EHS O2 Kompmaster User manual

All rights reserved. Maynot be photocopied or stored on a retrieval system without the prior written permission ofEHS.
Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
O2- Kompmaster
Composting Control Unit
In cooperation with:
© EHS Engineering Hard- + Software 2003

O2- Kompmaster
All rights reserved. Maynot be photocopied or stored on a retrieval system without the prior written permission ofEHS.
Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
Table of Contents
1 INTRODUCTION...........................................................................................................................1
2 DESCRIPTION...............................................................................................................................1
3 CONNECTION CONFIGURATION............................................................................................2
3.1 SUPPLY PIN CONFIGURATION ........................................................................................................ 3
3.2 CONTROL OUTPUT PIN CONFIGURATION ....................................................................................... 3
3.3 INPUTS .......................................................................................................................................... 4
3.4 OUTPUTS....................................................................................................................................... 4
4 INTERFACES.................................................................................................................................4
5 INDICATOR LAMPS ....................................................................................................................5
5.1 INTERNAL INDICATORS ................................................................................................................. 6
5.2 EXTERNAL INDICATOR .................................................................................................................. 7
6 REPLACING THE FUSE ..............................................................................................................7
7 SETTING THE ADDRESS............................................................................................................9
8 DATA STORAGE.........................................................................................................................10
9 NOTES...........................................................................................................................................12
10 TECHNICAL SPECIFICATIONS..............................................................................................13

O2- Kompmaster
Page 1
All rights reserved. Maynot be photocopied or stored on a retrieval system without the prior written permission ofEHS.
Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
1 Introduction
The “Kompmaster” compostingcontrol unit from EHS is designed to control and log
the compostingprocess bymeans of connected temperature and oxygen measuringsen-
sors. Onlymeasuringsensors authorized byEHS for operation with the compostingcon-
trol unit must be connected to the control unit.
An integrated and buffered memoryrecords and stores the data relevant to the assess-
ment of the compostingprocess, until theyare read and saved, which can be done using
the “Kompmaster” software for PCs provided.
It is recommended that you download the data in regular intervals and that you generate
and archive backup copies of your data.
2 Description
The “Kompmaster” control unit is used to control the compost decomposition and to log
the temperature values and the oxygen content. The control unit is designed for both
stand-alone and networked operation with maximum 32 control units.
In stand-alone operation, the connection to the control PC is achieved bymeans of an
RS232 interface which allows the use of anystandard computer.
In networked operation,the connection to the control PC is achieved bymeans of an
RS485 interface,which requires the use of correspondinginterface converters.
With the PC software provided it is possible to monitor the compostingprocess during
runningoperation, allowingcontrol of the compostingprocess at anytime. With the
help of the PC software you can also configure the settings and carryout the setup of the
compostingcontrol units connected.
For a detailed description of the software, please see the manual provided. In stand-
alone operation, onlythe control unit connected to the PC at the time (which must be
reinitialized after connecting) is visible in the PC software, and its measured values are
displayed.
In networked operation, the current measured values of all connected and active control
units are displayed on the PC. The settings and the control unit setup required can also
be carried out directlyfor all active control units usingthe PC software.
Once theyare initialized, both units work “stand-alone” without the PC. The PC is only
required for programmingand to archive and evaluate the data.

O2- Kompmaster
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For more information, see http://www.komposttechnik.de
3 Connector Configuration
The connectors on the side of the control unit are configured as follows.
Figure 1: Connector Configuration
(1) Temperature sensor
(2) Oxygen sensor
(3) RS485 connection 1
(4) RS485 connection 2
(5) 24V supply
(6) Control output
Please observe the configuration. Wrong connections can result in damage to the
control unit.

O2- Kompmaster
Page 3
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Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
3.1 SupplyPin Configuration
Figure 2: SupplyPin Configuration
Pin 1 +24V (controlled DC)
Pin 2 Power supplyground
Important:
The protective earth must be connected via the cable shield to the control unit.
3.2 Control Output Pin Configuration
Figure 3: Control Output Pin Configuration
Pin 1 K1
Pin 2 K2
In switched state K1 and K2 are electricallyconnected.

O2- Kompmaster
Page 4
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Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
3.3 Inputs
The input signals of the temperature sensors and the oxygen sensor are processed as ana-
logcurrents of 4 to 20 mA. The inputs are momentarilyprotected against over-voltage
and electrical interference.
For details please see the “Technical Specifications” table.
Onlyconnect measuringsensors authorized byEHS.
3.4 Outputs
The control output is designed as a potential-free make contact with a maximum load of
30 V and 1 A. The control output is used in the system to operate a relay(usually24V
relay) which again controls the fan.
Switch “open” = Signal blocked
Switch “closed” = Signal switched
Direct control of bigger loads than specified, e.g. a fan with higher voltages and currents
is prohibited and will damage the control unit.
The device is exclusively designed for low voltage. Non-observance of this specifi-
cation makes any warranty claimnull and void.
4 Interfaces
The are two control unit variations with different interfaces to the control PC.
(1) RS232/V24 “Stand-alone“ operation
Units which will not be networked are equipped with this interface. When oper-
atingseveral controls, you must connect them to the PC alternatelyto configure
the control or download the data.
The specification of the RS232/V24 interface in hardware and software complies
with the usual PC standard.
(2) In networked operation via RS485, up to 32 units can be operated at one PC in-
terface. Since this is not a standard PC interface, suitable converters must be
used. The RS485 interface is operated in 4-wire full-duplexmode, with each unit
havingits own network address which is set bymeans of micro-switches inside
the control unit. The control units are connected to each other and to the inter-
face converter usinga four-wire line. The wiringdiagram is as follows:
PC Komp-
master
TxD
RxD

O2- Kompmaster
Page 5
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For more information, see http://www.komposttechnik.de
Usingthis method a distance of max. 200 m is permitted, addingup the lengths of all
cables from the converter to the last control unit in the network. For larger distances the
use of fiber optics is recommended, alternativelysignal amplifiers for the RS485 bus
can be used..
When usingfiber optics, the individual units are connected to each other up to the
RS485/fiber optics converter usingcables. The transfer to the remote office buildingis
carried out bymeans of fiber optics and re-convertingto RS485 or—if connectingdi-
rectlyto the PC—to RS232.
Settingthe network address is described in the “Settingthe Address” chapter.
5 Indicator Lamps
A total of four LEDs are used to indicate various parameters of the control unit.
Three of those indicators are internal and onlyvisible after openingthe housing.
Caution:
Before opening the housing, unplug the power supply to prevent short-circuits
inside the control unit!!!
With the LEDs, the correct operatingvoltage supplyof both the electronics and the sen-
sors can be checked. In addition, there is an indicator showingwhether the control unit
activelyparticipates in the data communication with a connected control computer.
The fourth indicator is integrated into the housingand indicates the proper function of
the control unit bycyclic flashing(1 second on/1 second off).
RS485 Komp-
master 1
Tx-
Tx+
Rx-
Rx+
Komp-
master 2
Komp-
master “n”

O2- Kompmaster
Page 6
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Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
5.1 Internal Indicators
The LEDS are located at the positions illustrated and are allocated as follows:
Figure 4: Placement on the PCB
1) Operatingvoltage indicator: This LED must light continuouslyand indicates that
the internal supplyof the control unit is correct.
2) Communication indicator: This LED lights up momentarilywhen the control
sends data to the control computer at the control computer’s request.
3) This LED indicates whether the sensor supplyis applied correctly. This LED
must light continuously. If it does not light, the fuse of the sensor supplyhas
blown. In this case you must replace the fuse as described in the “Replacingthe
Fuse” chapter.
Figure 5: Layout ofthe LEDs

O2- Kompmaster
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For more information, see http://www.komposttechnik.de
5.2 External Indicator
The LED integrated in the front side indicates the correct function of the control unit by
cyclic flashing(1 second on/1 second off). This ensures that the supplyvoltage is ap-
plied correctlyand that the logic of the control unit operates correctly.
If you suspect a fault in the control unit, first check this operation indicator before open-
ingthe housingfor further fault localization.
Figure 6: External Operating Indicator
6 Replacing the Fuse
If the sensor supplyis not applied correctly, there is a high probabilitythat the fuse has
blown. To make the system operational again you must replace the fuse.
Before replacing the fuse, the cause for the fault must be located and eliminated.
You must check all connectors and cables to the sensors, both temperature and oxygen
sensors, and repair them if necessarybefore replacingthe fuse. A permanent short-
circuit can damage the control unit.
Before replacingthe fuse, please pull the connectors of the sensors out of the control
unit.
Caution:
Before opening the housing, unplug the power supply to prevent short-circuits
inside the control unit!!!

O2- Kompmaster
Page 8
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Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
Figure 7: Position ofthe Fuse Holder
To replace the fuse:
- Open the fuse holder with a large screwdriver bycarefullyturningit anti clockwise
until the cap is undone.
- Then pull out the fuse byremovingthe cap.
- Check whether the fuse reallyis damaged and replace it with a new fuse, if
necessary. For the technical specifications of the fuse please see the “Technical
Specifications” chapter.
- Close the fuse holder byrefittingthe cap and carefullyturningit clockwise with the
screwdriver until it snaps in securely.
- Now check the operatingvoltage indicator of the sensor supply. The corresponding
LED (see “OperatingIndicators” chapter) must be on.
- If this is the case, at first connect onlyone sensor to the control unit and check
whether the operatingvoltage indicator is still on or whether the fuse has blown
again.
- If the fuse has blown again, the sensor is defective and must be replaced.
- Carryout the last two steps for the second sensor.
- If, after connectingboth sensors, the operatingvoltage indicator lights up
continuously, the system is operational again.

O2- Kompmaster
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Figure 8: Fuse Holder
7 Setting the Address
In order for the PC software to separatelyacquire and archive the data of each control
unit, each control unit must have an individual address that is different to those of the
“Kompmaster” devices. The micro switch block for settingthe address is located on the
PCB.
Figure 9: Position ofthe Micro Switches
The address range is from 1 to 32. Usuallythe addresses are alreadyset correctlyon
deliveryof the control units. If you want to change the addresses or replace an old

O2- Kompmaster
Page 10
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Onlyfor use in conjunction with an Aerotronic control unit. © EHS- Engineering 2003
For more information, see http://www.komposttechnik.de
control with a new control and want to set the correspondingaddress, use the micro
switches 1-5 located on the PCB to set the desired address. For the individual switch
positions please see the followingtable.
Figure 10: Micro Switches for Setting the Address
0= Switch down/open 1= Switch up/closed
Address Table:
Address S1 S2 S3 S4 S5 Address S1 S2 S3 S4 S5
A1 0 0 0 0 0 A17 0 0 0 0 1
A2 1 0 0 0 0 A18 1 0 0 0 1
A3 0 1 0 0 0 A19 0 1 0 0 1
A4 1 1 0 0 0 A20 1 1 0 0 1
A5 0 0 1 0 0 A21 0 0 1 0 1
A6 1 0 1 0 0 A22 1 0 1 0 1
A7 0 1 1 0 0 A23 0 1 1 0 1
A8 1 1 1 0 0 A24 1 1 1 0 1
A9 0 0 0 1 0 A25 0 0 0 1 1
A10 1 0 0 1 0 A26 1 0 0 1 1
A11 0 1 0 1 0 A27 0 1 0 1 1
A12 1 1 0 1 0 A28 1 1 0 1 1
A13 0 0 1 1 0 A29 0 0 1 1 1
A14 1 0 1 1 0 A30 1 0 1 1 1
A15 0 1 1 1 0 A31 0 1 1 1 1
A16 1 1 1 1 0 A32 1 1 1 1 1
8 Data Storage
The control unit is equipped with buffered RAM, which “stand alone” stores the current
measured values in the integrated battery-buffered memoryat intervals set byyou, inde-

O2- Kompmaster
Page 11
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pendent of a connected PC. This data can be downloaded and archived with the PC
software at anytime. This procedure is described in the PC software manual.
The archivingintervals can be set byyou. Dependingon the storage interval selected,
the integrated memoryof 1000 measured value blocks lasts for a shorter or longer pe-
riod.
Example:
- If the archivinginterval is set to 1 min, the 1000 measure value blocks correspond to
1000 min = 16 h 40 min
- If the interval is set to 1440 minutes = 1 day, the memorysize lasts for 1000 days,
which is more than 2½ years.
- A storage interval of 60 min has proven to be practical. With the integrated memory
size, data of more than 1000 h can be recorded.
1000 h = 41 d 16 h.
This logs a complete compostingcycle in the memory.
You should download and archive the measured data from the control unit in time
before the memoryis completelyfilled.
If you missed readingout the measured data on time and the number of 1000
measurement cycles is exceeded, the current measured values continue to be logged and
the oldest measured values are deleted, ensuringthat the last 1000 measured values are
always stored and you can prove the current status of the compostingprocess.
Duringnon-networked operation, you must collect the data regularly.
The networked operation allows for automatic data storage. For details please see the
software manual. Here, all systems connected are addressed at the time specified byyou
and the data is loaded and stored on the PC.
Duringdownloadingof the measured data, an implemented fault protocol prevents data
loss duringfaults of the data transfer.

O2- Kompmaster
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9 Notes
The device is designed exclusively for low voltage. Non-observance of this
specification makes any warranty claimnull and void.
Only connect low voltage to the control output.
Only connect measuring sensors authorized by EHS or UTV to the control unit.
Only use the interfaces and cables provided by EHS/UTV to connect the control
unit to the computer.
Only use replacement fuses which comply with the specification. Fuses with other
values can cause damage to the control unit.
Eliminate all faults immediately and carefully.
Before opening the housing, unplug the power supply to prevent short-circuits
inside the control unit!!!
To not use pointed or sharp objects when working on or around the opened
electronics.
Make sure that no water penetrates the housing.
Proceed with great care when setting the composting control unit! The result of the
composting process directly depends on it.
Regularly save the logged composting data on the PC.
Back up your data regularly.
Observe the notes and technical specifications in the manual.
Important:
The protecting ground must be connected via the cable shield to the control unit.
10 Power supply
To supplythe control unit a power supplyunit with max. power of 100W has to be
used!

O2- Kompmaster
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11 Technical Specifications
Device type O2 Kompmaster
Nominal voltage 24 V DC
Supplyvoltage 22.0 ... 24 V DC controlled
Polarityprotection Yes (–24 V)
Power consumption without sensors 200 mA
Current consumption 11.0 A
Peak current 11.5 A
Fuse of sensor supply 4.0 A slow
Connectors 1- temperature measuringsensor
1- oxygen measuringsensor
2- RS485 (optional: 1- RS232)
1- control output
1- power supply
Control output 1 potential-free make contact
Control output load Max. 30V / 1A
Short-circuit proof All inputs and outputs 30 sec. against supplyand
ground
Operatingindicators 3 LED internal
1 LED external
Memory Static RAM with batterybuffer min. 8 years, 1000
records memorysize
Real-time clock chip Yes
Interface protocol 2400 baud, n, 8
Operatingtemperature –10 ... +50 °C
Protection class IP64
Material of housing Aluminum
Weight 0.7 kg
1 With temperature and oxygen measuring sensor connected

O2- Kompmaster
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For more information, see http://www.komposttechnik.de
List of Figures
Figure 1: Connector Configuration..................................................................................2
Figure 2: SupplyPin Configuration.................................................................................3
Figure 3: Control Output Pin Configuration....................................................................3
Figure 4: Placement on the PCB......................................................................................6
Figure 5: Layout of the LEDs..........................................................................................6
Figure 6: External OperatingIndicator............................................................................7
Figure 7: Position of the Fuse Holder..............................................................................8
Figure 8: Fuse Holder......................................................................................................9
Figure 9: Position of the Micro Switches........................................................................9
Figure 10: Micro Switches for Settingthe Address.......................................................10