC input voltage inclusive ripple must be higher than 19 V at all time.
General
The selection of the transformer must be in accordance with the applicable national and
international standards and regulations. Changes in time to these standards are always
possible. In case of doubt please do check them.
Examples:
For the American market (UL)
The selection of the transformer must be in accordance with the transformers
mentioned in the UL508(A) standard. This means that they have to be UL506 or
UL1585 or UL1310 approved (depending on the type).
The transformer or supply must be an UL Listed type or an UL recognized type. An
UL listed device in general does not need additional temperature measurements for
compliance, and is therefore recommended. An UL recognized transformer needs
additional temperature measurements by UL.
- 24Vac supply input:
A control transformer (UL506) or a Class 2 transformer (complying with the
requirements of UL 1585) must be used for the 24Vac power input of the Airmaster
R1. A not inherently limited transformer shall be provided with additional
overcurrent protective devices in accordance with the manufacturer’s instructions for
the component.
- 24Vdc supply input
Use an UL508 Listed 24V DC power supply with a usable power rating of at least
40W @ 60 degrees C. This supply must also comply to UL60950 if a connection is
made with IT equipment.
- Digital outputs with relaycontacts

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The contacts of the Airmaster R1 relays must only be used in conjunction with a
control circuit transformer (Class 1, UL506), except if a voltage less than 30Vrms is
used with a limited energy rating. In the last case a Class 2 transformer is also
allowed.
The secondary circuit of the control transformer can be grounded without damage to
the Airmaster R1 controller.
A suitable UL508 branch circuit protection must be provided on the primary side of
the transformer. A supplemental fuse (in accordance with UL248 series) with a rating
of 4A ‘T’ type (slow blow) is obligated for the secondary side. In case of doubt
please contact the transformer supplier.
Please consult the text of the UL508A and/or UL508 standard for more explanation
regarding this item.
For the European market (CE)
The transformer or power supply must be in accordance with the current applicable
European directives (e.g. Low Voltage Directive and EMC directive). This means
that it must conform to the EN61558 standard ( partly supersedes the older EN60742
standard) for the particular application. Also applicable are EN60204 (Safety of
machinery - Electrical equipment of machines) and EN60950. A CE marking must be
on the device.
The Airmaster R1 is a class I equipment in which protection against electric shock
does not rely on basic insulation only, but which includes an additional safety
precaution in that accessible conductive parts are connected to the protective earthing
conductor in the fixed wiring of the installation in such a way that they cannot
become live in the event of a failure of the basic insulation.
In the case of a proper grounding or earth connection an isolating transformer can be
used. However, if the chance exists that the earth connection can be disconnected
when the equipment is under voltage, a safety isolating transformer must be used.
Note that for EMC reasons an earth connection is obligatory.
The transformer or supply must be suitable for use in a standard industrial
environment.

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6.3 Analogue inputs
Analogue inputs are definable using plug-in analogue conditioning modules (ACM’s).
Up to four ACM’s can be fitted to the R1 base unit in any combination.
It is strongly recommended to use shielded cable for analogue inputs. Use the fastons near
the analogue inputs for connection of the cable shield. Shielding connections must be as
short as possible. Avoid long “pig tails”, as this will reduce EMC performance.
Connector X01 pin 5 C-AI1 Analog 1 common
pin 6 AI1 Analog 1 input
pin 7 C-AI2 Analog 2 common
pin 8 AI2 Analog 2 input
pin 9 C-AI3 Analog 3 common
pin 10 AI3 Analog 3 input
pin 11 C-AI4 Analog 4 common
pin 12 AI4 Analog 4 input
6.3.1 ACM type 1: digital input on analogue connector
The analogue inputs can act as a digital input when an ACM type 1 is used. The contact is
connected between the common (C) of the analogue input, and the analogue input. A voltage
free contact must be used.
6.3.2 ACM type 2: 0-10Vdc voltage input
A 0-10Vdc voltage can be used where the source is closely located to the basic controller.
Use earth shielded cable no greater than 2m in length. Note that a 4-20mA is a much better
choice regarding EMI and distance.
AI4
X01
AI3 AI2 AI1
P_dP_I T_d

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+V means a positive voltage to analogue ground (A GND). The signal voltage can be
different from the supply voltage of the external sensor.
6.3.3 ACM type 3: 4-20mA input (standard)
4..20mA loop powered
This configuration uses the available 24Vdc source on the base unit. No additional power
source is necessary. This configuration is recommended.
4..20mA self powered
In the self powered configuration the sensor uses an external DC power supply source. For
reference with the supply, the A GND must be connected to the Airmaster R1 analogue
ground pin.
6.3.4 ACM type 4: 4-20mA earth referenced (special type)
This ACM can be used with a special 4..20mA current sensor (with GND connected to
ground).

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6.3.5 ACM type 5: KTY temperature sensor (-10…+132 deg C)
A KTY temperature sensor is a semiconductor sensor. The standard sensor type that is used
is the type KTY10-62 or the less accurate version KTY10-6 or KTY11-6 variant.
6.3.6 ACM type 6: PT100 temperature sensor (-50…+250 deg C)
A PT100 temperature sensor can be connected to the base unit, but only for very short
distances (2 meters). If accurate measurements must be made it is much better to use a
PT1000 temperature sensor. You can run 10 times further with your cable for having the
same error due to the wire resistance as with PT100.
PT100 temperature sensors have a resistance varying with the temperature. When the
temperature is 0°C (32°F) the nominal resistance is 100 ohm. At 200.4°C this resistance is
raised to 176,0 ohm.
Use PT100 sensors with a mean temperature coefficient α of 0.003850 ΩΩ
−1
°C
−1
. In case of
doubt please contact your sensor supplier. (reference: IEC Publication 751)
The wires to a sensor must be as short as possible and with a big enough section in order to
reduce the wire resistance error.
The wires of a PT100 sensor of the same colour have to be kept together if the sensor has
more than 2 wires.
Connect the shielding of the sensor cable to the earth faston connector of the R1 unit.

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6.3.7 ACM type 7: PT1000 temperature sensor (-50…+250 deg C)
PT1000 temperature sensors have a resistance varying with the temperature. When the
temperature is 0°C (32°F) the nominal resistance is 1000 ohm. At 200.4°C this resistance is
raised to 1760 ohm.
Use PT1000 sensors with a mean temperature coefficient α of 0.003850 ΩΩ
−1
°C
−1
. In case of
doubt please contact your sensor supplier. (reference: IEC Publication 751)
The wires to a sensor must be as short as possible and with a big enough section, to reduce
wire resistance errors.
The wires of a PT1000 sensor of the same colour have to be kept together if the sensor has
more than 2 wires.
Connect the shielding of the sensor cable to the R1 unit faston terminal.

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6.4 Digital inputs
There are 8 digital inputs on the base unit: 1 for the emergency stop button, 5 general
purpose and 2 are PTC inputs.
Connector X03 pin 1 C+ Input 1 common
pin 2 C1 Input 1
pin 3 C+ Input 2 common
pin 4 C2 Input 2
pin 5 C+ Input 3 common
pin 6 C3 Input 3
pin 7 C+ Input 4 common
pin 8 C4 Input 4
pin 9 C+ Input 5 common
pin 10 C5 Input 5
pin 11 C+ Input 6 common
pin 12 C6 Input 6
pin 13 C+ Input 7 common
pin 14 C7 Input 7
pin 15 C+ Input 8 common
pin 16 C8 Input 8
Digital Input 1 (Emergency Stop)
Common Terminal 24VDC
Sink Current up to 200mA
Resistance closed contact < 3 ohm
Resistance open contact > 750 Kohm
OF AF
S1
+VC
+V
S2
S3
PTC1
116
X03
EXAMPLE
1C 2C 3C 4C 5C 6C 7C 8C
OSES

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Digital Inputs 2 to 6 (general purpose)
Common Terminal 24VDC
Sink Current 10mA max
Resistance closed contact < 13 ohm
Resistance open contact > 750 Kohm
Digital Inputs 7 and 8 (PTC thermistor)
Common Terminal 24VDC
Sink Current 1.4mA
Resistance closed contact < 750 ohm
Resistance open contact > 4000 ohm
Conformity IEC 34-11-2, VDE 0660
Note: all resistance are inclusive the resistance of the cabling.
6.4.1 The emergency stop contact input
The contact, which is connected between the first digital input and the common digital inputs
supply terminal is also feeding the internal relays of the Airmaster R1. As soon as this
contact opens, all relays are de-energised. In this manner, when an emergency occurs, all
outputs become non-active without intervention of the microprocessor or software. This
contact must be normal-closed, which opens in case of emergency stop.
Contactors, relays or other output devices connected to the
relay outputs of the Airmaster R1 must also be disconnected
by another contact on the emergency stop button.
Special precautions must be foreseen that no overvoltage is
applied to the emergency stop contact input.
6.4.2 The contact inputs
The status of all contact inputs can be read by the Airmaster R1. Over an open contact a
minimum voltage of 18Vdc is maintained. When the external contact is closed a minimum
current of 5mA runs through the contact. This is intended to prevent contact oxidisation
errors.
6.4.3 The PTC inputs