KAESER KOMPRESSOREN ADA 2 User manual

Operating manual
measuring and analysis system
ADA 2 EFFICIENCY OPTIMIZATION
No.: 901711 00 E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

Original instructions
/KKW/AADA 2.00 en BA_ADA_2
/KKW/AADA 2.00
20130503 140804

1 Regarding this document
1.1 Using this document ......................................................................................................... 1
1.2 Symbols and labels .......................................................................................................... 1
1.2.1 Warnings ............................................................................................................. 1
1.2.2 Other alerts and their symbols ............................................................................ 1
1.3 Copyright .......................................................................................................................... 2
2 Technical Specifications
2.1 Hardware .......................................................................................................................... 3
2.1.1 Logger ................................................................................................................. 3
2.1.2 Signal converter .................................................................................................. 3
3 Safety and Responsibility
3.1 Specified use .................................................................................................................... 4
3.2 Determining personnel ..................................................................................................... 4
3.3 Warranty ........................................................................................................................... 4
4 Design and Function
4.1 Function and capacity ...................................................................................................... 5
4.2 The basic measuring kit ................................................................................................... 5
4.3 The logger ........................................................................................................................ 6
4.4 The network kit ................................................................................................................. 9
4.5 The network switch .......................................................................................................... 11
4.6 The user interface ............................................................................................................ 12
5 Operation
5.1 Example of a measurement with ADA 2 ......................................................................... 14
5.1.1 Log on and enter the customer data ................................................................... 14
5.1.2 Defining the measurement configuration ............................................................ 16
5.1.3 Defining loggers and signals ............................................................................... 20
5.1.4 Assigning logger(s) ............................................................................................. 23
5.1.5 Starting, performing and concluding a measurement ......................................... 24
5.1.6 Preparing and sending measurement data for analysis ..................................... 26
5.1.7 Resetting the logger (RESET) ............................................................................ 28
6 Decommissioning, Storage and Transport
6.1 De-commissioning ............................................................................................................ 30
6.2 Storage ............................................................................................................................. 30
6.3 Packaging ........................................................................................................................ 30
6.4 Disposal ........................................................................................................................... 30
Contents
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ADA 2 EFFICIENCY OPTIMIZATION i

Contents
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Operating manual measuring and analysis system
ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

Fig. 1 Basic measuring kit: Hardware ................................................................................................... 6
Fig. 2 Logger, rear view ........................................................................................................................ 7
Fig. 3 Logger, front view ....................................................................................................................... 8
Fig. 4 Network kit: Hardware ................................................................................................................ 10
Fig. 5 Network diagram ........................................................................................................................ 11
Fig. 6 Rear view ................................................................................................................................... 12
Fig. 7 Elements of the user interface ................................................................................................... 13
Fig. 8 Address "02" ............................................................................................................................... 14
Fig. 9 Splash screen ............................................................................................................................. 15
Fig. 10 Specifying the configuration type ............................................................................................... 15
Fig. 11 Entering customer data .............................................................................................................. 15
Fig. 12 Creating a sketch as model of the compressed air station ......................................................... 16
Fig. 13 Logically linking the sketch elements ......................................................................................... 17
Fig. 14 Configuration with linked elements ............................................................................................. 18
Fig. 15 Data selection for "Compressor 1" ............................................................................................. 18
Fig. 16 Signal selection for "Compressor 1" ........................................................................................... 19
Fig. 17 Data selection for "Compressor 2" ............................................................................................. 19
Fig. 18 Signal selection for "Compressor 2" ........................................................................................... 20
Fig. 19 Assigning the logger to a measurement network ....................................................................... 20
Fig. 20 Assignment of signals to channels (analog inputs) at the logger ............................................... 21
Fig. 21 List of allocated analog inputs of the logger with assigned signals ............................................ 22
Fig. 22 Saving the configuration ............................................................................................................. 22
Fig. 23 Registering loggers for measurement ........................................................................................ 23
Fig. 24 Allocation of channels (analog inputs) ........................................................................................ 23
Fig. 25 Allocation of channels (analog inputs) with plot ......................................................................... 24
Fig. 26 Starting a measurement ............................................................................................................. 24
Fig. 27 Stopping a measurement ........................................................................................................... 25
Fig. 28 Stopping a measurement: Entering a password ........................................................................ 25
Fig. 29 Downloading measurement data from the logger to the notebook ............................................. 26
Fig. 30 Saving the ZIP file ...................................................................................................................... 26
Fig. 31 Retrieving the deletion code from the "delcode.txt" file .............................................................. 26
Fig. 32 Deleting the measurement data on the logger ........................................................................... 27
Fig. 33 Entering the KAESER e-mail address ........................................................................................ 27
Fig. 34 Sending measurement data to KAESER ................................................................................... 28
Fig. 35 Data and P&I diagram of the mailed measurement .................................................................. 28
Fig. 36 Triggered overload monitoring ................................................................................................... 29
List of Illustrations
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List of Illustrations
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Operating manual measuring and analysis system
ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

Tab. 1 Danger levels and their definition ............................................................................................... 1
Tab. 2 Colour coding of the analog inputs (channels) at the logger ...................................................... 8
Tab. 3 Component symbols for the sketch ............................................................................................ 16
List of Tables
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List of Tables
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ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

1 Regarding this document
1.1 Using this document
The operating manual is a component of the ADA 2 measuring and analysis system. It describes
the application and its hardware and software at the time of the initial shipment following produc‐
tion.
➤ Please retain this operating manual until the disposal of the hardware and software of ADA 2.
➤ Pass the manual on to the next owner or user of the equipment.
➤ Ensure that any amendments received are inserted in the manual.
1.2 Symbols and labels
1.2.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
1. DANGER!
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The signal word "DANGER" indicates that death or severe injury can result from ignoring the
warning.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent threat of
danger
Will result in death or severe injury
WARNING Warns of possible danger May result in death or severe injury
CAUTION Warns of a potentially dangerous
situation
May result in moderate physical injury or damage
to objects
Tab. 1 Danger levels and their definition
1.2.2 Other alerts and their symbols
This symbol indicates particular important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This symbol is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
1 Regarding this document
1.1 Using this document
No.: 901711 00 E
Operating manual measuring and analysis system
ADA 2 EFFICIENCY OPTIMIZATION 1

Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Further subjects are introduced here.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1 Regarding this document
1.3 Copyright
2
Operating manual measuring and analysis system
ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

2 Technical Specifications
2.1 Hardware
The components of the hardware belonging to the ADA 2 measuring and analysis system as they
are supplied in the basic measuring kit, the network kit and the accessory kits, must be stored in a
dry environment. Even during the measurement, they must not be exposed to high levels of humid‐
ity.
2.1.1 Logger
Power supply
■ Via PoE: 48 V
(PoE: Power over Ethernet)
■ Via barrel connector: 24 – 36 V DC
■ Power consumption: <15 W
Sensor connection
■ Voltage output:
─ Supply voltage: 15 V
─ Max. output current per channel: 40 mA
■ Signal input
─ Apparent ohmic resistance: 100 Ω
─ Max. input current: 25 mA
Temperature range
Ambient temperature: -20 °C bis +45 °C
2.1.2 Signal converter
Analog interface:
■ Input voltage: 15 – 24 V DC
■ Signal output: 4 – 20 mA
Digital signal input:
■ Permissible input voltage: 0 – 600 V AC/DC
■ Signal voltage range: 10 – 600 V AC/DC
2 Technical Specifications
2.1 Hardware
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3 Safety and Responsibility
3.1 Specified use
ADA 2 is designed solely for the measurement and analysis of compressor and blower stations.
Any other use is considered incorrect. The manufacturer is not liable for any damages that may
result from incorrect use. The user alone is liable for any risks incurred.
➤ Comply with the instructions in this operating manual.
The measurement results are confidential and must be evaluated only by KAESER.
The specified use of the device also comprises the confidential treatment of the data obtained
which must not be disclosed to third parties.
➤ Send the file with the saved measured values to KAESER for analysis.
3.2 Determining personnel
This operating manual is intended for trained personnel familiar with compressed air stations.
These persons must know how and where to connect the various sensors for measuring the differ‐
ent values at the compressed air station.
The subject of this document is the handling of ADA 2 for the proper preparation, performance, and
analysis of the measurement of your compressed air station. In this context, the function of the rel‐
evant hardware such as loggers, sensors, the network switch, etc. are also described.
➤ Only trained personnel shall be tasked with measuring compressed air stations.
3.3 Warranty
This operating manual contains no independent warranty commitment. Our general terms and con‐
ditions relative to warranty apply.
The precondition of any warranty on our part is the intended use of the hardware and the software
of the ADA 2 measuring and analysis system, taking into consideration the specific circumstances
of their application.
Due to the multitude of possible applications, the user is obliged to determine the suitability for a
specific application.
Furthermore, we do not assume any warranty obligation for damages caused by:
■ the use of unsuitable parts or operating materials,
■ unauthorised modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of genuine KAESER spare parts and operating
materials.
➤ Contact KAESER regarding the suitability of your specific operating conditions.
3 Safety and Responsibility
3.1 Specified use
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ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

4 Design and Function
4.1 Function and capacity
ADA 2 is a measuring and analysis system for determining the degree of utilisation oh compressed
air stations. Using this device, you can perform measurements on all KAESER machines but also
on competitors' equipment.
For each measuring process, it must be established individually which values are to be taken by
ADA 2.
Analog signals can be evaluated for:
■ Pressure
■ Temperature
■ Capacity
■ Speed
■ Pressure dew point
■ Free air delivery
■ Current (raw value in mA; for possible additional measurands).
Signal converters are used to take digital values for other user-definable measurands and to con‐
vert these into analog signals, such as
■ Motor On, Motor Off
■ LOAD, IDLE
The system takes measurements until it is being stopped, or the memory is full.
4.2 The basic measuring kit
The basic measuring kit contains the basic equipment required for a measurement of compressed
air stations with ADA 2.
Power supply units are supplied for both loggers provided with the basic measuring kit. A logger is
powered via a supply unit if it is directly connected to the notebook as an individual logger. If multi‐
ple loggers are installed within a network, then they are powered via a network switch.
4 Design and Function
4.1 Function and capacity
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Fig. 1 Basic measuring kit: Hardware
1Logger (2x)
2Signal converter with 2 digital channels
(4x)
3Power supply unit (2x)
4Connector cable (4x)
5Pressure transducer (4x)
One signal converter can acquire the values from two digital channels and convert them to analog
signals.
The most common applications are the measurement of the "LOAD/IDLE" and "Motor On/Motor
Off" status pairs.
Use a connector cable to create the connection of a signal converter from the machine's measuring
point to a logger.
Pressure transducers are used to measure the pressure at the desired locations within a com‐
pressed air station.
Although not visible, the basic measuring kit also contains four adapters for measuring devi‐
ces that can be provided in special accessory kits. Specific accessories are necessary for all
measurements that cannot be taken with pressure transducers or signal converters (see Ta‐
ble 2).
4.3 The logger
Measuring data are captured by and recorded on a logger of the ADA 2 measuring and analysis
system.
When measuring with a single logger, this logger is directly connected to the notebook which is
used to access the ADA 2 user interface, and with the compressed air station for which measured
values are to be captured.
4 Design and Function
4.3 The logger
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ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

Fig. 2 Logger, rear view
1Power supply unit port
2Address field with rotary controls
3Rotary control for setting the logger ad‐
dress
4Internal memory card
5USB port
6Network port (Ethernet/PoE)
Power supply unit port
The power supply unit from the basic measuring kit is connected to the 24 V port 1 to provide cur‐
rent to the logger.
Address field
The logger's address field 2 provides the following setting options:
■ 2 rotary controls 3 to be set to a value between 0 and 9.
■ A number circle mapping the setting positions for the possible values of the rotary controls.
The two set values together create the logger's address.
Example:
The left rotary control is set to 3 and the right one is set to 7, giving the logger the address 37.
The address of every connected logger must be unique for the duration of a measurement.
Memory card
The bay to the right of the address field 4 contains an internal memory card storing the measured
values during the measurement.
This memory card is exclusively designed for this function, and can never be replaced by another
memory card not specifically designed for this function.
➤ Never try to replace a defective memory card.
➤ Please contact the authorised KAESER Service if the memory card in your logger is defective.
4 Design and Function
4.3 The logger
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USB port
The USB port 5 to the right of the memory card bay is not in use.
Ethernet/PoE port
Use the Ethernet/PoE port 6 to connect the logger either directly with a notebook or to a network
switch.
If the logger is defined as only logger for a measurement, this port is used to directly connect the
logger to the notebook used to accessing the ADA 2.
If the logger is installed in a ADA 2 network, this port is used to connect the logger to a network
switch. In this case, the network switch is connected to the notebook used to accessing the ADA 2
user interface.
Fig. 3 Logger, front view
1Analog signal inputs/channels (8x)
2Channel LEDs (8x)
3Power LED
4Overload LED
Analog signal inputs (channels)
Every analog signal input 1 can evaluate either one analog signal or two digital signals during a
measurement. The measured values are displayed in a measuring range between 4 and 20 mA.
A channel LED 2 flashes in the following events:
■ No sensor is connected to the signal input.
■ The sensor connected to the signal input is defective.
A channel LED is illuminated when the signal input is active and free of errors.
The LED's colour above the signal input indicates the type of value measured at this channel, that
is, what type of sensor can be connected.
Colour Measurand
Orange Pressure
Red Temperature
4 Design and Function
4.3 The logger
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ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E

Colour Measurand
Pink Capacity
White Signal converter (freely selectable)
Yellow Speed
Turquoise Dew point
Blue Free air delivery
Green Current (raw value in mA)
Tab. 2 Colour coding of the analog inputs (channels) at the logger
The colour coding of the sensor plugs indicates which sensor can be connected to which signal
input.
The basic measuring kit contains sensors for measuring pressures and signal converters. Ac‐
cessory kits containing the required hardware are provided for the measurement of additional
values such as temperature, speed, etc. (see Table 2).
Power LED
The power LED 3 indicates the following:
■ It is illuminated when the logger is connected to a power source.
■ It flashes during a measurement and when this logger is defined as master (master logger).
If only one logger is connected for measuring, it is automatically defined as the master.
Overload LED
The overload LED 4 is illuminated when the global overload monitoring device has responded and
subsequently disconnected all signal inputs from the supply voltage. Use the software to reset to
the current state (see also Fig. 36 in the example session).
4.4 The network kit
The network kit contains the accessories required in addition to the hardware of at least one basic
measuring kit to install a ADA 2 network.
4 Design and Function
4.4 The network kit
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Fig. 4 Network kit: Hardware
1Network switch
2Power supply unit
3Patch cable (4x)
In this case, all loggers are supplied with power by the network switch.
4 Design and Function
4.4 The network kit
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Fig. 5 Network diagram
1Notebook
2Network switch
3Logger
4Compressed air station
5Mains supply
4.5 The network switch
A network switch is absolutely necessary when multiple loggers are installed for a measurement.
This network switch has its own power supply unit. The following components are connected to the
network switch:
■ One to four loggers
■ The notebook to access the ADA 2 user interface.
If one logger is connected to the network switch, this logger saves all data captured during the
measurement. If multiple loggers are connected, the data are saved only by the master logger.
Logger ports
The ports 1 identified with a yellow bar and the lettering "PoE" are reserved for up to four loggers.
Four loggers are capable to capture up to 32 analog signals or up to 64 digital signals in any com‐
bination.
4 Design and Function
4.5 The network switch
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Ports for the notebook and additional network switches
At one of the four ports to the right 2, the notebook is connected from which the ADA 2 user inter‐
face is accessed. The remaining three ports are available for the connection with additional net‐
work switches.
Power supply unit port
The port for the power supply unit is located at the rear of the network switch.
Fig. 6 Rear view
1Logger ports (4x)
2Ports for notebook and network switches (4x)
4.6 The user interface
ADA 2 provides a convenient user interface for planning and executing a full measurement:
■ Entering customer data
■ Define the compressed air station to be measured
■ Define the hard configuration used for ADA 2
■ Start and terminate the measurement, and send the measured values to KAESER for analysis.
4 Design and Function
4.6 The user interface
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Operating manual measuring and analysis system
ADA 2 EFFICIENCY OPTIMIZATION No.: 901711 00 E