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21st MAY , 2003 AIF-TRAINING 1
COMPRESSORBASICS - ELECTRIC
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 2
CompressorBasic
Electrics
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 3
Content :
• Some definitions and basic laws
- DC, AC Single phase, AC Three phase
• Three phase systems - Star and Delta connections
• Motor Data
• Motor Insulation Class and service factor• Motor protections - Electrical protections
- Overload protections• How to read a service diagram
• Device connections and measurements
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 4
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 5
ELECTRICITY - What ?
Something - INVISIBLE
- POWERFULL
- DANGEROUS !!
Something - SIMPLE for
QUALIFIED PEOPLE
TAKE CARE !!!
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 6
Power sources Direct Current (DC)
VoltageUdc
Time
Voltage is polarised with + and -• Examples : Batteries
Rectified power supplies ; 12….24 V• Applications : Electronic instrument supplies
Control equipmentSupply for pressure transmitter, etc...
• Safety : Voltages up to 24 VDC are safe, higher voltages can be dangerous for people.
Ex: 12 Volt
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 7
Alternating Current (AC) - Single PhaseCharacteristic : Voltage and current regularly changes strength and direction in a sinusoidal variationApplication : General use
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 8
Alternating Current (AC) - Single PhaseCharacteristic parameters :
• Period T = Time for 1 cycle• Frequency (Hz) = 1/T
• 50 HZ = 50 periods per second• 60 Hz = 60 periods per second
• RMS value : = max amplitude divided by sqrt 2 (For sinus)
Safety : - A.C. Voltage <= 24 V is Safe for personnel
> 24 V is dangerousTerminology : < 50 V : extra low voltage
< 1000 V : Low voltage 1000 V < U < 10000 V : Medium voltage > 10000 V : High voltage
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 9
Alternating Current (AC) - Three Phase
Characteristics :
• Three phase alternating current is produced in a generator with three separate windings.
• All values on the sinusoidal voltage are displaced 120° in relation to each other
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 10
Alternating current systemPhase 1Phase 2Phase 3
NeutralGrounding
1-Phase
3-Phase Y 3-Phase Delta
L1L2L3
N
UL=Line voltage = UL1-UL2
Uf =Phase voltage = UL
3
UL
UL
UL
Uf
In a net 3 x 400 V UL = 400 V and Uf = 230 V
Compressor Basics - Electric
IL
21st MAY , 2003 AIF-TRAINING 11
Relation between Reactance (X) - Resistance (R) - Impedance (Z) - Phase displacement ()
ZX
R
Power factor - cos
Uac
X
R
Reactance
Resistance
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 12
Basic laws
Direct Current
• Law of OhmI = U / R with I = Current in Ampere
U = Voltage in Volt R = Resistance in
Ohm
• Absorbed powerP = U x I with U = Voltage in Volt
I = Current in Ampere P = Power in Watt
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 13
Alternating Current• Law of Ohm I = U / Z with
I = Current in Ampere
U = Voltage in Volt
Z = Impedance in Ohm
= Sqrt (R² + X²) where X is the reactance• Power in a single phase system
P = U x I x cos
• Power in a three phase systemP = UL x IL x cosx Sqrt (3)
with
P = Power in Watt ( other units as stated above)
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 14
Units and measurements
Tension : Difference in potential between two points
Unit = VOLT
Example :
L1
L2220 V
Measurement in V ac Between V and Com
Compressor Basics - Electric
Current : Measures current flow in a circuit Unit = Ampere
L1
L2PS
Measurement in A (of mA) between A and Com
21st MAY , 2003 AIF-TRAINING 15
Motor connection in Star
Terminal box
U1
U2
V1
V2
W2
W1
400 V400 V
400 V
230 V
Power = Pn 3
W2 U2 V2
U1 V1 W1
Compressor Basics - Electric
Un
U v1-v2= Un/root 3
21st MAY , 2003 AIF-TRAINING 16
Motor connection in Delta
W2 U2 V2
U1 V1 W1
Terminal box
U1
U2
W2 W1
V1
V2
400 V
400 V
400 V
400 V
Uw1-w2 = Un
Power = Pn
Compressor Basics - Electric
Un
21st MAY , 2003 AIF-TRAINING 17
• TORQUE• A turning force applied to a shaft , tending to cause rotation . Torque is equal to the force applied , times the radius through which it acts.• Continuous [rated]torque• The maximum torque a motor can deliver continuously• Starting [breakaway] torque• The torque required to start a machine / compressor from stand-still. It is always greater than the torque required to maintain motion.
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 18
• Full load torque• The torque necessary to produce the rated HPat full load speed• Locked rotor torque• The minimum torque that a motor will developat rest for all angular positions of the rotor [with rated voltage applied at rated frequency]• Pull-out torque• The maximum running torque of a synchronous motor .
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 19
• Pull-up torqueThe torque required to accelerate the load fromstandstill to full speed , expressed in % of running torque.• Stall torqueThe torque that the rotor of an energized motor produces when restrained from motion.
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 20
• MOMENT OF INERTIA…!!!• Definition…???• A measure of a body’s resistance to changes in velocity , whether the body is at
rest or moving at a constant velocity.The velocity can be linear or rotational. The moment of inertia [ WK square] is the product of weight [W] of an object and the square of the radius of gyration [ K Square ].
• The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation. WK square is expressed in units like lb-ft square , kg-met square etc.
• Total Moment of Inertia = motor +coupling +compressor• GD square = 4 X WK square
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 21
Torque curve for a short circuited, induction motor
Tstart Tmin Tmax
Tnom
RPM
Torque
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 22
Torque curve of a screw compressor - started in Star/Delta
Torque curve (
Loaded compressor
Unloaded compressorSpeed
Torque curve (Y
Speed : +/- 90-95 %
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 23
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 24
V Hz A KW cos t/m IA / In IP 55400 50 430 250 0,87 1488
+/- 10 %460 60 430 285 0,87 1784
KL 13 EN 60034 IEC 34-1SF : 1,1SF : 1,0
Weight : 1,3 tSFA : 470 ATemp rise : 105 K
S I E M E N S
1080 2846 42Nmax : 3000 RPM
3 f Mot 1LA8 315 4AB91 - Z
ROTOR SQU. CAGE
Temp rise : 80 KAmbient temp : 40°CAmbient temp : 55°C
MOTOR DATA PLATECompressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 25
PROTECTION CLASS (According IEC 34-5)
• States how an electrical device is protected• against contact and • against water
Code : I P X Y Protection against water
Protection against human contact
and penetration by a solid object
• Example : IP 55 Protected against water jet
Protection against dust
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 26
Values for x0 Open motors PROTECTED AGAINST 1 Bodies with a diameter > 50 mm2 Bodies with a diameter > 12 mm3 Bodies with a diameter > 2.5 mm4 Bodies with a diameter > 1 mm5 Dust can still penetrate, but not
in such a quantity that it disturbs
6 Full dust protection
Values for y0 No protection PROTECTED AGAINST1 Vertical dripping2 Water falling as a spray at an
angle equal to or smaller than 15° with respect to vertical
3 Iden. as 2 but angle of 60°4 Water splashed against the
motor from any direction5 Against water jet6 Against condition on ship’s
decks7 Against the effect of immersion
Most frequently used are IP23, 44 and 54
Protection degree of electrical equipment : IP xyCompressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 27
V Hz A KW cos t/m IA / In IP 55400 50 430 250 0,87 1488
+/- 10 %460 60 430 285 0,87 1784
KL 13 EN 60034 IEC 34-1SF : 1,1SF : 1,0
Temp rise : 105 K
S I E M E N S
1080 2846 42Nmax : 3000 RPM
3 f Mot 1LA8 315 4AB91 - Z
ROTOR SQU. CAGE
Temp rise : 80 KAmbient temp : 40°CAmbient temp : 55°C
Weight : 1,3 tSFA : 470 A
MOTOR DATA PLATECompressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 28
Insulation classScope
• The toughness of winding insulation is influenced by• The temperature of the winding• The insulation class
• The maximum allowable temperature rise of the windings is defined by the insulation class• The power delivered by a motor is limited by the temperature rise of the winding !!IMPORTANT REMARK :
If the upper limit winding temperature is exceededby 10 °C, the service life of the insulation is shortened by about half
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 29
MOTOR TEMPERATURE RISE
Insulation class A E B F HAmbient temp °C 40 40 40 40 40Temp increase °C 60 75 80 105 125Thermal margin °C 5 5 10 10 15Max. final temp °C 105 120 130 155 180
INSULATION CLASSES
020406080
100120140160180200
A E B F H
Tem
p (°
C)
Ambient temp °C Temp increase °C Thermal margin °C
21st MAY , 2003 AIF-TRAINING 30
V Hz A KW cos t/m IA / In IP 55400 50 430 250 0,87 1488
+/- 10 %460 60 430 285 0,87 1784
KL 13 EN 60034 IEC 34-1SF : 1,1SF : 1,0
Temp rise : 105 K
S I E M E N S
1080 2846 42Nmax : 3000 RPM
3 f Mot 1LA8 315 4AB91 - Z
ROTOR SQU. CAGE
Temp rise : 80 KAmbient temp : 40°CAmbient temp : 55°C
Weight : 1,3 tSFA : 470 A
MOTOR DATA PLATECompressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 31
Service factor …!!!
Definition …???
• When used on a motor name plate , a number that indicates how much above the name plate rating a motor can be loaded without causing serious de-gradation .
•That is a motor with 1.15 S.F. can produce 15% more torque than one with 1.0 S.F.
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 32
Service factor ?
What ??• The service factor of an electric motor is :
•A multiplier which, when applied to the related power, indicates a permissible higher loading which may be carried out, on condition that the maximum ambient temperature limit of 40 °C is not exceeded
Example : - Motor rated power : 100 KW - Service factor : 1,2 - Motor may be loaded to : 120 KW - If Ambient temp <= 40 °C
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 33
Service factor ?
Used why ??
MARKET DRIVEN
• Competitors even use higher service factors
ATLAS COPCO POLICY
• Only use service factor within the safe limits of the insulation class
• the thermal margin ( see table of insulation class) is never used.
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 34
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990
500Kg
1000Kg
1500Kg
Development of the motor-weight (4-pole TOFC-motor 30 kW) from 1900 until today
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 35
Service factor
Criteria for Atlas Copco motor selection :
• High efficiency• No oversizing for efficiency and starting torque• Class F winding• High protection degree (IP55)• Long life time for bearings and windings Minimum 40 000 hours• Service factor
Motors are selected to work in the worst conditions within the SAFE AREA of the insulation class !!!
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 36
Service factor
Motor power is influenced by :
• Spreading of the compressor element performance• Fouling of the coolers• Tolerances on the nominal voltage
Atlas Copco is testing very thoroughly by :
• Measurement of the electrical parameters on different voltages and power output• Measurement of temperatures around the motor• Measurement of DT winding temperatures on various voltages
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 37
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 38
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 39
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 40
Motor protection
Possible protection based on the line current :• FUSE : - Prevent sustained overcurrent while avoiding
blow out on starting- For larger motors, mainly used as short
circuit protection
• THERMAL RELAY- A bimetallic element is heated by the line current, to actuate the protection mechanism
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 41
Motor protection
• MAGNETIC RELAY- Respond to magnetic field set up by the line current - Almost no time function
Above mentioned protections do not respond to :•Over temperature caused by hot ambient conditions• Blocked ventilation or cooling
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 42
Motor protection
OPTIONAL TEMPERATURE RESPONSIVE PROTECTORS : THERMISTORS and RTD’s
• Integrated (embedded) in the motor windings to protect against dangerous overheating
• Closely thermally coupled to the motor windings
• Need additional conditioning equipment to interrupt the contactor
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 43
Termistor protector
Conditioning relay
PTC
Power supply
Outputs for control
Alarm Trip
Remarks :• Thermistors can not be used for measuring• Thermistors can be connected in series(R total cold < 1500 ohm)
• Same sensor can be used for protectionsAlarm and Trip
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 44
Motor protection
RTD’s = Resistance Temperature Detector
RTD’s used in Atlas Copco :• Pt 1000 : used in almost all compressors• Pt 100 : Sometimes used to measure motor winding temperaturesPt 1000
Resistance value - 1000 Ohm - at 0 °C Platin based resistor
• Pt 100 : Resistance value of Pt 1000 divided by 10 for the same temperatureValues : See table and chart
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 45
TEMP
(°C) 0 1 2 3 4 5 6 7 8 9-10 960,9 964,81 968,72 972,63 976,54 980,45 984,36 988,27 992,18 996,090 1000 1003,9 1007,8 1011,7 1015,6 1019,5 1023,4 1027,3 1031,2 1035,110 1039 1042,89 1046,78 1050,67 1054,56 1058,45 1062,34 1066,23 1070,12 1074,0120 1077,9 1081,78 1085,66 1089,54 1093,42 1097,3 1101,18 1105,06 1108,94 1112,8230 1116,7 1120,57 1124,44 1128,31 1132,18 1136,05 1139,92 1143,79 1147,66 1151,5340 1155,4 1159,26 1163,12 1166,98 1170,84 1174,7 1178,56 1182,42 1186,28 1190,1450 1194 1197,84 1201,68 1205,52 1209,36 1213,2 1217,04 1220,88 1224,72 1228,5660 1232,4 1236,23 1240,06 1243,89 1247,72 1251,55 1255,38 1259,21 1263,04 1266,8770 1270,7 1274,52 1278,34 1282,16 1285,98 1289,8 1293,62 1297,44 1301,26 1305,0880 1308,9 1312,71 1316,52 1320,33 1324,14 1327,95 1331,76 1335,57 1339,38 1343,1990 1347 1350,8 1354,6 1358,4 1362,2 1366 1369,8 1373,6 1377,4 1381,2
100 1385 1388,79 1392,58 1396,37 1400,16 1403,95 1407,74 1411,53 1415,32 1419,11110 1422,9 1426,67 1430,44 1434,21 1437,98 1441,75 1445,52 1449,29 1453,06 1456,83120 1460,6 1464,36 1468,12 1471,88 1475,64 1479,4 1483,16 1486,92 1490,68 1494,44130 1498,2 1501,96 1505,72 1509,48 1513,24 1517 1520,76 1524,52 1528,28 1532,04140 1535,8 1539,53 1543,26 1546,99 1550,72 1554,45 1558,18 1561,91 1565,64 1569,37150 1573,1 1576,83 1580,56 1584,29 1588,02 1591,75 1595,48 1599,21 1602,94 1606,67160 1610,4 1614,12 1617,84 1621,56 1625,28 1629 1632,72 1636,44 1640,16 1643,88170 1647,6 1651,3 1655 1658,7 1662,4 1666,1 1669,8 1673,5 1677,2 1680,9180 1684,6 1688,3 1692 1695,7 1699,4 1703,1 1706,8 1710,5 1714,2 1717,9190 1721,6 1725,28 1728,96 1732,64 1736,32 1740 1743,68 1747,36 1751,04 1754,72200 1758,4 1762,07 1765,74 1769,41 1773,08 1776,75 1780,42 1784,09 1787,76 1791,43210 1795,1 1798,76 1802,42 1806,08 1809,74 1813,4 1817,06 1820,72 1824,38 1828,04220 1831,7 1835,35 1839 1842,65 1846,3 1849,95 1853,6 1857,25 1860,9 1864,55230 1868,2 1871,83 1875,46 1879,09 1882,72 1886,35 1889,98 1893,61 1897,24 1900,87240 1904,5 1908,12 1911,74 1915,36 1918,98 1922,6 1926,22 1929,84 1933,46 1937,08250 1940,7 1944,32 1947,94 1951,56 1955,18 1958,8 1962,42 1966,04 1969,66 1973,28260 1976,9 1980,5 1984,1 1987,7 1991,3 1994,9 1998,5 2002,1 2005,7 2009,3270 2012,9 2016,49 2020,08 2023,67 2027,26 2030,85 2034,44 2038,03 2041,62 2045,21280 2048,8 2052,37 2055,94 2059,51 2063,08 2066,65 2070,22 2073,79 2077,36 2080,93290 2084,5 2088,07 2091,64 2095,21 2098,78 2102,35 2105,92 2109,49 2113,06 2116,63300 2120,2
Resistance(in Ohm) of PT 1000 element as a function of the temperature
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 46
Sensor PT 1000
9001000110012001300140015001600170018001900200021002200
°C
Ohm
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 47
RTD’s Pt 100 and Pt 1000
RTD’s Can be connected to Elektronikon extension module without other conditioning amplifiers
Remark for trouble shooting :
Always disconnect both wires of a RTD for checking its value in case of troubles.
RTDElektronikon
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 48
RTD’s Pt 100 and Pt 1000RTD’s Can be connected to Elektronikon extension
module without other conditioning amplifiersRemark for trouble shooting :Always disconnect both wires of a RTD for checking
its value in case of troubles.
RTDElektronikon
Readings in Ohm
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 49
Cables and dimensions
• Low Voltage power cables and connections• The cable connection points have to be connected in the correct way
• Loose connection points can be the source of mechanical damage to the compressor and will damage the cables
• Use cables with dimensions as specified in the A.C. instruction manual of each compressor. Cables with too small dimensions cause excessive voltage drop.
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 50
Cables and dimensions
• Medium Voltage cables
• Selection of M.V. cables is the work for electrically qualified people.
• Cable connections and insulation at both ends have to be done extremely careful
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 51
How to read a service diagram ?• Symbols : ref condensed symbol list (details ref A.C. Standard E1282 K)• Numbering of components• Numbering of aux. Contacts• circuit numbers on diagram• Cross reference• Terminal rows Ex: 1 X1- 74
Terminal numberTerminal row1 = Cubicle
2 = Elektronikon Master module3 = Consecutive module or component numbers Cables and wires
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 52
Basic symbols
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 53
Basic symbols
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 54
Part of wiring diagramCompressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 55
Transformer for auxiliary power
Important• Always take out fuses F1,F2,F3 before commissioning• Measure Uin and make primary connections acc table• Put F1,F2 in place and measure Uout• If Uout is correct, close F3; otherwise adjust connections
F1
F2
F3
Uin Uout
Table as example only !
VOLT208220230380440460575
110220
TRANSFORMER CONNECTIONS
32-3831-35
1-37 & 31-21-36 & 32-21-35 & 33-2
3-4 & 5-64-5
PRIM
ARY
SEC
33-35 34-35
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 56
Part of wiring diagramCompressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 57
Part of wiring diagram
Attention :
Remark about the 24 Vac secondary :
• Secondary 24 V ac may never be grounded• secondary is protected by two circuit breakers
• NEVER change this !!!
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 58
Part of wiring diagram( for compressor supplied without starter)
K02 and K03
can be used for
control of
Y - D starter
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 59
Part of wiring diagram(for compressor supplied without starter)
Important
Take care of
interfacing connections
to be in phase with
ECB AIF 1133
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 60
Interfacing connections with Elektronikon
Auxiliary inputsRelay contactoutputs
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 61
Interfacing connections with Elektronikon
Relay outputsTemp inputs
Pt 1000Pressure sensor
inputs
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 62
Interfacing connectionsDevice connections
Pressure transducers3 - wire connection
Temp sensors Pt10002 - wire connection
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 63
PRESSURE SENSORS
B
C
A
A = Ground (-)B = Supply voltage(+5 V)C = Signal (+)
Measurement in Volts DC
Range : Zero = 0.5 Volt DCFull scale = 4.5 Volt DC
Sensor must remain connected to Elektronikon
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 64
SERVICE DIAGRAM
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 65
[ l]
21
22 1 3 5
642
13
14
Q28
Fanmotor circuitonly for unitswithout compr. motor
M28PE
W 1 V1U1
M3
(T1) (T3) (T2)
[ l]
Remote/local press. sensingS 3 'Remote setpoint changeS 5 '
Remote start but tonRemote emergency stop button
S 1 'S 2 '
Compressor motor starterK2 1Undervoltage relay
CUSTOMER'S INSTALLATION
Overload relay compressor motorF6F2 1
3
To b e in stalled b y costu mer [n ]
0 3 /0 22
0 2 /0 1
3[b ]
Customer's installation
53
I>F 21
95
96
242
A2
A1K21
M1Compressor motor
M3
U<
F6
62
PE
[ f]
02/2
02/1
[ f]
F32
1
1 X4X
X
XX
1 X4X
X
XX
1
2
133
2
1 X4X
X
XX
230V
50Hz
[ e]
T1
30
F2F1F0L1
3231
L2L3
FANMOTOR CANOPYDRIVE MOTOR
1 X3
[b ]
1 X3
[m]
LEGEND
CUBICLE
Start button
Programmed S top button
Elektron ikon RegulatorCOMPRESSOR CONTROL MODULE
Blocking relayAux. relay Y-con tactorAux. relay D-contactorAux. relay load/unloadAir Press.High/Air Press.Low relayDryer + fan startAutomatic operation relayGeneral alarm relayGeneral sh ut-d own relayPrinted circuitboard connectors
E1K0 1K0 2K0 3K0 4K0 5K0 6K0 7K0 8K0 92X1/12
MOTOR HEATER
[l] In case of High Voltage supp lyfor the drive motor, use aseparate 3-ph ase supply forthe fan motor and single-phase supply for the regulator.
Power supp ly to be connected forcounterclockwise rotation ofcompressor motor and- clockwise rotation fanmotor for ZR 300-750Rotation to be observed whilefacing the end shaft ofthe motor.
[b ]NOTES
When remote stop button is
terminals of 1X4 and 1X6.be removed on the correspondinginstalled, the br idges should
[g ]
4 : sealed with dummy
1 : supply voltage2 : ground3 : output
423 1
[ i] Pressure transducerpin configuration
metric thread size M10: 40Nm (29 lbft )C.P.E. = Customer Provided Equipment
For field wiring : USE COPPER WIRE ONLYmetric thread size M5 : 5Nm ( 4 lbft)metric thread size M8 : 20Nm (15 lbft)metric thread size M6 : 8Nm ( 6 lbft)tightening torque for bolts :
[ o]
To avoid Electro Magneticbe used and earthed.Interference : screened cable shall
[n ]
X
XXX
X
XXX
T N
R96
CT.0 3 .1 1 1 8 .0 0 A 0 0 0 0 0 0
M/s
. A
TL
AS
CO
PC
O I
ND
IA L
TD
.
Not
to b
e us
ed w
itho
ut t
he p
erm
issi
on o
f
Confi
dent
ial
Prop
erty
of
ATLA
S CO
PCO
IND
IA L
TD.
Appurtenant drawing s and doc uments .
R
Q
P
O
N
M
L
K
J
I
H
G
F
E
D
C
B
A
2019181716151413121110987654321
Note: Pos i tion: M odified fro m: Date: Intr/Appd:
FINISH :
00
9095 ---- 00DD/MM/YY
(1/1)
--
1 : 1
XA 125See drg. area
PARTNAME432
REVISIONAC 1356KAC 1356KAC 1350K
Transferred toATLAS COPCO (I) LTD
Kg.Kg. SheetDesignation
Replaces
CompareRef.no.
finished wt.
DateAppd.Prod.chd.
Blank wt.Blank no.
Design chd.Std.chd.
Drawn
Scale
3
2
Name
ClassClassClass
flame cuttingWelding
flame cutted holesSheet metalpunched holes
Mach.surf./dril ledaccording toTolerance if not indicated
A1
DN:PNA90000000
15119 00 005.S GK .
0 7 /0 2 /0 3
(1/2)
9096 3823 009823 1897 32
1 : 1
(FOR ZR 355 AIR COMPRESSOR.)WIRING DIAGRAM FOR CONTROL PANEL
PT100
R11 R13R12 R14 R16R15 R17 R19R18 R20 R22R21 R23 R25R24 R26 R28R27 R29 R31R30 R32 R34R33
temp. s ens orBearing N-end
te mp. s ens ortemp. s ens orM o tor winding 1U1 Bea ring D-endM otor winding 2W2
temp. s ens o rtemp. s ens o rM oto r wind ing 1V1 M otor winding 1W1
temp. s ens orM otor winding 2V2temp. s ens o r
M otor winding 2U2temp. s ens or
SpaceHeater
CT
A
415 VAC, 3PH, 50HZ, BHELLT LINE FROM THESAME FEEDER OFHT LINE
GEAR WITH NECESSARY INTERLOCKS.POWERED DIRECTLY FROM CUSTOMER'S HT SWITCH
[t ] MAIN ELECTRIC MOTOR SPACE HEATERS TO BE
(THIS IS NOT IN ACIL SCOPE.)
(PAC)FROM
LAPTOP.
230 VAG 3 PINSOCKET FOR S6
109
M1~ AIR DRYER
K11
F21B
(IAC)
(IAC)108 (DRYER)
1x1
110
VAC
T132
(F) 2
F2 1
415
v31
(F) 1
F1 2
L2L1
1X11X12
1X11
230VAC POWER SUPPLYFROM HT SWITCH GEAR
PANELTUBE LIGHT
VA A 21K14,15 VA A 11- (2N O,2NC)
Q28 MIN IATURE CIRCU IT BREAKER FOR FAN MOTORS
F21A OVERLOAD RELAY-FAN MOTOR-M28.
K21 POWER CONTACTOR FOR FAN MOTOR M28
EMERGENCY STOP
1X3 EARTH BOLT 1X1 TERMIN AL STRIPT2 TRANSFORMER 110V AC / 24 V ACT1 MAIN TRANSFARMERS6 SELECTOR SWITCHS2 MUSHROOM-SHAPED PUSH BUTTON
F21 OVERLOAD RELAY-MAIN MOTOR.
K13 AUX. RELAY FOR STARTER CONTROL (4NO+4N C) K11 AUXILIARY RELAY LOADINGF1/5 FUSE L INKS, CONTROL CIRCU IT
A AMMETER
CONT
ROL
CIRCU
IT.CU
STOM
ER H
.T. P
ANEL
HT S
W.GE
AR
K14 K15
(+)
START / STOP / TRIP SCHEME.
65
STOP/TRIP
1x11x163
START
COIL.CLOS ING
(-)
DOL HT STARTER WITH ALL MOTOR NTPC`S IN STALLATION
661x1
K13
641x1
S HUNTCOIL.
/TR IP
PROTECTION S.
K3 1 Time relay water shut-off valve
. . .
PT100
. ..
PT100
.. .. .. .. . . .. . . . .. . . . . . . .
PT100PT100P T100 P T100PT100
. . . . . .. .. . . . .. . . ...
( NTPC-RIHAND 3.3 KV )
BY CUSTOMER
: PE-VO-200-555- .
NATIONAL THERMAL POWER CORPORATION LTD.
PROJECT ENGINEERING MANAGEMENT,
: 1230-001-10PE-PVM-B- .NEW DELHI, INDIA.
BHELJOB NO.
NTPC DRG. NO.
: 200 BHELDRG. NO.
BHARAT HEAVY ELECTRICALS LTD.
RIHAND SUPER THERMAL POWER PROJECT.NTPC
2 x 500 M.W.
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 66
F1
(F)
F2(F)
(F)
1X12
1X1
T3
T1
8
81X1
1X1
1x19
24 VA
C
(E) 1
10 VA
C
1X16
1X16
1X16
39
6
6
1X11X1 1X17 7 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
3132
L1L2
2
33
1
1X1
110
VAC
1
7
40
Y1 K11 A1
A2
8
9
2X7
2X7
K04
17
18
2
1
2
1
1
F31
2
1(F)
F42
2(F)
F51
415
v
K2
HK1K2
K1
1KK2
S3
S10
YS1
16
15T31
1X199
1001x1
1314
2122
1X13
1X13
13
14
GREEN
OFFM1M1
A1
A2K13
RED
ON
3A2
K21A1
M1
YELLOW
TRIP
K31A1
A2
K15A2
A1
T2A2
T1A1
K14
A2
A1
A2
A1
(G)
K21K13
452X8
1X1
5
K13K13 K13 K13
11
1X144
S2
12 K13
K01
1X13
2X8
1X13
6A1
F21AB1
K21 F21AA1
C1
T2 T1
4241 43 44
123NO NC NCNO
-NCNO-
4 13CUS. HT PANEL
151411
CUST'SHT PANEL
CUST' SHT PANEL
Gnd
1 2 3 4 5 6 7 8 9 1 0
B0 2 /2 2
1B 2B 4B3B 5B
0 2 /2 9C
9B6B 7B 8B 10B 1C
2 X 6
Sign T
01Gnd Sig
n T02
Gnd Gnd Sign T
03
Sign T
04Gnd Sig
n T05
Gnd
1 2 3 4 5 6 1 2 3 4
0 2 /3 5D
3C2C 4C 6C5C 1D 3D2D 4D
Gnd
2 X 7
Sign T
07
Sign T
06Gnd Sig
n T08
Gnd
2 X8
Sign T
10
Sign T
09Gnd
...19
Sign P
0412A
1 2 3 4 5 6 7 8 9 1 0 1 1
1A 2A 4A3A 5A 9A7A6A 8A 10A 11A
V+V+Gnd Sign P
01Gnd Sig
n P02
Gnd V+ Sign P
03Gnd V+
1 2
D
91
0 2 /1 2
20A
L AN
...
2 X1
NC1
2 X5
2 0 A
0 2 /1 71 X4 3
35
4
345
6 NOK0 2
K0 3
NCNO3
2 C
54 C Y
K0 1BLOC K INGNC
87 C
NO9
RS 4 852 X2
/S TART
G. S HUTDOW N
E1
G. WA RNING
K 0 9
DR YE R ( +FAN)
AUT.OPE RATION
K 0 8
M KIV D K 0 7APL/A PH
1 X50 2 /2 0
9
2 X 1 0
NCK0 6
NC9
NO78 C
K0 4
K 0 5
L/UL
4 NO56 C
NC
23 C
2 X1 10 2 /5 163 X
6
24 Vac
NO1
2 X9 1 2
DI013
DI024
0 3 /0 8
...1
I /O
9
2 X30 2 /3 2
8CNC 9
10
NO 7
16
1 X 7
15
NC
NC 6
NOC
45
NOC 2
31
2 X 1 2
1314
1112
DI079
DI081 0
DI091 1
62 XX
X X63 XX
DI101 2
Supp
ly1 3
XX64 X
1 X50 2 /2 2
[g ]
551X6
7 6 XX
X 56X 1X6
XX
X 57X 1 X6
7
DI05
DI04
DI035 6
XX
X 58 XX 1X6
XX 59 X
X1 X6X X
DI068
60X XX
X1 X6 X
60
1 X6 X 1X6 X X1 X6
64
[ r ]54
1X6X
X
XX
02 /39
53
Remote
load
/unloa
d
0 2 /3
0 2 /3
S1 ' 13
14p
Remote
start
/stop
Emerg
ency
stop
1 X61X6
53
53 XX
XX 53
13 S3 '14
13
U<14
F6
14
S 5' 13
14
02 /39
[ r ]Q4 1 13
14
( clos
ed =
load
)
( link =
remo
te )
Remote
/loca
l pres
s.sen
sing
Starte
r feed
back
Fan m
otor o
verlo
ad ZT
110-2
75
Overlo
ad dr
ive mo
tor
1X6 1 X6X
X
XX 53 X
I>F 2 1
XX
X
53 X
XX
1 X6
Q25 13
53X XX
XX
53
Dryer
(+fan
) ove
rload
Remote
setpo
int ch
ange
EC dra
in (wa
rning
)+
[ r ]
1 X6 1X653 X
X
XX X53 X
X
X
EC dry
er
1 X653 X
XX
53
X
AUXILIARY INPUTS
pres s . trans ducerDP air filter
pres s . trans ducer
2A 3A
Compres s o r outPT 29
P
1A
A B C
20A
20A
pres s . trans ducerpres s . trans ducer
PT 18Intercooler
5A 6A4A 8A 9A7A 10A
PDT 02Oil
P
A CB
PT 49
P
2 1 3
P
20A
20A
11A 12A
A B C
A
4C3C2C 6C5C
TT 58PT1000
out temp. s ens o rCooling water IC
u
1C
1
temp. s ens o rout temp. s ens o r
2
Cooling water ACTT 59PT1000
2
u1
OilTT 44PT1000
u1 2
20A
20A
0 2 /4 9C
20A
TT 21PT1000
temp. s ens orElement 2 out
6B5B2B 7B4B3B
TT 11
temp. s ens orElement 1 out
te mp. s ens or
1B
Compres s o r outTT 29PT1000
u1 2
temp. s ens or
TT 18PT1000
Element 2 in
PT1000
u1 2 1
u2
u1
20A
20A
20A
20A
0 2 /4 6B
8B 10B9B
in letc ool ing water
TT 51PT1000
2
u1 2
20A
12 14
121X7
14XX
XX X
1X7
2 X1 2
K07
2 2X12
K0 8
16 18
X161 X7
XX
X
X
XX 18
1X7X
X
XX
5 2X1 2 8
K0 914
K1 113
20
201 X7
XX
XX
54K13
53
230VA
C 3A A
C15
Genera
l shu
t down
Load-U
nload
Autom
atic o
perat
ion
Genera
l warn
ing
11
2 X1 2
111X7
1 2X12
13
XX
XX 13 X
1X7
230VA
C 10A
X
4 2X1 2 7
15
1 X7X
X
X
15 X
XX
17171X7
XX
XX
230VA
C 10A
230VA
C 10A
230VA
C 6A A
C15
Motor
runn
ing1919
1 X7X
X
XX
VOLTAGE FRE E CONTACTS
REFE
R FR
OM
SHEE
T 1/
2
0 3 /0 2
L2L11X0
L1 L2 L3 L3 31 32 1X3 01X4 11 1 2 2 2 5
5
22 3 3 3 4
3 3 4
45
[g ]
24 44 7371
2 X 1 00 2 /3 8
45
77661X5 6 7 7
66 6 7 7
9 531X6
53
0 2 /4 19
2 X 9
55
[g ]
535353 53 53 54 5756 58 6059 62
[ r ][ r]
0 2 /3 8 K
1616
666463 65 67
[ r ]
111X7
12 1413 15
1311 12 14 15
1917 18 20 1X9
2 X 1 20 2 /5 3
9796 98 99
0 2 /3 82 X1 1
To b e in stalled b y cu stomer [ n ] 9090
1 X1 753242 62 1 X1 8 2 1
E 7
23
76 E 7
1 X1 1
E
1
7 9
23 1
E 7 9
01/10
E7 9 907 E
Y 1
1 2
Y 5 1
1 2
s olenoid v alveCool ing wa ter
s o lenoid v alveL oading
71 73E
M 40
1M
dry erGearmotor
0 2 /4 3
325 4
31
0 2 /4 35 3
1
CT.0 3 .1 1 1 8 .0 0 A 0 0 0 0 0 0
M/s
. A
TL
AS
CO
PC
O I
ND
IA L
TD
.
Not
to b
e us
ed w
itho
ut t
he p
erm
issi
on o
f
Confi
dent
ial
Prop
erty
of
ATLA
S CO
PCO
IND
IA L
TD.
Appurtenant drawing s and doc uments .
R
Q
P
O
N
M
L
K
J
I
H
G
F
E
D
C
B
A
2019181716151413121110987654321
Note: Pos i tion: M odified fro m: Date: Intr/Appd:
FINISH :
00
9095 ---- 00DD/MM/YY
(1/1)
--
1 : 1
XA 125See drg. area
PARTNAME432
REVISIONAC 1356KAC 1356KAC 1350K
Transferred toATLAS COPCO (I) LTD
Kg.Kg. SheetDesignation
Replaces
CompareRef.no.
finished wt.
DateAppd.Prod.chd.
Blank wt.Blank no.
Design chd.Std.chd.
Drawn
Scale
3
2
Name
ClassClassClass
flame cuttingWelding
flame cutted holesSheet metalpunched holes
Mach.surf./dril ledaccording toTolerance if not indicated
A1
DN:PNA90000000
15119 00 005.S GK .
0 7 /0 2 /0 3
(2/2)
9096 3823 00.9823 1897 32
1 : 1
(FOR ZR 355 AIR COMPRESSOR.)WIRING DIAGRAM FOR CONTROL PANEL
remote emerg ency stop
[g ]
45 X
1 X4X
XX 55 X
1X6X
XX
S 2'
441 X4
XX
XX 54
1X6X
X
XX
S
1X11
108 110109 111 1X10
TO S C ANNE R
1X43 X
X
XX
3
[ s]
2 X
1X4
PE
XX
X
M5FAN
2 x 500 M.W. RIHAND SUPER THERMAL POWER PROJECT.
BHARAT HEAVY ELECTRICALS LTD.NEW DELHI, INDIA.
PROJECT ENGINEERING MANAGEMENT,
NATIONAL THERMAL POWER CORPORATION LTD.
JOB NO.
NTPC DRG. NO.BHEL
NTPC
DRG. NO.BHEL : PE-VO-200-555- .
: 1230-001-10PE-PVM-B- .
: 200
Compressor Basics - Electric
21st MAY , 2003 AIF-TRAINING 67
ELECTRICITY
ATTENTION !!!
Something - INVISIBLE
- POWERFULL
- DANGEROUS !!
Something - SIMPLE for
QUALIFIED PEOPLE
Compressor Basics - Electric
TAKE CARE !!!
21st MAY , 2003 AIF-TRAINING 68
Elektronikon MkIV
State-of-the-art compressor control
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 69
What is the Elektronikon?What is the Elektronikon?
State of the art electronic controller that optimizes all aspects of compressor maintenance and operation
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 70
The Elektronikon monitorsThe Elektronikon monitors
The Elektronikon system continuously and accurately monitors all defined critical functions of the compressor package
The Elektronikon display is clear and easy to read
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 71
Elektronikon elegant simplicityElektronikon elegant simplicityOlder electro-pneumatic control
•Many more components required than with Elektronikon regulation
•More opportunity for failure due to complexity than with Elektronikon regulation
•More involved trouble shooting than with Elektronikon regulation
•More simplified due to reduction of components
Advanced electronic control
•More reliable and easier to troubleshoot than electro-pneumatic regulation
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 72
Elektronikon Elektronikon electronic precisionelectronic precision
Older electropneumatic
control
Advanced electronic control
Elektronikon advanced electronic advantage in accuracy...
•Electronic sensors maintain setpoint with same accuracy throughout lifetime
•A mechanical switch's setpoint can drift over its lifetime
•Electronic sensors’ setpoint is easily adjusted through the Elektronikon faceplate
•A mechanical switch requires inaccurate manual adjustment
•Reaction of the Elektronikon system is very fast insuring tight system pressure band and assured compressor protection [ better response time ]
•The reaction of the control system to a process deviation is slow with electropneumatic control•Display versus switch readout of parameter has deviation •The process value readout is a function of the
sensor’s electrical signal
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 73
Chapter 1
Differences with MkIII
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 74
Improvements compared to MkIII – 1 Hardware related improvements:• Better viewing angle of LCD screen• No more expansion modules for standard machines
(except ZH)• Expansion and communication modules DIN rail
mounted => less wiring to cubicle door• No more COM module for VSD compressors• Key switch integrated in software• Improved hardware, better electrical connections to
terminals
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 75
Improved LCD• LCD glass has updated technology
• This allows for better reading in all conditions
• Viewing angle less restricted than in Mk3
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 76
Improvements compared to MkIII – 2 Software related improvements:• Improved menu structure• Improved troubleshooting
– E.g. to check module connection• Help Screen for Service contact (e.g. web site, e-mail
address)• Readout in MPa possible• 2 pressure settings possible
– Automatic switching with a week timer– Manual switching– Remote switching
• Digital input– “1” = pressure setting 1– “0” = pressure setting 2
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 77
Double Pressure Setting
• Each compressor can have 2 sets of pressure settings • E.g. to have lower pressure during the weekend. • You don’t have to pump-up your compressor network.
• Selection can be made• by hand• based on the timer function
• Timer can start/stop compressor and change pressure band
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 78
Improvements compared to MkIII – 3 Other improvements:• Field programming simplified
– Only master module has to be downloaded– All components in the CAN network can be downloaded from 1
point• Multiple Compressor Control (MCC) function as option
– Energy savings • No more cascading => smaller pressure band• With remote pressure sensor in the air net => better control of
the net pressure– Equal wear
• Easier networking: CAN does not require interfaces• Only 1 module required for external communication
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 79
New New FeaturesFeatures
More intelligent user interface for improved navigationHelp screen for service contact2 sets of pressure settingsImproved LCD (better visibility)Relay Expansion Box is integratedHardware improvements in general resulting in neat professional lookImproved communication skills via Computer Automation Network or CANOptimised & modified menu to accommodate new functions3 languages (3rd=Dutch For factory use only)°C/F and PSI/Bar can be defined independently
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 80
Chapter 2
Hardware
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 81
Elektronikon MKIV The familyElektronikon MKIV The family •Physically the same size as Elektronikon II•Uses symbols instead of text•No programming required, parameter set selection based on machine type at assembly•No communication, options or expansions. No clock functions.
Hardware I/O
• 1 Pressure– Compressor outlet
• 2 Temperatures– Element outlet– LAT
• 3 Digital Inputs – Emergency stop– Motor overload– Remote start/stop
Input Output
• Star contactor• Line contactor• Delta contactor• Load/unload sol.
Valve• General
shutdown• Dryer control
Controller functions• DSS• ARAVF• ID control• Service indication• Counters• Remote start/stop• Protections
Elektronikon I
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 82
•Physically the same size as Elektronikon I•Two out of a selection of 23 languages can be downloaded•Two pressure sets can be programmed, selected manually or timer based•Full expansion capability, up to eight modules per compressor•Two hardware versions, MKIV-IIA or MKIV-IIB•4x16 back lit LCD
Hardware I/O Version A•1 pressure input•2 RTD temp inputs•8 digital inputs•9 digital outputs•No RS485 (no VSD)•CAN connection•I/O expansion port
Version B•2 pressure input•3 RTD temp inputs•10 digital inputs•9 digital outputs•RS485 (VSD)•CAN connection•I/O expansion port
Elektronikon II
Elektronikon MKIV The familyElektronikon MKIV The family
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 83
Elektronikon MKIV The familyElektronikon MKIV The family •Physically larger than the Elektronikon I and II•Two out of a selection of 23 languages can be downloaded•Two pressure sets can be programmed, selected manually or timer based
•Full expansion capability, up to eight modules per compressor
•Two hardware versions, MKIV-IIIC or MKIV-IIID
•4x40 backlit LCD
Elektronikon III Hardware I/O
Version C•4 pressure input•8 RTD temp inputs•10 digital inputs•9 digital outputs•No RS485 (no VSD)•CAN connection•I/O expansion port
Version B•4 pressure input•10 RTD temp inputs•10 digital inputs•9 digital outputs•RS485 (VSD)•CAN connection•I/O expansion port
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 84
Elektronikon MKIV The familyElektronikon MKIV The family
MKIV regulator type Compressors it is installed on as standard
Type I Pack style GAs, GA 5-11C and SF 1-5
Type IIA WorkPlace style GA 11-90C, GA 5-11C(optional) and SF Multi core
Type IIB GA less than 90 VSD
Type IIIC ZT less than 55 kW
Type IIID ZR, ZVSD and all other AIF compressors
Where the Elektronikon MKIVs are used
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 85
MkIV Master Module for AIF• On all AIF machines the “D-controller” is used:
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 86
D-Controller The D-controller has following features:• User Interface
– 4 * 40 characters– Higher Quality LCD than MkIII
• Inputs and outputs:– 4 * pressure inputs (0-5 V)– 10* temperature inputs (PT1000)– 10 * digital inputs– 9 * digital outputs=> No expansion modules for standard machines (except ZH)
• RS485 connection for converters• CAN connection => communication without interface • I²C connection for I/O• 24 Vac power supply required
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 87
Expansion modules • All modules are DIN rail mounted (less wires to door)
• Some modules require 24 Vac power supply• Expansion modules are mainly used for machine-options (but are also
available as sales kit)– AIE1 = 2 * pressure inputs (0-5 V) + 2 * PT1000 inputs
• E.g. for delta p over integrated DD-filter– AIE2 = 4 * 4-20 mA inputs
• E.g. for dew point meter on IMD or remote speed control on VSD machines
– AIE3 = 5 * PT100 inputs• E.g. for motor winding/bearing temperatures
– AIE4 = 5 * PT1000 inputs• E.g. for motor winding/bearing temperatures
– DIOE = 2 * digital inputs + 2 * digital outputs• E.g. for thermistors in motor windings
– SPM 5/7 = for 5 or 7 SPM inputs (= NEW option)
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 88
• AIE1 : 1900 0710 41• 2 Kavlico Pressure inputs• 2 Jumo Temperature inputs• No supply• No download • Low power consumption (mA)
Mountable on DIN rail
• AIE2 : 1900 0710 51• 4x 4..20mA passive (2 wires)• Needs external power supply (17…30VDC)• No download • Low powerconsumption (mA)
• AIE3 : 1900 0710 61• 5x Pt100 for motorprotection (2bearings, 3 windings)• No supply• No download • Low powerconsumption (mA)
• AIE4 : 1900 0710 81• 5x Pt1000 for motorprotection (2bearings, 3 windings)• No supply• No download • Low powerconsumption (mA)
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 89
• DIOE : 1900 0710 71• 4 voltage Free contactsK01 … K04• 4 digital inputs• No download• 24Vac 50/60Hz supply• consumption 9VA
Mountable on DIN rail• SPM : 1900 0711 11
• I/O for7 SPM channels• No supply• consumption not known
• COM Box :• MODBUS to CAN 1900 0711 41• COM1(RS232) to CAN 1900 0711 41• PROFIBUS to CAN 1900 0711 42• Communication with compressor network & customers system• modbus, profibus, ethernet to be downloaded
Updated !
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 90
Communication modules • All modules are DIN rail mounted• All modules require 24 Vac power supply• Communication modules are only available as sales kit:
Combox-S (CAN to Serial)• For external communication via Modbus• To connect old units (MkI/II/III and E/P) to the CAN network• To connect ES100/300 to the CAN network
Combox-P (CAN to Profibus)• For external communication via Profibus Combox-E (CAN to Ethernet)• For external communication via Ethernet • Will also be used for the AIRmonitor (communication to
Internet for Service contracts)
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 91
A typical compressor controller
= CABLE 1622 0661 01, -02, -03To be ordered seperately.3 lengths available.Number of modules is limited by Hardware
24Vac(some module types require external power supply, others get there power from the Main Controller)
P&T SensorsDigital Inputs Relay Outputs
Extra Inputs,Outputs or both
24VacRS485 Converter on models B/Dattention software PROTOCOL defines converter typeAvailable : Siemens,ABB & Vacon
Updated ! 1622 0661 00
INSTRUMENTATION & ELECTRONICS
21st MAY , 2003 AIF-TRAINING 92
• Weidmüller & Phoenix screw terminals
• Sometimes became loose
• PartNr: 1088 0014 xx
• Wago ‘spring’ connectors
• Also mechanically better fixed
• PartNr: 1088 0031 xx
Improved connectorsImproved connectorsMk3Mk3 Mk4Mk4
1088 0031 00_ed1.pdf
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Other hardware CAN connectors
– To connect modules to a CAN network– Connector 1 for single node– Connector 2 for 2 nodes or laptop connection
CAN repeater– For longer CAN networks (2 * 250 m)
MCC (Multiple Compressor Control) dongle– Hardware key to activate the MCC function
I²C cables– To connect modules (lengths of 150/600/1100 mm)
ES002– To connect an E/P unit to CANES003 = ES002 + Combox-S– To connect an E/P unit via CAN to ES100/300
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B
DIOE
StandardDigital InputsD1 = Emergency StopD2 = start/stopD3 = load/unloadD4 = local/remote pressureD5 = main motor overloadD6 = fan motor overload
Digital inputsOption CONDR
D7 = Cond. DrainOption FIKIT D8 = DD filterD9 = PD filterOption PHSR
D10 =Phase sequence
AIE1AIE1
StandardKavlicoinputsP1 = delivery air P2 = DP oil separatorPt1000 inputsT1 = element outletFeature MDVAR= FF T2 = Dryer LAT
T3 = not used
StandardDigital outputsK01 = LineK02 = StarK03 = DeltaK04 = Load/Unload SolenoidK05 = APH / APLK06 = FD Dryer ControlK07 = Automatic OperationK08 = General WarningK09 = General Shutdown
Digital InputsOption THERM
DI01 : Thermistor WarningDI02 : Thermistor
Shutdown
DI03 : QD Filter (not used)DI04 : not used
Digital Outputs DO1=CD dryer (not used)
DO2 : not usedDO3 : not usedDO4 : not used
Pt1000 inputsFeature COOL=WATER
T1: Water InT2 :Water Out
Pt1000 inputsOption ENREC
T1 = ER Water InT2 = ER Water
Out
AIE3
Pt100 inputsOption Bearings (not
used)T1 : D bearing
T2 : ND bearingOption Windings (not
used)T3 : U windingT4 : V windingT5 : W winding
Kavlico inputs
P1 : not usedP2 : not used
Kavlico inputs P1 : not
usedP2 : not used
e.g. GA 55-90C
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Hardware data
• INTERESTING TO KNOW :
• Line Voltage Limits
• + 40 % to - 30 % of the nominal supply voltage.
• Supply drop-out
• The device will operate without disturbance with a supply voltage drop-out of 40 ms every second.
• Degree of Protection of Enclosure and Connectors
• degree of protection at the front of IP 55 and at the back of IP 23, both according to IEC 529. Other devices have an overall protection of IP 23.
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Chapter 3
Main functions
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Control
The Elektronikon controlsThe Elektronikon controls
The Elektronikon regulates the compressor to maintain the desired system pressure
System pressure System pressure is compared to the
programmed pressure band
Load/no load fixed speed machines
Variable Speed Drive, VSD, machines
or
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The Elektronikon protectsThe Elektronikon protects
Electronic precision scans all vital functions…shuts the compressor down if trouble exists...
Cooling fan motor
Compressor element
Drive motor
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The Elektronikon advisesThe Elektronikon advises
System pressure
Compressor status and data Service requirements
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Compressor controlThe MkIV has following control functions:• Manual start/stop of the compressor
– Emergency stop is separate button• Choice between “forced unload” and “automatic control” (=
pressure control) • Pressure control
– For load/unload• By loading and unloading the compressor
– For VSD• By speed control between min and max speed (in this zone the MkIV tries to reach the set point)• By stop/start (and unload for Z VSD) < min speed
– Required pressure band (and set point for VSD’s) to be specified• Choice between local and remote control
Load/unload pressure control
VSDpressurecontrol
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Compressor monitoringThe MkIV has following monitoring functions:• Status of the compressor
– Voltage on/off– Loaded/unloaded/stopped– Warnings and shutdown
• Control mode– Forced unload/automatic– Local/remote control
• Measured values – Pressures/temperatures/…– Speed of the motor and accumulated volume for VSD’s– “Running”/”Loaded”/”Module” hours – Number of motor starts– …
For details: see MkIV Instruction Books
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Compressor protectionThe MkIV has following protection functions:• To stop the machine (shutdown)
– When an input indicates that the machine can be damaged– E.g. element outlet temperature too high (HH)
• To give a shutdown warning– When the machine comes close to a shutdown– E.g. element outlet temperature high (H)
• To give a service warning– When the machine needs service– E.g. air inlet filter high (H)
• Delay second stop (DSS)– To protect overheating of motor windings– Motor can only stop once every 20 minutes (if 3 starts per hour
allowed by motor vendor)
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Converter control• Each VSD device has a frequency converter• Our compressors can have 3 converters:
– For the main motor– For the dryer (in FF machines or behind the machine) – For the fan motor (in air cooled machines)
• The converter controllers are linked with the MkIV; but the MkIV is the master controller
• Advantages:– Only 1 User Interface (of the MkIV)– Because of the integrated controls
• More stable dew point with MD VSD and ID VSD• Better fine-tuning of the main motor converter
– Bigger operating range (higher max and lower min speed)– More energy savings (lower energy consumption by fan-
motor and ID-dryer)
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Chapter 4Special options (sales kits):
sequencing + external communication
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Multiple Compressor Control – What ?• Multiple compressor Control (MCC)• = sequencing • = central control
• Purpose– Pressure band reduction => energy savings– Equal wear of the compressors
• Limitations– Max. 4 compressors– Of the 4 compressors max. 1 can be a VSD
Without MCC With MCC
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Elektronikon Elektronikon MMultiple ultiple CCompressor ompressor CControlontrolNet pressure
Com
p 1
Com
p 2
Com
p 3
Typical overall pressure band 1.5
barAvg pressureWith MCC overall system pressure can be drastically
reduced
Traditional cascade control
•Up to four compressors can be controlled with MCC, one of which can be a VSD
•Reduce system pressure band - save energy, reduce leakage and stabilize system pressure
•Equalize running hours of all compressors integrated
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Multiple Compressor Control – How ?
Set-up– Compressors to be connected in a CAN network– No extra controller required
• The sequencing software is installed in every MkIV• Hardware key (dongle) on 1 of the master modules to activate the sequencing
software (=> 1 MkIV machine in the network is enough) Algorithm
– MCC keeps the pressure at the outlet of the “master compressor” in the require pressure band
• In Q1 2003 a remote pressure sensor will be possible: with pressure transmitter (4-20 mA) and AIE2 module
– If present VSD controls the pressure– Compressor with lowest running hours is started/loaded– Compressor with highest running hours is stopped/unloaded
• Hour counters can be initialized• Change-over at regular intervals can be forced
– Week timer with 2 pressure bands
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External communication• There are 3 ways to go to the customer’s plant management system (DCS):
– Via Modbus with Combox-S– Via Profibus with Combox-P – Via Ethernet with Combox-E
• 1 Combox is enough for a complete CAN network• Combox is sold as a sales kit (not a machine option)• Functionality:
– Monitoring of all compressors in the network:• compressor status • all measured values
– Control of all compressors in the network:• Start/stop• Forced unload/automatic• Change of pressure band (and set point for VSD)• Remote speed control (for VSD)
For details => see User Guide on Elektronikon software market
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Chapter 5The CAN network
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Elektronikon MKIV Elektronikon MKIV CommunicationCommunication NetworkingNetworking
• The MKIV regulators use a field bus called CAN
Controller Area Network (CAN) is an ISO approved standard for a low cost real time communication protocol. It has a relatively high transmission speed (up to 1Mbps). It is a fault tolerant and robust system.
CAN was initially developed by Bosch for in-vehicle data transfer and was defined in 1984
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Overview of the CAN network
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Elektronikon MKIV Elektronikon MKIV CommunicationCommunication
CAN
Conversion Box“Communication”
COM1
MkIII
Conversion Box“Communication”
MkI/MkII E-P and Competition
RS232 RS232Relay(s)/Wiring
CAN graphical network representationCAN graphical network representation
Combox ComboxES002
MKIV MKIV MKIV MKIV
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CAN
Conversion Box“Communication”
COM1
MkIII
Conversion Box“Communication”
MkI/MkII Electro-Pneumatic and Competition
RS232 RS232
Relay(s)/Wiring
Combox ComboxES002
MKIV MKIV MKIV
Conversion Box“Communication”
Customer’s LAN
Combox
Other LAN graphical network Other LAN graphical network representationrepresentationElektronikon MKIV Elektronikon MKIV CommunicationCommunication
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The Compressor Network for Control
System Bus(CAN)
Central Control Unit
• Reduced & simpler wiring• Simplification of software• CAN = very reliable connection• Every model of Elektronikon II or III can be directly connected to this network
• Max. length = 200M without CAN repeater• Max. length = 500M with CAN repeater every 250M
ElectroPneumatic
E/PHard wired
Mk1..3
RS232C
COM box ES002
!! IMPORTANT !! : Never ADD/REMOVE any device from the network without disconnecting the power supply
CAN cable : LAPP cable UNITRONIC BUS-CAN – AC p/nr : 0017 2610 102x2x0.34mm²
Alternative : Belden3106A – AC p/nr : 1900 0707 92 (300M)
Updated !
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The Compressor Network for Communication
Customer PLCe.g. Simatic S7
Profibus Network
System Bus(CAN)
Central Control UnitRS232C
E/P
Hard wired
COM-BoxLocate in any ofthe cubicle, or
outside
Mk1…3
COM box ES002
!! IMPORTANT !! : Never ADD/REMOVE any device from the network without disconnecting the power supply
Updated !
CAN cable : LAPP cable UNITRONIC BUS-CAN – AC p/nr : 0017 2610 102x2x0.34mm²
Alternative : Belden3106A – AC p/nr : 1900 0707 92 (300M)
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The Compressor Network for Communication : Next Step
System Bus(CAN)
Central Control UnitRS232C
E/P
Hard wired
E-BoxLocate in any ofthe cubicle, or
outsideInternet Explorer
Commercial Modem or
Router
Outside WorldEthernet
Mk1…3
!! IMPORTANT !! : Never ADD/REMOVE any device from the network without disconnecting the power supply
Updated !
CAN cable : LAPP cable UNITRONIC BUS-CAN – AC p/nr : 0017 2610 102x2x0.34mm²
Alternative : Belden3106A – AC p/nr : 1900 0707 92 (300M)
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Elektronikon MKIV Elektronikon MKIV CommunicationCommunication
• Local communicationMeans for communicationMeans for communication
Communication and control of the regulator is done by an operator locally at the face plate of the module by manipulation of the modules screens through its membrane switches
• Digital communicationCommunication and control of the regulator is done remotely by digital, potential free, contacts or switches. An operator in a remote station can control the machine and see the status of the digital outputs that are free for use. Could also mean control or monitoring by a PLC or similar device.
• Network communicationCommunication and control of the regulator is done remotely over a computer local area network connection. This could mean central control using an Atlas Copco ES product, including the new MCC, or network monitoring using our standard protocol conversions modules or the new e-Box and monitor over the world wide web.
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How to wire a CAN network ?• Components (compressors, etc.) are connected in a “Daisy-
chain” = multi-drop• CAN connector on each component in the network
– E.g. 2 compressors + Modbus = 3 connectors• 2 types of wires possible:
– Lapp-cable Unitronix ( AC nr. 0017 2610 10)– Belden 3106A (AC nr. 1900 0707 92)
• Limitations:– Max. 30 components in the network– Max. 250 meter total length– With a repeater max. length = 500 meter
• More details in the “How to wire a CAN network” instruction– On Lotus Notes
=> Database called “Elektronikon software market”=> Programs => Technical Notes
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Description Remarks
ComBox-Modbus Communication module that converts CAN toModbus protocolApplication software dependent load atcommmissioning
ComBox-Profibus Communication module that converts CAN toProfibus protocol
ComBox-Ethernet Communication module that converts CAN toEthernet protocol
ComBox-RS232 Communication module that converts RS232from COM1 to CANCan be used to connect an older generationElektronikon to the CANApplication software dependent load atcommmissioning
ComBox-DIOE Communication device that convertsdigital inputs to CANCan be used to connect an elpn regulatedcompressors or digital accessory to CANSeparate enclosed product similar to ES001
Elektronikon MKIV Elektronikon MKIV Communication modules Communication modules
Conversion Box“Communication”
CAN
“X”- bus
Customer DCS
ComBox
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Description Remarks
e -Box I Device that allows an authorised user tomonitor a compressor installation overthe web from a remote PC. Applicationsoftware is imbedded in the device.
e -Box II Device that allows an authorised user toconnect a compressed air installation toAtlas Copco's World Wide Web e-services.
Cable Connects an expansion module to the master600 mm in overall length with end connectors
Cable Connects an expansion module to the master150 mm in overall length with end connectors
Instruction How to wire the CAN
Instruction MCC operation and instruction manual
Instruction ComBox instruction manuals, ModbusProfibus and Ethernet
Instruction e -Box instruction manual
Elektronikon MKIV Elektronikon MKIV Monitoring Monitoring
World Wide Web
CAN
e-Box
Modem
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Chapter 6Flexibility + Remote monitoring +
Operating costs
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Elektronikon comprehensive flexibilityElektronikon comprehensive flexibility
Electronic gearing
Two programmable pressure sets
Simple modification of parameters at
faceplate
Additional non standard inputs possible
Multiple language selections possible
Timer based control as standard
Remote control and annunciation
standard
Automatic restart after power failure
as standard
Elektronikon platform used on AII and AIF compressors as well
as AIQ dryers
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Elektronikon remote monitoringElektronikon remote monitoring
The Elektronikon allows a compressor installation to be monitored over a computer
network
•Modbus
•Profibus
•Ethernet
•Standard protocols available
•Customized monitoring packages available, as part of standardized service plans
•Monitoring via your own PC over your network or the internet
•Monitoring via Atlas Copco trained engineers over the internet
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Saves energy
Elektronikon lowers Elektronikon lowers operating costoperating cost
Facts about working pressure:
For each bar reduction in working pressure a 7% energy savings is realizedFor each bar reduction in working pressure a 13% lower leakage rate is realized
Elektronikon lowers operating pressure...
•Electronic precision - more accurate•Electronic decision making - anticipates•Electronic decision making - DSS algorithm
•Electronic sophistication - Multiple Compressor Control, MCC
Savings potential of up 30% in energy costs over conventional electropneumatic control
•Two programmable pressure bands - flexible
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Chapter 7MK-IV REGULATOR
ENERGY SAVER
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Elektronikon MKIV Elektronikon MKIV ES evolutionES evolution EEnergy nergy SSaver sequencingaver sequencing
The new ES Millennium series sequencers•Based on the CRC hardware platform from Oil Free•Can be combined with monitoring, each is up gradable to the next series with software
•Three modes; Energy savings, Equal wear and forced sequence
Today Tomorrow
Product Use Product Use
ES100 Sequences 2 to 7 load/no load MCC Sequences 2 to 4 compressorscompressors load/no load with 1 VSD from MKIV
ES200 Sequences 2 to 8 compressors ES1000 Sequences an unlimted numbermix of load/no load and ZH of load/no load compressors
ES300 Sequences 2 to 16 load/no load ES2000 Sequences an unlimted numbercompressors of load/no load and VSD
compressors
ES3000 Sequences an unlimted numberof load/no load, VSD and ZHAtlas Copco compressors
ES4000 Sequences an unlimted numberof load/no load, VSD andturbo compressors of other mfrs
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Elektronikon MKIV Elektronikon MKIV ES evolutionES evolution EEnergy nergy SSaver monitoringaver monitoringToday Tomorrow
Product Use Product Use
ES400 Monitors up to seven Atlas e -Box I Allows up to four compressorsCopco compressors over serial to be monitored. Web applicationconnection built in device
e -Box I I Allows up to four compressorsto be connected to the Atlas Copcoweb services of monitoring or PMservice by Atlas Copco reps
ES - X Local monitoring of installationbased on CRC hardware platform
ES - XX Internet monitoring of installationbased on CRC hardware platformAtlas Copco web services can beused
The new ES Millennium series monitoring•Based on the CRC hardware platform from Oil Free•Can be combined with sequencing, each is upgradable to the next series with software
•Web services will be fee related based on level of services contracted with local customer centers
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• DIDITAL CIRCUIT1] a switching circuit that has only two states : ON and OFF.2] a circuit that provides a step function3] contrasted with analog circuit
• ANALOG CIRCUIT1] a circuit in which the signal can vary continuously between specified
limits.2] a circuit that provides a continuous function3] contrasted with digital circuit
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• RS - 232 - C An EIA standard that specifies electrical , mechanical and functional
characteristics for serial binary communication circuits in a point - to - point link.
• RS - 485 An EIA standard that specifies electrical characteristics of balanced -voltage
digital interface circuits in a multi-point link• SCADA Supervisory Control And Data Acquisition• RTD Resistance Temperature Detector. A resistor for which the electrical resistivity
is a known function of the temperature
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INSTRUMENTATION & ELECTRONICS•POWER FACTORA measurement of the time phase difference between the voltage and current in an ac circuit. It is represented by the cosine of the angle of this phase difference. Power factor is the ratio of real power [ in watts ] to apparent power [ in volt-amperes ]
21st MAY , 2003 AIF-TRAINING 131
Time to have coffee ...
Compressor Basics - Electric
INSTRUMENTATION & ELECTRONICS
&