ASC - AIR SYSTEM CONTROLLER. Version 2.0 User s Manual

Transcription

1 ASC - AIR SYSTEM CONTROLLER Version 2.0 User s Manual

2 Rev. D Date of Issue: 01/05/05

3 PREFACE Information and Illustrations Information and illustrations are not binding. Ingersoll-Rand Company reserves the right to make changes to its products. Trademarks All terms used in this publication to denote Ingersoll-Rand Company products are trademarks of Ingersoll-Rand Company. All other terms used in this publication to denote products may be registered trademarks and/or trademarks of the corresponding corporations. Microsoft is the registered trademark of Microsoft Corporation; Windows 2000 Server and Windows 2003 Server are brand names of Microsoft Corporation in the USA and other countries. Belden is the registered trademark of Belden Wire and Cable Company. Modbus is the registered trademark of Schneider Automation, Inc. Belkin is the registered trademark of Belkin Components. Copyright All rights are reserved. This document may not be reproduced or transmitted in any form or by any means without permission in writing by Ingersoll-Rand Company. The user is not authorized to translate this document into any other language Ingersoll-Rand Company. All rights reserved Rev. D Date of Issue: 01/05/05 3

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5 TABLE OF CONTENTS WHATS NEW... 7 REFERENCES OVERVIEW REQUIREMENTS User List System Computer Modbus to Ethernet Bridge ASC Application CD Network Wires Local Panels INSTALLATION Prework Network Wiring Modbus to Ethernet Bridge Operating System Installation Notes ASC Software Installation ASC Configuration Starting and Stopping ASC Logging on ASC USING THE SOFTWARE System Building System Settings Scheduler Charting Reporting Logs Change Password Admin SYSTEM CONTROL Sequencing Machine control of Centrifugal Compressors Machine Control of Rotary and Recip. Compressors Loadsharing of Centrifugal Compressors TROUBLESHOOTING Configuration Error During Installation Testing The Ethernet Wiring Testing the Modbus Wiring Scheduler Skips Job at Midnight APPENDIX A: QUICK START APPENDIX B: ACCESSING THE DATA Rev. D Date of Issue: 01/05/05 5

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7 WHATS NEW Revised EPROM requirements for Intellisys controllers Added troubleshooting for Password Complexity issue Added Air System tab to ASC Configuration Added Component list to Translation tab of ASC Configuration Added Site Name to notification message Revised description of when Inlet Valve Load-Sharing is active Added note to review settings prior to enabling communications when upgrading Rev. D Date of Issue: 01/05/05 7

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9 REFERENCES CMC Technical Reference Manual, Ingersoll-Rand Company. Intellisys Remote Interface, Operators/Instruction Manual Parts List, Ingersoll-Rand Company. Intellisys Energy Optimizer, Operators Manual, Ingersoll-Rand Company. Larry Byard; How to Make Your Own Cat 5 Twisted-Pair Network Cables, Dux Computer Digest, February 2000 ( Modbus to Ethernet Bridge User Guide; Schneider Electric, April 1999 ( EtherNet/IP Media Planning and Installation Manual; Rockwell Automation, Publication ENET-IN0001A-EN-P, January Rev. D Date of Issue: 01/05/05 9

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11 1.0 OVERVIEW Air System Controller (ASC) is Human Machine Interface (HMI) software specifically developed for automatic pressure control of air compressor systems. ASC integrates various types of compressors as well as components associated with the compressed air system. ASC provides a window into the compressor room by making the raw data available to plant operators and managers in a format that is clear and concise. The primary goal of ASC is to monitor and control the compressed air system and optimize its operation. ASC provides energy management through load sharing and reduction of air by using the minimum amount of energy to meet the system demand. Access to ASC can be completed anywhere, anytime, depending on network configuration; permitting the checking of equipment status, set point changes and equipment on/off functions. ASC also collects and records historical data for production of graphs for analysis. Figure 1-1: ASC Architecture Overview I/O Box UCM I/O Box UCM CMC CMC SE IRI UCM UCM Modbus IR ASC Network - TCP/IP ASC Server Router Control Room Maintenance Customer Network Operations Production Firewall SG IRI Modbus Modbus to Ethernet Bridge Home User Remote User Internet ASC utilizes Modbus/TCP protocol and standard Web-browser based software to provide a powerful yet user-friendly Internet ready solution. Route ASC to the plant network and view the status of the System anywhere from inside the plant or even outside the plant. Change system settings on the fly, view status of specific equipment Rev. D Date of Issue: 01/05/05 11

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13 2.0 REQUIREMENTS The follow requirements are needed to complete the installation of the Air System Controller. Refer also to section 3.0, Installation, of this manual. 2.1 USER LIST Create a list of people who will be using the ASC program. The ASC is configured with security features to prevent unauthorized access to compressor data and control. A username and password is required to access ASC. The ASC Setup will create three default users for the system. These three users represent the three security levels in ASC. It is recommended to remove the default accounts after the users have been setup. The default usernames and passwords are published and are the same for every ASC. For additional information on security levels, see section 4.9 of this manual. The default Username and Passwords are: Username: ascengineer Password: engineer Username: ascoperator Password: operator Username: ascmanager Password: manager 2.2 SYSTEM COMPUTER The ASC requires a computer running Windows 2000 Server or Windows 2003 Server (Standard Edition) operating system. Multi-Language Editions of the operating system is required for non-english applications. An electrical power receptacle for the PC is required. These minimum computer requirements should be observed: 2.0 GHz Pentium IV processor 512MB RAM 40GB free hard drive space Internet Explorer Version 6.0 or later. 10 Mbps Network Interface Card (NIC). CD-ROM drive Access to a SMTP server if Remote Notification is purchased and used. (Refer to section for more details) If the ASC computer will be connected to a local area network (LAN) then an additional NIC is required. Refer to your LAN administrator for NIC requirements. Recommended: 100 GB hard drive CD-R, CD-RW drive 17 or larger monitor with minimum 1024 by 768 screen resolution 104 alphanumeric keyboard Two-button mouse Rev. D Date of Issue: 01/05/05 13

14 2.3 MODBUS TO ETHERNET BRIDGE As CMC and Intellisys panels utilize Modbus protocol, the Modbus to Ethernet Bridge provides a means for transacting messages between Ethernet TCP/IP devices and Modbus serial devices. A bridge is furnished with each ASC in a separate NEMA 12 box with its own power supply. A / VAC, 50/60 Hz power source is required. There are a number of devices on the market to choose from when selecting a bridge. One such device is the 174 CEV Modicon TSX Momentum Modbus to Ethernet Bridge. This bridge will be supplied and configured by an Ingersoll-Rand Service Technician to match your system application. 2.4 ASC APPLICATION CD An ASC Application CD is provided for each ASC installation. The CD is labeled with the part number, site name, and CD key. 2.5 NETWORK WIRES Ethernet Side Wiring the network is accomplished by connecting the Server to the Bridge (ref. Figure 1-1: ASC Architecture Overview) using Category 5 (or better) cables. The connection point on the Server is an RJ-45 port located on the Network Interface Card. If the bridge will be directly connected to the Server, a crossover cable must be used. If the Bridge will be connected to a network consult the LAN administrator to determine if a crossover cable is required. Figure 2-1: Crossover Schematic white/green 2 1 RJ-45 green RJ Top Side white/orange blue white/blue orange white/brown Bottom Side brown Figure 2-2: RJ-45 Plug The Ethernet cables are terminated with CAT 5 RJ-45 modular plugs. RJ-45 plugs are similar to those seen on the end of a telephone cable except they have eight versus four or six contacts on the end of the plug and they are about twice as big. (RJ means "Registered Jack"). Some RJ-45 plugs are designed for both solid core wire and stranded wire while others are designed specifically for one kind of wire. Use plugs appropriate for the wire that will be used Rev. D Date of Issue: 01/05/05

15 2.5.2 Modbus Side Cabling for the Modbus side of the network must meet or exceed Belden Figure 2-3: Belden 9842 Cable Data Figure 2-3: Belden 9842 Cable The 422/485 connections on the Bridge are wired to the local panels in a daisy chain fashion. Each Intellisys panel requires a modular surface phone jack to complete the network wiring. This device is available from most stores that sell electrical components. Refer to section 3.2 of this manual for wiring details. Figure 2-4: Modular Jack 2.6 LOCAL PANELS Communication to all air system components shall be accomplished using Ingersoll- Rand microcontroller panels. Local panels must be either Centac Micro Controller (CMC) or Intellisys as manufactured by Ingersoll- Rand Company. IMPORTANT CMC Panels CMC panels must be fitted with a Universal Communication Module (UCM) and Remote Communications switch. The Remote Communications If the driver of a system component is other than an electric motor, special considerations are required. Any driver may be utilized as long as that driver can be started or stopped at will. switch must be in the Enabled position before it will accept commands from ASC. Note that data may be read and set points may be changed with the switch in the disabled position. The switch determines if the CMC will accept commands from the network such as start, stop, load, unload, acknowledge, and reset Rev. D Date of Issue: 01/05/05 15

16 Intellisys Panels Intellisys Panels must be fitted with an Intellisys Remote Interface (IRI). Intellisys controllers other than SG and Nirvana need to have its controller software revision at or above the following minimum level. Table 2-1: EPROM Revision Requirements Horsepower SE 1.1 SSR Horsepower (Red-eye) 1.9 SSR Horsepower (SG) 1.0 Sierra Horsepower (SE) 1.0 Sierra Horsepower (Red-eye) 2.0 Sierra Horsepower (SG) 1.0 Recip 1.5 Nirvana Horsepower c-c 1.3 Nirvana Horsepower c-c 2.0 The ASC will automatically load/unload but not automatically start or stop Intellisys controlled compressors. The auto start/stop function is controlled locally. Each compressor must be placed in a remote mode before the ASC can take control. See the Table 2-2 for placing the panel in this mode. Note if the compressor is stopped locally then it must be started locally. Table 2-2: Remote Mode SE Models Turn the sequence option set point "On" Start the compressor (it auto loads) SSR/Sierra Turn the sequence option set point "ON" Start the compressor For "red-eye" controllers only, press the ON-LINE/OFF-LINE button Recip Turn the sequence option set point "ON" Start the compressor Press the CONSTANT SPEED CONTROL or AUTO/DUAL button. Nirvana Turn the sequence option set point "ON." Start the compressor. Additionally, steps need to be taken so that the compressor may be started or stopped manually by ASC. The Remote Start/Stop option in the Intellisys controller must be enabled and the Remote Stop contacts must be jumpered on the Intellisys controller. This is typically labeled as RSP on the electrical schematics. For example, the SSR/Sierra must have a jumper placed between pins 19 and 20 on connector P Rev. D Date of Issue: 01/05/05

17 I/O Box When field devices such as flow meters, pressure or temperature transmitters, etc. are to be included on the ASC network and are not part of an existing Ingersoll-Rand microcontroller panel, an Ingersoll-Rand I/O Box is required. When simple control functions such as starting and stopping are required for an air system component (e.g. dryers, pumps, cooling towers, etc.) and the local panel for that component is not a Ingersoll-Rand microcontroller, the local panel may be hardwired to an Ingersoll-Rand I/O box. In this way control functions can be communicated across the network Rev. D Date of Issue: 01/05/05 17

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19 3.0 INSTALLATION 3.1 PREWORK Before the Service Technician begins the ASC commission, the following items should be completed. 1) ASC CD and Modbus to Ethernet Bridge on hand. 2) Electrical power receptacle for PC. 3) Electrical power for Bridge (and I/O box if provided) terminated in local box. 4) System components operational. 5) Modbus network cables pulled. 6) Ethernet network cables pulled, terminated, and tested. 7) Field instrumentation in place, calibrated and wiring pulled. 3.2 NETWORK WIRING Wiring the network is accomplished by wiring from the Server to the Bridge and from the Bridge to each component local panels communication module (UCM or IRI). Route the network wires in its own grounded conduit. The connection point on the Server is an RJ-45 Network port. The connection point on the Bridge is the RJ-45 port labeled 10/100 BASE-T. A crossover cable is required if the Server will connect directly to the Bridge. Refer to section for a crossover schematic and wire requirements. Figure 3-1: Typical Ethernet Network Wiring SERVER (Modbus Master) Receptacle To Server's Network Card Ethernet Cable Cat5 or Better Ethernet / Modbus Bridge Rev. D Date of Issue: 01/05/05 19

20 The Modbus network wiring is then completed from the serial connections on the Bridge to all monitored equipment. Refer to Section for wire requirements. The following example shows a network with two CMC panels and two Intellisys panels. Note that the wiring from the Bridge to the first panel (Compressor Panel #1) have the Rx and Tx connections swapped. All connections downstream of the first panel do not have Rx and Tx swapped. Figure 3-2: Typical Modbus Network Wiring Compressor Panel #4 Compressor Panel #3 COM1 to Phone Jack COM2 to Intellsys COM1 to Phone Jack COM2 to Intellisys 2-Twisted Pair Wires Rx- Rx+ Tx+ Tx- (Serial Connections) Tx- Rx+ Tx- Rx+ Rx- Tx+ Rx- Tx+ Modular Surface Phone Jack Tie Gnd Together 174 CEV BRIDGE 2-Twisted Pair Wires Plus Gnd. (5 Wires Total). Connect Ground One End Only. Tie Gnd Together To Power Supply To BCM Tie Gnd Together To Power Supply To BCM 24+ Gnd Power DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485 RS-232 DB Gnd Power DL+ DL- Gnd Tx+ Tx- Rx+ Rx- Gnd RS-485 RS-422/485 RS-232 DB-9 Universal Communication Module (UCM) Universal Communication Module (UCM) Modbus Address - 01 (Set through software) Modbus Address - 02 (Set through software) Compressor Panel #1 Compressor Panel # Rev. D Date of Issue: 01/05/05

21 For each Intellisys panel a Modular Surface Phone Jack is required to complete the network wiring. This device is available from most stores that sell electrical components. Standard wire colors and pin outs are shown below (Belkin F4E112 shown). Figure 3-3: Modular Jack Wiring Green Red Yellow Black For each Intellisys panel a cable assembly is required to connect from the COM1 connection on the IRI to the Modular Surface Mount Phone Jack. Also, a cable assembly is required to connect from COM2 on the IRI to the Intellisys controller. Figure 3-4: IRI COM1 to Modular Phone Jack RJ-11 Release Tab on Top orange/white blue/white white/orange white/blue RJ-11 Release Tab on Bottom Figure 3-5: IRI COM2 to Intellisys Controller RJ-11 Release Tab on Top orange/white white/orange RJ-11 Release Tab on Bottom The cable for both assemblies is 22 gauge, 4 conductor twisted pair telephone type wire. The plugs are 6 position RJ-11. Both may be purchased from Ingersoll-Rand. The wire is available on a 1000 foot roll and it's part number is The RJ-11 plug part number is and is compatible with solid wire. Note that the IRI to Intellisys Controller cable assembly utilizes only 1 pair of conductors. Refer to Intellisys Remote Interface Operators/Instruction Manual Parts List for additional information Rev. D Date of Issue: 01/05/05 21

22 3.3 MODBUS TO ETHERNET BRIDGE A Modbus to Ethernet Bridge is included with each ASC System purchased. The Modbus to Ethernet Bridge (Ingersoll-Rand part number ) is mounted in an 8 x 10 x 6 NEMA 12 enclosure. In addition to the bridge, inside the box is mounted a single-phase fuse protected power supply that has an output rated 24 VDC at 300 ma. Figure 3-6: Modbus to Ethernet Bridge Incoming Single Phase Power Modbus Network Termination Serial Port Switch Reset Switch Ethernet Network Termination The Bridge must be configured to match the system. Two methods of connecting to the Bridge are via RS-232 and Telnet. The next section will describe the steps required to connect to the Bridge. Section will describe the settings Rev. D Date of Issue: 01/05/05

23 3.3.1 Connecting to the Bridge Ingersoll-Rand ASC User's Manual Connecting by the HyperTerminal To configure the Bridge at its local RS-232 port, use the 174 CEV Programming Cord (Ingersoll-Rand part number ) or build one from the following schematic. Figure 3-7: 174 CEV Programming Cord DB9 female viewed with the wide side toward you RJ45 plug viewed from the cable side Gray Brown Yellow Green Red Black Orange Blue 1) Remove power from the Bridge. 2) Label, and disconnect the Modbus network terminations. 3) Position the Bridge s RS-232/RS-485 Serial Port Switch to RS-232 (up). 4) Connect the Programming Cord s RJ-45 connector to the Bridge socket labeled MODBUS. 5) Connect the Programming Cord s DB9 connector to the PC s serial port. 6) Apply power to the Bridge. 7) Run HyperTerminal program. 8) When the window titled Connection Description appears, click Cancel. 9) In the program s menu, select File, then Properties. 10) In the dropdown list labeled Connect using, select the com. port connected to the Bridge 11) Click Configure, and the COM port Properties window and change the Bits per second to ) Click OK in the COM Properties window, and Click OK in the New Connection Properties Window. 13) Make sure Caps Lock is off. 14) Hold down the x key on the PC and use a pointed instrument to press and release the Bridge reset button. 15) When the setup screen text appears, let go of the x key and press Enter. 16) Proceed to section to configure the Bridge Rev. D Date of Issue: 01/05/05 23

24 Connecting by Telnet: IMPORTANT To use Telnet to set an initial IP address in the Bridge, the Telnet host (PC or Server) must be on the same sub network (same IP range) as the Bridge IP Address. If configuring the Bridge with a direct Ethernet connection, a crossover patch cable is required. Refer to section for information regarding crossover cables. To Configure the Bridge: Follow steps 1-7 if the IP address has not been set. If the bridge is programmed with a known IP then start on step 8. 1) Write down the MAC (Media Access Control) address printed on the Bridge s side panel. It may be necessary to partially remove the Bridge to read the address. An example of the MAC address is A 51 1D. 2) Connect one end of the patch cable to the Bridge s 10/100 BASE-T port. Connect the other end to the Network Interface Card port on the computer. 3) Apply power to the Bridge. 4) Open Command Prompt window at root directory. 5) Issue an arp (Address Resolution Protocol) Command using the following syntax: arp s <IP Address> <MAC Address>. Example: arp -s A- 61-2C F1 6) Open a telnet connection to the address you just assigned. Use port 1. Example: telnet ) This connection will fail. The Bridge will, however, change its IP address per above. 8) Open another telnet connection to the IP address using port Example: telnet ) When the setup screen appears press Enter. 10) Proceed to the next section to configure the Bridge Configuring the Bridge Once connected to the Bridge, settings can be changed. Refer to the following steps to configure the Bridge to work with ASC. 1) Press 1 to change Network/IP Settings 2) Select and type a valid IP address for the Bridge 3) Type N for Set Gateway IP Address 4) Type Y for Set Netmask 5) For Bridges that are directly connected to the ASC Server type For Bridges connecting to a network consult the LAN administrator. 6) Type N for Change telnet config password 7) Type 2 to change Serial & Mode Settings Rev. D Date of Issue: 01/05/05

25 8) Press 1 to set Attached Device to Slave 9) Press 1 to set Serial Protocol to Modbus/RTU 10) Press 2 to set Interface Type to RS422/RS485+4-wire 11) Enter the serial parameters 9600, 8, N, 1. 12) Type 4 to change Advanced Modbus Protocol Settings 13) Press 0 to set Slave address to auto 14) Press 1 to Allow Modbus Broadcast 15) Press 2 to Use MB/TCP 0x08/0x0A Exception Responses 16) Press 1 to set Disable Modbus/TCP pipeline to No 17) Type 50 for the Character Timeout 18) Type 1500 for the Message Timeout 19) Press 0 for Serial TX delay after RX 20) Press N for Swap 4x/0x to get 3x/1x 21) When finished your screen should look something like the following (Serial Number, MAC address, and Network/IP Settings will be unique for your site): Figure 3-8: Modbus/Ethernet Bridge Settings *Schneider Automation, Inc. - Modbus Bridge (174 CEV ) Serial Number MAC address 00204A61AD01 Software version V01.0 (030609) DLX Press Enter to go into Setup Mode Modbus Bridge Firmware Setup, Schneider Automation, Inc. 1) Network/IP Settings: IP Address Default Gateway not set --- Netmask ) Serial & Mode Settings: Protocol... Modbus/RTU,Slave(s) attached Serial Interface ,8,N,1,RS422 3) Modem Control Settings: Modem control not available with RS422/RS485 4) Advanced Modbus Protocol settings: Slave Addr/Unit Id Source.. Modbus/TCP header Modbus Serial Broadcasts... Enabled (Id=0 used as broadcast) MB/TCP Exception Codes... Yes (return 0x0A and 0x0B) Char, Message Timeout msec, 01500msec 22) When finished making changes, press s to save settings. 23) After settings are saved allow the Bridge to reboot. 24) Remove power from Bridge. 25) Disconnect the programming cord. 26) Position the Bridge s RS-232/RS-485 Serial Port Switch to RS-485 (down position). 27) Reconnect the Modbus network terminations. 28) Apply power to the Bridge. The Bridge is now ready for use Rev. D Date of Issue: 01/05/05 25

26 3.4 OPERATING SYSTEM INSTALLATION NOTES If the customer will be connecting the ASC Server PC to a LAN, the administrator for the network should be consulted prior to proceeding. The administrator should also be present when the server is set up. IMPORTANT During setup of Windows Server Multi- Language Version, English (United States) should be selected to set the default locale for the system. This can be changed after setup for each Windows user. Refer to the Installation Notes in the following sections prior to installing the operating system. Windows 2000 Server During Windows installation a list will be displayed and the user will be asked which components needs to be installed. The default selections of components are sufficient to run ASC. Windows 2003 Server Windows 2003 will install no components by default. After installation is completed a screen will display titled Managing Your Server Roles. The Application Server Role must be installed prior to installing the ASC. Additionally, Internet Information Services (IIS) needs to be configured to allow Active Server Pages (ASP). Select Start->Control Panel->Administrative Tools->Internet Information Services (IIS) Manager. Expand the list in the left window and select Web Server Extensions. Select Active Server Pages in the right window and click the Allow button. Security Patches, Service Packs, and Updates Ingersoll-Rand is not responsible for including security patches and does not include security patches with updates to ASC. If the ASC computer is installed on a LAN that has access to the Internet, the recommended practice is to install patches and updates to the operating system prior to installing ASC software. These items may be downloaded and installed by using Windows Update Installing Drivers After Windows Server software has been successfully installed on the PC, it is necessary to install any drivers that came with the PC. This includes drivers for display, network ports, etc. Follow the instructions provided with the PC for installation Rev. D Date of Issue: 01/05/05

27 Configuring Network Adapters The IP address of the computer where ASC is installed needs to be a valid IP address for the network to which it will be connected. If ASC will be connected to a local computer network, then contact the LAN administrator to insure the proper addresses are used. Computers open a connection to port 80 on the ASC server to view the pages. Communications to the Ethernet/Modbus bridge is on port ASC SOFTWARE INSTALLATION Insert CD into drive and the ASC CD Browser should start automatically. If it does not start automatically, select Start, Run and type x:\launch.exe where x is the drive letter for the CD-ROM and click OK. The ASC Setup will configure your computer to run ASC. There are several software requirements for ASC and the setup will launch the setup for each requirement it determines is not installed. When the setup for one of the requirements is started please install completely and allow the computer to restart, if necessary. The ASC setup should automatically restart after the computer restarts, if for some reason the setup does not automatically restart, then please restart the ASC setup manually from the installation CD. IMPORTANT When upgrading an ASC from version 1.0 to version 2.0 communications will be disabled by default when installation is completed. Review all settings prior to enabling communications. If ASC will be installed on a server that will be attached to your company's network, then your company's Information Technology (IT) staff should be informed that ASC uses the following 3rd party software. This will allow your IT personnel to be prepared for security issues as they arise with the following software. o Microsoft Windows 2000 Server or Windows 2003 Server o Microsoft Internet Information Services 5.0 or 6.0 o Microsoft SQL Server 2000 Desktop Edition (MSDE) o Microsoft XML Parser 3.0 o Microsoft.NET Framework 1.1 o Microsoft Visual Basic 6.0 Runtime Ingersoll-Rand is not responsible for including security patches and does not include security patches for the software listed above with updates to ASC Rev. D Date of Issue: 01/05/05 27

28 3.5.1 Activation ASC requires the product to be activated prior to use. When the computer reboots after the software has completely installed, the user will be prompted to provide the key that is supplied on the ASC CD. The program automatically generates a Registration Number when you click on the field. If the Server is connected to a LAN with access to the Internet, click on the Activate ASC hyperlink. Otherwise, write the Registration Number and go to a computer that is connected to the Internet and go to Enter the Registration Number and an Activation Key will be returned. If access to the Internet is not available, contact your local Ingersoll- Rand representative. Figure 3-9: ASC Activation Screen 3.6 ASC CONFIGURATION Figure 3-10: ASC Configuration Icon During installation ASC places an icon on the desktop of the Server for configuring communication parameters and text, backing up and restoring databases, and archiving. When ASC software is installed and activated, configuring the software is the next step before running. IMPORTANT Close all Internet Explorer windows on the ASC Server prior to making any configuration changes. If the ASC Configuration icon is double-clicked, a prompt will appear for a user name and password. This user must have Engineer security role privileges in order to use this program. Refer section 2.1 for the default users and passwords. When logged in, a box with different tabs will be displayed. The following discusses each tab and corresponding settings Rev. D Date of Issue: 01/05/05

29 3.6.1 Site Name Changing this text changes the text displayed above the ticker in Internet Explorer window. Names containing < or > may produce unexpected results. Figure 3-11: Site Name Configuration Rev. D Date of Issue: 01/05/05 29

30 3.6.2 Air Systems The ASC is capable of controlling multiple air systems. For example, a site may have centrifual air compressors operating at 100 psi and reciprocating compressors operating at 400 psi. One ASC can sequence and control both systems. Each system will have setpoints independent from the other air system. This tab controls the description ASC displays for the air system. For example, a customer may want to identify the 100 psi air system as "Low Pressure" and the 400 psi air system as "High Pressure." Figure 3-12: Air System Translations Rev. D Date of Issue: 01/05/05

31 3.6.3 Panels Each panel (CMC or Intellisys) that was designed to be in the system is listed. Each panel will have a Network Address, Network Port, Device Address, and Description. The Network Address is the IP address of the Modbus to Ethernet Bridge attached to the panel. In a system with one bridge, all compressors will have the same network address. Port number also relates to the Modbus to Ethernet Bridge. The 174 CEV Modicon TSX Momentum, which is typically supplied, communicates on port 502. Device address is the decimal (not hexadecimal) Modbus address of the panel. This will correspond to the address programmed in the UCM or IRI. Description is name of the compressor or I/O box. Frequently customers want to use a unique identifier or tag to refer to their equipment. For example, a customer may want to identify the compressors AC-1, AC-2, AC-3, etc. This feature allows the customer to change the description as desired. Descriptions containing < or > may produce unexpected results. Figure 3-13: Panel Configuration Rev. D Date of Issue: 01/05/05 31

32 3.6.4 Components Components refer to the equipment, not the local panel, that communicate with ASC. Many panels control one component such as an air compressor. Some panels, such as I/O boxes, may control components such as pumps, fans, non-ir controlled compressors, etc. The user may want to provide a unique identifier or tag for each of these components. Descriptions containing < or > may produce unexpected results. Figure 3-14: Component Configuration Rev. D Date of Issue: 01/05/05

33 3.6.5 Translations Often users want to change the text displayed in the ASC. Text may be edited to display something more meaningful to the user. For example, a user may want to change the display for Flow Meter 1 to Building B Flow. The following example shows how to change the indication of the running unloaded shutdown timer for a CMC controlled compressor from RUST Enabled to Shutdown Timer. The components listed on the right are all of the components that use this translation. Descriptions containing < or > may produce unexpected results. Figure 3-15: Translations Configuration Rev. D Date of Issue: 01/05/05 33

34 3.6.6 Digital Digital inputs and outputs may be normally open or normally closed. For example, the seal air switch on the compressors may be normally closed. This means that if the compressor has enough pressure for seal air, the input will be true. Other inputs may be normally open. For example, the emergency stop may generate an output that is true only if the button is pressed. For normal operation, this would result in the seal air switch being checked and the emergency stop being unchecked in the ASC. The user may interpret this to mean that the seal air switch has tripped when it has not. Select the panel on the left to edit and inversion may be enabled or disable on the right. Figure 3-16: Digital Inversion Configuration Rev. D Date of Issue: 01/05/05

35 3.6.7 Notification (Optional) This feature is provided only if purchased. ASC may be configured to send a message for alarms, trips, or both. This message may be sent to a device that is configured to receive SMS messaging or . Many wireless service providers have pagers or cell phones equipped to receive SMS messages. The message has the site name, component name, and associated trip or alarm message. Notification sends all messages through a mail server. This server is the same as the server used by programs like Microsoft Outlook. This means, for this function, the ASC Server needs to be connected to a LAN that includes a mail server. Local IT personnel will be able to provide the name of the SMTP (Simple Mail Transport Protocol) Server. Place addresses for remote devices (contact the wireless service provider to determine the address) or in the Notification Addresses field. Figure 3-17: Remote Notification Configuration Figure 3-18: Notification Example From: ASC@donotreply.com To: @WirelessService.com Date: Wed, 28 Jan :51: Subject: Ingersoll-Rand: AC-8: Oil Pressure Low Trip Rev. D Date of Issue: 01/05/05 35

36 3.6.8 Archive The Desktop Edition of SQL Server 2000 is shipped with the product. This edition limits the size of any database to 2 GB. The amount of time it takes to reach this limit depends on the system. For example, a system with 3 compressors will typically take longer to reach this limit than a system with 10 compressors. Figure 3-19: Archive Configuration SQL Server will have multiple databases for the ASC. The Main Database stores schedules, system level set points, charts, users, etc. The History Database stores data recorded from the panels. Archiving applies only to the History Database. There will be multiple history databases. Archiving will be explained with the following example: A maximum number of two history databases are selected. The ASC will begin populating the first database. When that database reaches the 2GB limit, the ASC will begin filling the next database. When both databases are full, the Auto Archive feature will determine what will be done with the first database. If Archive oldest history database to offline file is selected then the database will be copied to the specified directory and stored as a compressed file. If Delete oldest history database is selected then the database will simply be erased Rev. D Date of Issue: 01/05/05

37 The bar graph gives the user a glimpse at the space requirements of the history databases. The white represents files stored on the computer not relating to ASC. Blue space represents how much disk space would be available if all space allocated to the ASC were used. Green displays unused space allocated to the database. Red is used space by ASC. Lastly, attaching an archived database allows the user to view the information contained in the database as though it is online. For example, if someone wanted to chart pressures or create a report based on archived data then simply click on Add and select the archive. The data will be available for reports or charts Backup/Restore The ASC Configuration tool can manage backups and restores. The table below has a brief description of the options for backing up. Databases will be backed up in a compacted (empty space removed) format and the configuration files will be compressed in a zip file. The Configuration Files and Main Database both contain panel description information. Therefore if panel descriptions change then backup both at the same time in order to maintain backup files that have panel descriptions synchronized. Main Database History Database Configuration Files Table 3-1: Backup/Restore Options Saved schedules, stored report definitions, stored chart definitions, text translations, user names/passwords, and component descriptions. I/O values for the components as well as system level information such as system pressure and power consumption. Product activation information, communication parameters, and web server parameters Rev. D Date of Issue: 01/05/05 37

38 Figure 3-20: Backup/Restore Configuration 3.7 STARTING AND STOPPING ASC The ASC collects, processes information, and executes commands to/from connected panels. The ASC Service executes this function. The ASC Service is started as follows: 1. Start the ASC Service by right clicking on this icon that is located at the bottom right corner of the screen. 2. Select ASC Service Start. After a few moments the icon will change to Rev. D Date of Issue: 01/05/05

39 The ASC may be configured to start automatically with Windows. This means that ASC will start when the Server boots up. A user will not need to log on Windows. To enable this feature, right click on the ASC Service icon and select Auto-start ASC Service with Windows. Figure 3-21: Service Manager Options Stopping the service is accomplished in the same manner as starting. Note that logging off of the Server does not stop ASC. 1. Stop the ASC Service by right clicking on this icon that is located at the bottom right corner of the screen. 2. Select ASC Service Stop. After a few moments the icon will change to The ASC also displays the information on a series of web pages that may be viewed locally or remotely. Microsoft's Internet Information Service controls this. This service will start automatically with Windows. This is not connected to the ASC Service. Internet Information Services will make web pages available though the ASC Service is not running. 3.8 LOGGING ON ASC The final step for configuring the software is to log into ASC. From the Server 1. Start Internet Explorer by double clicking this icon 2. The ASC Login screen appears 3. Login. Refer to section 2.1 for default Usernames and Passwords. 4. ASC opens to the default System Data page Rev. D Date of Issue: 01/05/05 39

40 IMPORTANT Multiple users may Login at the same terminal. If a user does not Logout, anyone will be able to utilize the logged on user s security rights. Located on the left side of the ASC screen is the System Menu that includes links to various pages. At the bottom of the System Menu is a Logout selection. 1. Clicking on Logout will log the current user out of ASC and return to the Login screen. From a Client/Remote Computer 1. Start Internet Explorer by double clicking this icon. 2. Go to the website by typing the IP of the Server followed by /asc on the address bar. For example, 3. If you are visiting the site for the first time, then the following message will display The computer is not configured to run ASC. Please click the link below to download and run the ASC Client setup. Click on the hyperlink to download. 4. Select Save to save the file to the local computer. 5. When the download is completed select Open to execute the program. 6. Select the appropriate options during the installation of the program. 7. Now run the program by going to Start->All Programs->Air System Controller- >Client Security Configuration. 8. Click Add. The following screen will appear Rev. D Date of Issue: 01/05/05

41 Figure 3-22: Client Security Configuration Ingersoll-Rand ASC User's Manual 9. Type the computer name of the ASC Server in the Server Name field (The computer name may be determined by going to the Control Panel at the ASC Server. Select System. Go the Network Identification or Computer Name tab. The full computer name will be displayed.) 10. If your site does not use DNS or you cannot determine if it does: a. Select Include an Entry In The Windows Host File. b. Type the IP address of the ASC server in the IP address field 11. Select Add New 12. Go to the Web Site for the ASC Server by typing the name of the ASC Server followed by /asc. For example, All future logons to the ASC will use this address. 13. The ASC Login screen appears 14. Login. Refer to section 2.1 for default Usernames and Passwords. 15. ASC opens to the default System Status page Rev. D Date of Issue: 01/05/05 41

42 IMPORTANT Multiple users can Login at the same terminal. If a user does not Logout, anyone will be able to utilize the logged on user s security rights. Located on the left side of the ASC screen is the System Menu that includes links to various pages. At the bottom of the System Menu is a Logout selection. Clicking on Logout will log the current user out of ASC and return to the Login screen Rev. D Date of Issue: 01/05/05

43 4.0 USING THE SOFTWARE Figure 4-1: System Menu The information in this section will follow the layout of the ASC System Menu layout as shown on the right. This menu, as well as the Active Ticker Status (see below) is visible on each screen. The System Menu is a static frame of links that will allow quick and easy movement through the Air System Controller. At anytime you can move to another page for the current system or access pages for another system or any component. A menu item with a (symbol) to the left indicates additional menus are available for that subject. The mouse cursor will change for all items that are selectable. Active Status Ticker The active status ticker is displayed at the top of each viewed screen. The active status ticker scrolls across the upper screen section, updating every few seconds. The area in the upper right corner will scroll the Date/Time on the ASC Server and the data from the System Data section for each system. Items in the ticker are always active. Clicking on a data value takes you to the corresponding graph. Clicking on a component takes you to the Operating Data page for that component. Figure 4-2: Active Status Ticker In the event of an alarm or trip, a bar will appear below the ticker with the component identification and the event. A yellow bar will appear for an alarm and a red bar will appear for a trip. Clicking on this colored bar will take you to the alarm and trip log for that component and will acknowledge (clear) the alarm or trip bar. Clearing the bar does not acknowledge the event at the local panel. Any alarm or trip contact, horn, or light must be acknowledged on the local panel by depressing the Acknowledge pushbutton. In addition to the colored bar indicating alarm or trip the active ticker shows each component s status. A good indication of the status of a component can be determined by two pieces of information in the active ticker. The background color provides one piece of this information. The following is a list of background colors and their meaning: Rev. D Date of Issue: 01/05/05 43

44 Table 4-1: Ticker Bar Colors Background Color Green Yellow Red White Orange Gray Black Meaning Running without an alarm (CMC) / warning (Intellisys) Running or not running with an alarm (CMC) / warning (Intellisys) Not running due to a trip (CMC) / alarm (Intellisys) Not running and no alarm, trip, or warning No Communication - System Settings Communication block not checked or com. error Local Control (CMC only) - Remote Communication Switch is Disabled Server Error - SQL Server is not running on the ASC Server or the Server is off In addition to the ticker component background color a status message is also included. A status message of No Comm. indicates that communication for the device is disabled. This is due to communications being disabled in the System Communication page (see section 4.3.3). Refer to the manual that came with your compressor for an explanation of other status messages. 4.1 SYSTEM Figure 4-3: System Menu Placing the cursor on the System menu selection displays two options from which to select. System Status and Control System Details Rev. D Date of Issue: 01/05/05

45 4.1.1 System Status This System Status page displays an overview of the current status of the system. It is the default display upon starting ASC. Features of the System Status page are an Active Status Ticker, a System Data section, a Controlled Compressors and Sequenced Compressors section, a Manual Compressors section, a Other Components section and system Graph(s). The System Data screen is a view only screen; changes cannot be made from this screen. Figure 4-4: System Status Page Controlled and Sequenced Compressor System Data Active Status Ticker System Graphs Manual Compressor System Data The System Data portion of Figure 4-5: System Data the screen provides average system pressure and total power consumption. The average system pressure includes only running machines that are loaded and remote communication is enabled. If no compressors are loaded then the average system pressure includes all machines (running or not running) with remote communications enabled. Power Consumption is the total of all running compressors that have a CMC local panel and have remote communications enabled. System Flow will also be displayed if provided to ASC. The mouse cursor changing indicates active fields. Click on values to view graph Rev. D Date of Issue: 01/05/05 45

46 System Graphs A thumbnail graph is provided for each input shown in the System Data section. The graphs display values recorded during the previous 24 hours. The mouse cursor changing indicates active fields. Click on the thumbnail graph to expand the size of the graph. Controlled/Sequenced Compressors The Controlled/Sequenced Compressors portion of the screen shows the discharge pressure and the power usage of the compressors. The title of this section will display either Controlled Compressors or Sequenced Compressors. Figure 4-6: Controlled Compressors Controlled Compressors will be displayed when the compressors are in sequence and Auto Control is enabled for the system. Sequenced Compressors will be displayed when the list of compressors is in sequence but Auto Control is not enabled for the system. For additional information on sequencing and Auto Control see the section titled Systems Settings, Control. The mouse cursor changing indicates active fields. Click on values to view graph. In addition to Pressure and Power display, this section also shows the status of the compressor. Each status will have a background color and status message. Background colors and status messages are the same as previously defined for Active Status Ticker. Click on a compressor status to view the Alarm and Trip Log (see section 4.7.1). Manual Compressors These compressors are not in the sequence and Auto Figure 4-7: Manual Compressors Control is enabled for the system. A compressor may be moved to the Manual Compressors section if desired. For additional information on Manual Compressors see Systems Settings, Control. A compressor will be automatically moved to the Manual Compressors section if it becomes not available due to a trip. The mouse cursor changing indicates active fields. Click on the compressor status to view the Alarm and Trip Log. Click on values to view graph. In addition to Pressure and Power display, this section also shows the status of the compressor. Each status will have a background color and status message. Background colors and status messages are the same as previously defined for Active Status Ticker. Click on a compressor status to view the Alarm and Trip Log Rev. D Date of Issue: 01/05/05

47 Other Components Other system components Figure 4-8: System Data are shown is this section. Example of components displayed here are Dryers, Cooling Towers, Water pumps, etc. A status as well as analog data may be displayed Control System Details The Control System Details screen gives the details of how the ASC Control Engine is currently controlling the system. Features of the System Status page are an Active Status Ticker, a Controlled Compressors and Sequenced Compressors section, a Manual Compressors section, a section for Timers and a section for Control. The Control System Details screen is a view only screen; changes cannot be made from this screen. Figure 4-9: Control System Details Page Controlled and Sequenced Compressor Active Status Ticker Manual Compressor Timers Control Rev. D Date of Issue: 01/05/05 47

48 Controlled/Sequenced Compressors The Controlled/Sequenced Compressors portion of the screen shows the inlet and Figure 4-10: Controlled Compressors bypass valve positions, the discharge pressure and the user pressure set point of the compressors. The title of this section will display either Controlled Compressors or Sequenced Compressors. Click on the title of the compressor table to access the System Control screen. Controlled Compressors will be displayed when the compressors are in sequence and Auto Control is enabled for the system. Sequenced Compressors will be displayed when the list of compressors is in sequence but Auto Control is not enabled for the system. For additional information on sequencing and Auto control see section The mouse cursor changing indicates active fields. Click on values to view graph. In addition to valve positions and pressure, this section also shows the status of the compressor. Each status will have a background color and status message. Background colors and status messages are the same as previously defined for Active Status Ticker. Click on a compressor status to view the Operating Data screen. Manual Compressors The Manual Compressors portion of the screen shows the inlet and bypass valve positions, the discharge pressure and the user pressure set point of the Figure 4-11: Manual Compressors compressors. These compressors are not in the sequence and Auto Control is enabled for the system. Click on the title of the compressor table to access the System Control screen. A compressor may be moved to the Manual compressors section if desired. For additional information on Manual Compressors see Systems -> Control (see section 4.3.2). A compressor will automatically move to the Manual Compressors section if it trips. The mouse cursor changing indicates active fields. Click on values to view graph. In addition to Pressure and Power display, this section also shows the status of the compressor. Each status will have a background color and status message. Background colors and status messages are the same as previously defined for Active Status Ticker. Click on a compressor status to view the Operating Data screen Rev. D Date of Issue: 01/05/05

49 Timers and Control The Timers and Control sections of the screen Figure 4-12: Timers and Control contains data about what the next action the control engine will take and associated timer. For additional information on Timers and Control actions see Systems Settings -> Setpoints (see section 4.3.1). The mouse cursor changing indicates active fields. Click on timer and control values to access the Setpoints screen. 4.2 BUILDING A single click on word Building in the menu section displays an overview of the components. The building view is based on information received with the order and is not configurable in the field. Basic component data is also included. The mouse cursor changing indicates active fields. Click on component values to view graph. Click on the component picture to access the Operating Data screen for that component. Figure 4-13: Example of Component on Building Page Placing the cursor on the word Building in the menu selection expands the menu to show the component list from which to choose. Figure 4-14: Sample Building Menu Rev. D Date of Issue: 01/05/05 49

50 Placing the cursor over the component identification expands the menu to show the available screens for a given component. Figure 4-15: Sample Component Menu Due to the many possible variations in components not every component or system will have the same available data and some screen layouts will differ. Every component page will have two buttons at the top right Clear Data and Save Data. These buttons will be used when editing any values. Clicking Clear Data will cause any unsaved values to go back to the previous value. Clicking Save Data will immediately save and implement any changes. If the component accepts commands (start, stop, load, unload, etc.) then push buttons for those commands will be displayed on every screen available for the component. The following examples show push buttons for start, stop, load, unload, reset, and acknowledge. Each pushbutton requires confirmation before the command is sent to the component. Moving the mouse cursor over values may cause the cursor to change. This indicates an active field. Click on the active field to view a chart of values for the previous 24 hours. The following sections will describe typical screens for centrifugal air compressors. See compressor manual for description of functionality and data Rev. D Date of Issue: 01/05/05

51 Operating Data Operating Data views the current actual measurements on the component as well as the available inputs and outputs. The mouse cursor changing indicates active fields. Click on values to view graph. In addition, changes can be made on the Alarm and Trip settings by editing the set point value. The background color of the Actual value will change color when an alarm or trip event occurs for the specific input. Ingersoll-Rand ASC User's Manual Figure 4-16: Sample Operating Data Page Other information shown on the example screen is the component tag identification and the component s status. Discrete status is also indicated as well as analog valve command outputs and counters. The Operating Data page is limited not by the ASC but by the availability of information from the component. Anti-Surge The Anti-Surge screen has all the settings for controlling and detecting surge conditions and protecting the main drive motor from overload conditions. It also includes the settings for Auto-Dual control. Figure 4-17: Sample Anti-Surge Page Rev. D Date of Issue: 01/05/05 51

52 PID Proportional, Integral, and Derivative (PID) settings provide for tuning the controls system to match the system. Figure 4-18: Sample PID Page Setup The Setup screen has specific number settings related to the pressure and timing issues of start up and stop on a unit basis. IMPORTANT Intellisys controllers prior to SG (includes SE and Redeye) require the compressor to be stopped before making setpoint changes to the units. 4.3 SYSTEM SETTINGS Figure 4-19: System Settings Menu Placing the cursor on the words System Settings displays four options from which to select. Setpoints, Control, Communication, and Control Value. Before proceeding it is important to understand control functionality and the parameters that control it. Refer to section 5.0 of this manual for an explanation of machine control. Every System Settings page has a button located at the top right called Saved Data. Click this to implement any changes Rev. D Date of Issue: 01/05/05

53 4.3.1 Setpoints The Setpoints screen has specific settings related to the how the ASC will determine when to start, stop, load and unload controlled compressors. IMPORTANT A Target Pressure value should be entered prior to selecting Save Data. If this value has not been set, there may be an interruption to the air supply. Figure 4-20: System Setpoints Page Rev. D Date of Issue: 01/05/05 53

54 4.3.2 Control This screen is where automatic control of the compressors can be enabled or disabled. Compressors also are selectively placed under manual or sequenced control. Under manual control the compressors will not be started, stopped, loaded, or unloaded automatically nor will it participate in load sharing. A sequenced compressor will be automatically put in manual sequence if a trip or surge unload occurs. Figure 4-21: System Control Page Communication The Communications screen will allow the user to enable or disable communications to a specific device. If the ASC receives multiple communication errors with a particular device it will automatically disable communications. Once communications is disabled, the compressor is removed from sequencing. Go to the Control page (section 4.3.2) to put the compressor back into sequencing. Figure 4-22: System Communication Page Rev. D Date of Issue: 01/05/05

55 4.3.4 Control Value The Control Value screen will allow the user to select the pressure indicator that the ASC uses to determine when to start, stop, load, and unload compressors. This parameter and the set points that affect the automatic control functions need to be carefully coordinated. For example, if a pressure transmitter is located on the demand side of a dryer then the Load/Start pressure needs to relate to this value not the pressure located at the compressor discharge. In the event that ASC loses communication to the controlling pressure transmitter, it will revert to Average Pressure. Figure 4-23: System Control Value Page Rev. D Date of Issue: 01/05/05 55

56 4.4 SCHEDULER This powerful feature of the ASC allows a user to schedule device set point changes, system set point changes, sequence changes, control commands (start, stop, load, unload), etc. This could be used, for example, to rotate the sequence of compressors weekly or to reduce the air pressure for a night shift. This could be configured to stop compressors on a holiday and start before the next work shift. This tool can have multiple jobs. ASC Job Scheduler On the initial schedule page, a list of jobs will be displayed. This will display the name, current status, date and time the job was last executed, and if it was successful. The name of the job will be hyperlinked so that the job configuration can be viewed or edited. This screen will also allow the user to add a new job. Figure 4-24: Job Scheduler General Information Page General Information The job description should have enough information to identify the particular job from a list of jobs. The description for schedules must be limited to numbers, letters, spaces, and hyphens. Descriptions containing < or > may produce unexpected results. The scheduler allows a job to occur on a daily or weekly basis. A daily basis means that it occurs every days and weekly basis means that it occurs every 1-52 weeks. The job may be enabled or disabled and can be configured to begin or end at a predetermined date Rev. D Date of Issue: 01/05/05

57 Frequency This page varies based on whether a job is configured to occur daily or weekly. Either allows the job to be setup to occur one time during the day or occur at a particular frequency defined in hours or minutes during the day. A predetermined start and end time can be selected. Figure 4-25: Job Scheduler Frequency Page Task Configuration The scheduler can change set points on components, send commands, rotate sequences, and/or change system set points. The user must first assign the task that is to be executed. The task must then be edited to configure the settings associated with the task. Once the task has been completely configured then it needs to be saved by clicking Save Data. The user may proceed configuring other tasks associated with the job. Once all tasks have been configured and saved then the entire job needs to be saved by clicking Save Job. Figure 4-26: Job Scheduler Task Configuration Rev. D Date of Issue: 01/05/05 57

58 Figure 4-27: Sample of Manual Commands for Scheduler 4.5 CHARTING The ASC includes functionality for charting data. This data can be any data that is recorded by the ASC such as Motor Current for compressor AC-8. Figure 4-28: Charting Page Rev. D Date of Issue: 01/05/05

59 Charting Toolbar Figure 4-29: Charting Toolbar The charting function includes a toolbar with access to common functions. If the mouse pointer is held over an icon a short description of the icon is displayed. The following is an explanation of each tool. The details follow the same order as the icons from left to right. Load Graph This loads a stored definition of the graph. Save The parameters that define the graph may be saved for viewing later. If a custom date range is specified for the x-axis then it will always retrieve the graph data for that date range. If a relative date such as Last Day or Last Month is used then it will retrieve the graph data for the time period relative to the current date. For example, suppose a graph was stored two months ago for Last Day. If the chart were loaded today it would show data over the past 24 hours rather than the day two months ago when the graph was saved. Scroll Back This function will move the graph backwards in time. It is moved by ½ the range of the x-axis. For example, the user is viewing data from 2:00-2:30. If the user selects scroll back then the date ranged will be changed to 1:45-2:15. Scroll Forward This function will move the graph forwards in time. It is moved by ½ the range of the x- axis. For example, the user is viewing data from 2:00-2:30. If the user selects Scroll Forward then the date ranged will be changed to 2:15-2:45. Refresh Selecting Refresh will update the data displayed on the graph to its current values. Reset Zoom Zooming may be accomplished by dragging a window around an area on the chart. The chart will zoom into that area. If the user wants to go to the original extents of the graph then click on Reset Zoom. Previous Zoom If the user wants to go to the extents of the previous view (prior to the last zoom) then click on Reset Zoom. Copy The copy function may be used to put an image of the graph into programs such as Microsoft Word. The copy function will place a bitmap of the graph that is currently being viewed into the Clipboard. This may be pasted into most programs. Save As The save function will create a.bmp (bitmap) file that has an image of the graph currently being view Rev. D Date of Issue: 01/05/05 59

60 Print This function will send an image of the current view of the chart to the selected printer. Figure 4-30: Options This tool will allow the user to select the variables to display, how they will be represented on the graph, the x-axis range. On the Data Selection tab, select the variables from the left side. Click on the > or < buttons to add or remove variables from the chart. Each variable can be configured with a color and marker. Click on Use custom color and click the button to select the desired color. Click User custom shape to display a shape at each reading. On the X-Axis tab, select what the x-axis will represent. It may be date/time or a variable. The Date Range tab is where the user controls what is displayed. Chart Options Real-Time Graph If Real-Time Graph is enabled then it will update automatically. This will display each new reading as it is recorded. Real-Time Graphing is limited to one variable. Predefined Charts The ASC has five predefined graphs. Any of the graphs may be customized to include other recorded parameters All Inlet Valves This graph displays a line chart of each inlet valve position measured as percent open. The default setting includes the last 24 hours of operation for all the centrifugal compressors ASC is currently monitoring. This includes any unit that is loaded, unloaded or stopped. Compressors running at full load will show the inlet valve at 100%. All Bypass Valves This graph displays a line chart of each bypass valve measured as percent open. The operation of the Bypass Valves for each unit is shown here as a "percent open value". The default settings include the last 24 hours of operation for all the centrifugal compressors ASC is currently monitoring. All Sys Pressures This graph displays a line chart of each system pressure. The default settings include the last 24 hours of operation for all the centrifugal compressors ASC is currently monitoring Rev. D Date of Issue: 01/05/05

61 All IV/Total Bypass (all) This graph displays a line chart of inlet valve position and sum of bypass valve positions measured as percent open for all centrifugal compressors. The default settings include the last 24 hours of operation for all the centrifugal compressors ASC is currently monitoring. All IV/Total Bypass (in sequence) This graph displays a line chart of inlet valve position and sum of bypass valve positions measured as percent open. The values are display for only the compressors that are under automatic control at the time that the chart is generated. The default settings include the last 24 hours of operation for all the centrifugal compressors ASC is currently monitoring. 4.6 REPORTING The ASC has a function that can create a report in pdf format. Two types of reports may be created. Current Data Report will display the most current reading of the data for the report whereas the History Data Report will refer to a specified date range. Figure 4-31: Reporting Page The reporting function has a tool bar. The icons are, from left to right, new, open, copy, refresh, preview, and delete. New creates a new report and open displays the configuration of the selected report. Copy adds a copy of the selected report to the list. Refresh updates the list. This is important when multiple users are logged onto the system. Preview will open a window that displays the resulting pdf. Delete will remove the report from the list Rev. D Date of Issue: 01/05/05 61

62 4.6.1 Current Data Report Current Data Reports will display a report with variables in rows and components in columns. Figure 4-32: Current Data Report Wizard If you create a report, you will first need to select the type of report that will be generated. Next you will be prompted to select the Components that are to be displayed. Select the components from the list on the left. Click the arrows to add or remove the variables from the list. An option for Report Orientation is also available. If Portrait orientation is chosen then a maximum number of four Components may be selected. If Landscape is chosen then a maximum of six Components may be selected. Figure 4-33: Sample Output Rev. D Date of Issue: 01/05/05

63 4.6.2 History Data Report History Data Reports will display the variables in columns and the date/time in rows. If you create a report, you will first need to select the type of report that will be generated. Next you will be prompted to select the variables that are to be displayed. Select the variable from the list on the left. Click the arrows to add or remove the variables from the list. An option for Report Orientation is also available. If Portrait orientation is chosen then a maximum number of four variables may be selected. If Landscape is chosen then a maximum of six variables may be selected. Figure 4-34: History Data Report Wizard After the variables have been selected then a date range must also be chosen along with an averaging period. Figure 4-35: Sample Output Rev. D Date of Issue: 01/05/05 63

64 4.7 LOGS Alarm & Trip Log ASC tracks alarms and trips for components in the system. This allows an engineer or technician to plan for required maintenance or remove the failing component from operation. Figure 4-36: Alarm & Trip Log Page The information in this section will remain saved until a user clears the log. The data is not stored in any other area and is not retrievable after the log is cleared. For ease in reading, you can sort the data by any field or search for information using the separate Search function System Log ASC tracks activity for components in the system. This allows an engineer or technician to review operations of any single component, job or system in the plant. The information in this section will remain saved until a user clears the log. The data is not stored in any other area and is not retrievable after the log is cleared. For ease in reading, you can sort the data by any field or search for information using the separate 'Search' function. Figure 4-37: System Log Page Rev. D Date of Issue: 01/05/05

65 4.8 CHANGE PASSWORD Ingersoll-Rand ASC User's Manual The Air System Controller allows access to critical set points and operation of the air system. As a user, you are able to change your password to protect data as well as the critical set points of the Air System. It is essential for all users to change their password periodically to prevent unauthorized users from making changes in the Air System operations. Figure 4-38: Change Password Page 4.9 ADMIN Security Roles The ASC is designed to accommodate a number of different users using predefined roles. The three roles are Manager, Operator, and Engineer. The roles are defined based on the basis that managers will need to view operating information, operators will be able to control compressors as they could from the faceplate, and engineers can change any system parameter. The default users and passwords are published in this manual therefore it is recommended practice to remove the three default user accounts when configuring the software. Table 4-2: Security Roles Role Manager Operator Engineer Rights View all pages other than Scheduling and Admin. Cannot change set points. Cannot start, stop, load, or unload. View all pages other than Scheduling and Admin. Can change set points. Can start, stop, load, or unload. Full access to all functionality Rev. D Date of Issue: 01/05/05 65

66 Figure 4-39: Adding New Users Add a User Any names or passwords using < or > may produce unexpected results. 1. Must be logged into an account that is designated with an Engineer security role. Select Admin 2. Select New User 3. Select the Role (refer to prior section for more information) 4. Type the user name for the person 5. Type the full name of the person 6. Type the password 7. Type the password again in the Confirm Password field 8. Click on Save Data Rev. D Date of Issue: 01/05/05

67 5.0 SYSTEM CONTROL This section will describe how ASC will control CMC and Intellisys equipped compressors. Italicized terms will indicate setpoints that have an effect on this behavior. In order to understand the control methodology sequencing must first be considered. 5.1 SEQUENCING Definition: Selecting the order of the compressors either manually or automatically. Sequencing is a feature of the ASC. The following figure is taken from the System Control page and controls sequencing for ASC. Refer to section of this manual for more details on the System Control page. Figure 5-1: Sequencing as Shown on System Control Page Manual Compressors lists all compressors not being controlled by ASC. Sequenced Compressors lists all compressors being controlled by ASC (if Auto Control is enabled and the ASC Service is running). Selecting a compressor from the Sequenced Compressors list and clicking Remove will put the compressor in the Manual Compressors list. Selecting a compressor from the Manual Compressors list and clicking Assign will put the compressor in the Sequenced Compressors list Rev. D Date of Issue: 01/05/05 67

68 Referring to Figure 5-1, AC-6A is the first compressor in sequence and AC-8 is the last. Consider the example of AC-6A being loaded while compressors AC-9 and AC-8 are not. If the ASC decides that another compressor needs to come online to maintain pressure, AC-9 will be the next compressor commanded to load. Now consider the example of all compressors are running. If the ASC determines to take a compressor offline, AC-8 will be the first to unload. Selecting a compressor and clicking either the up or down arrow will move the compressor up or down in sequence. Selecting Rotate Backward will move each compressor down in sequence and the last compressor will become the first. In the example if Rotate Backward were selected, the sequence would become AC-8, AC-6A, and AC-9. Rotate Forward performs a similar function by moving compressors up in sequence. In the example if Rotate Forward were selected, the sequence would become AC-9, AC-8, and AC-6A. 5.2 MACHINE CONTROL OF CENTRIFUGAL COMPRESSORS Definition: Functionality that selects the compressor to load, start, unload, and stop as well as executing the function. There are several settings that must be defined before the functions of machine control can be explained. These settings are: Load/Start Pressure Start Timer Load Timer Wait Timer Target Pressure IV Load-sharing Gain BV Load-sharing Gain Unload/Stop Pressure Unload Timer Stop Timer Allowed Bypass Unload Test Pressure Unload Test Rate Unload Test Max. Bypass Each of these will be explained in the following pages. There are some basic rules that apply when describing automatic machine control. These basic rules are: If a compressor is running unloaded, that compressor will be loaded before another is started. If a compressor is running unloaded, that compressor will be stopped before another is unloaded. Compressors load and start as needed beginning from the top of the list. Compressors unload and stop as needed beginning from the bottom of the list. A compressor is a candidate for loading or stopping if it is running and in the unloaded state (Unloaded, Unloading, or Autodual Unloaded) A compressor is a candidate for starting if it is in a ready state (Ready) A compressor is a candidate for unloading if it is running and in a loaded state (Minload, Maxload, Loaded, Full Load) Rev. D Date of Issue: 01/05/05

69 To understand the settings that make possible automatic machine control function, an understanding of the air system Pressure Limits is necessary. Not only must Pressure Limits be considered Time Limits must also be considered Pressure Limits To maintain a desirable operating pressure in the system it is necessary to input a set point in the compressor s pressure controller. For the purpose of this explanation that setpoint will be referred to as Target Pressure. The Target Pressure is transmitted to the sequenced compressors local panels when ASC Service is started, changes are saved to Target Pressure, or any time the sequenced compressors pressure setpoint does not equal the Target Pressure. The Target Pressure (100 in this example) is indicated on the next graph. Figure 5-2: Example of Air System Typically, the air system has a pressure window in which it operates; a pressure not to exceed and a pressure not to go below. By design the pressure controller should limit the rise in system pressure, regardless of the number of machines running. The results will not necessarily be very efficient as some or all the compressors could be bypassing air to the atmosphere. The pressure controller cannot prevent a pressure from going low if enough compressors are not on line. Upon this premise the need for automatic control is realized. With automatic machine control, an increase in pressure above a certain level marks the time to evaluate if a compressor may be unloaded or stopped. At a lower pressure level it is usually suitable to not do anything, as pressure is acceptable. At an even lower level it is time to evaluate if a compressor may be loaded or started. Graphically, this is illustrated below: Rev. D Date of Issue: 01/05/05 69

70 Figure 5-3: Example of Air System After we consider pressure limits we can now consider the first two set points necessary for automatic machine control that is Load/Start Pressure and Unload/Stop Pressure. What is Load/Start Pressure? This is a pressure that is not normally reached unless an additional compressor needs to be started or loaded. This limit would be lower than the Target Pressure and the Unload/Stop Pressure. How is it used? The system pressure must be below this level before a start or load command can be sent. What is Unload/Stop Pressure? The lower limit of normal operating pressure fluctuation. This limit would normally be the same or slightly lower than the Target Pressure. This may, at first, seem incorrect because typically a compressor is unloaded if pressure is higher than necessary. However, a properly tuned controller will throttle the compressor or open the bypass valve to keep pressure near Target Pressure. The goal is to unload compressors that are not needed. The Unload Test (refer to section 5.2.5) will prevent a compressor from unloading if it is needed. How is it used? The average system pressure must be above this level before an unload or stop command can be sent. (To conduct the Unload Test, pressure must be above this level.) Adding these pressure limits to our first system pressure graph results in the following: Rev. D Date of Issue: 01/05/05

71 Figure 5-4: Pressure Limits Time Limits Not only must Pressure Limits be considered. Time Limits are another factor. A fluctuation in system pressure is the result of some event that has taken or is in the process of taking place. Examples of events are: Compressor start or stop Workers taking breaks Shift changes Air demand increase or decrease If the event is of short duration, it might be unnecessary to respond to an increase or decease in pressure. If the recovery of a drop in pressure were imminent it would not be necessary to start or load another compressor. Assume the pressure to load or start the next compressor was 94 psi. If the event bottomed out at 93.5 psi and started to recover, the load or start command would not be necessary. See the next graph for illustration Rev. D Date of Issue: 01/05/05 71

72 Figure 5-5: Example of Acceptable Pressure Fluctuations Therefore, timers add a delay to the automatic functions for the purpose energy conservation. The timers that perform this function are Load Timer, Start Timer, Unload Timer, and Stop Timer. We will also cover the Wait Timer. Load Timer What is the Load Timer? This is a delay before sending a Load command to an unloaded compressor. How is it used? The system pressure must be below the Load/Start Pressure for the duration of this timer before the Load command can be sent. Setting this value to 0 disables automatic loading. Start Timer What is the Start Timer? This is a delay before sending a Start command and a Load command to a compressor that is Ready. Starting includes loading so that additional delay will not be added. How is it used? The system pressure must be below the Load/Start Pressure for the duration of this timer before the start and load commands can be sent. Setting this value to 0 disables automatic starting. Unload Timer What is the Unload Timer? This is a delay before starting an Unload Test and trying to unload a compressor. How is it used? The system pressure must be above the Unload/Stop Pressure for the duration of this timer before an Unload Test will begin. (Unload Test will be discussed later) Setting this value to 0 disables automatic unloading Rev. D Date of Issue: 01/05/05

73 Stop Timer What is the Stop Timer? This is a delay before sending a Stop command to an unloaded compressor. How is it used? The system pressure must be above the Unload/Stop Pressure for the duration of this timer before a stop command can be sent. Setting this value to 0 disables automatic stopping. Wait Timer What is the Wait Timer? This is a delay before any additional control functions may be evaluated. It allows the system to recover or respond to what has been done to it. How is it used? This delay is used after a start, stop, load, unload, unload test pass, or unload test fail Automatic Loading One of the basic rules listed earlier says that If a compressor is running unloaded, that compressor will be loaded before another is started. This basically answers the question of which compressor to load next. The requirements of when to automatically load are: There is a compressor running Unloaded Pressure falls below the Load/Start Pressure The Load Timer starts Figure 5-6: Unacceptable Pressure Drop If the Load Timer finishes and the pressure is still low then the compressor is commanded to load Rev. D Date of Issue: 01/05/05 73

74 Figure 5-7: Compressor Loads The Wait Timer now allows the system to recover or respond to what has been done to it Automatic Starting One of the basic rules listed earlier says that A compressor is a candidate for starting if it is in a ready state (Ready). This basically answers the question of which compressor to start next. The requirements of when to automatically start are: There is not a compressor running unloaded Pressure falls below the Load/Start Pressure The Start Timer starts Figure 5-8: Unacceptable Pressure Drop If the Start Timer finishes and the pressure is still low, the compressor is commanded to start and load Rev. D Date of Issue: 01/05/05

75 Figure 5-9: Compressor Start Ingersoll-Rand ASC User's Manual The Wait Timer now allows the system to recover or respond to what has been done to it. System pressure could recover. If pressure is still low at the end of the Wait Timer the Start Timer starts timing again Automatic Unloading One of the basic rules listed earlier says that A compressor is a candidate for unloading if it is running and in a loaded state (Minload, Maxload, Loaded, Full Load). This basically answers the question of which compressor to unload next. Before further discussion on Automatic Unloading, Allowed Bypass and Unload Test Max Bypass (check valve closed) must be defined. What is Allowed Bypass? A number that indicates that the total bypass in the system is great enough to allow unloading a compressor. How is it used? The Unload Test will not begin until the total bypass valve sum is greater than this value. What is Unload Test Max Bypass? (check valve closed) A point in the bypass valve travel that is more open than the point that the check valve closes. How is it used? The compressor will not be unloaded until its bypass valve is open more than this value Rev. D Date of Issue: 01/05/05 75

76 Unload Test What is the Unload Test? The Unload Test tests to ensure that a compressor can be safely unloaded. The test forces the compressor out of the system to determine if it is needed or not. How does it work? It lowers the compressor s setpoint by the amount specified by Unload Test Rate. It monitors the system pressure to see that it stays above the Unload Test Pressure. If the pressure falls below the Unload Test Pressure the test fails and the setpoint is restored. It monitors the compressors bypass valve position to see if it opens past Unload Test Max Bypass. If the bypass valve is open more than the Unload Test Max Bypass then the test passes and the setpoint is restored. The above is repeated periodically until the test passes or fails. As a compressor s set point is lowered the discharge pressure on that machine begins to fall as the bypass valve goes further open. If System Pressure remains above the Unload Test Pressure the test will continue. Before the valve reaches the Unload Test Max Bypass the check valve will go closed. When the valve reaches the unload point the compressor will unload. The Unload Test will continue once started until it either passes or fails. How does the Unload Test fail? The compressor s Target Pressure (or User_PSP) is lowered The compressor s bypass valve is slowly forced open The system pressure is affected by the increased bypass (decrease discharge pressure) The other compressors in the system respond to the dropping system pressure by opening their inlet valves. The other compressors in the system cannot maintain system pressure. The system pressure falls farther each time the setpoint is lowered The system pressure falls below the Unload Test Pressure. The compressor s Target Pressure (or User_PSP) is set back to its normal value. (See following graph) Rev. D Date of Issue: 01/05/05

77 Figure 5-10: Unload Test Fails Ingersoll-Rand ASC User's Manual The above graph shows that if the Unload Test were not conducted the system pressure would remain acceptable but the one or more compressors would by bypassing (see light gray) How does the Unload Test pass? The compressor s Target Pressure (or User_PSP) is lowered The compressor s bypass valve is slowly forced open The system pressure is affected by the increased bypass (decrease discharge pressure) The other compressors in the system respond to the dropping system pressure by opening their inlet valves to correct system pressure The bypass valve opens farther than Unload Test Max Bypass (the check valve closes) The system pressure remains O.K. for the duration of the test The compressor is unloaded The compressor s Target Pressure (or User_PSP) is set back to its normal value. (See the next graph) Rev. D Date of Issue: 01/05/05 77

78 Figure 5-11: Unload Test Passes The above graph shows that system pressure is unaffected by unloading a compressor. (see light gray) Automatic Stopping One of the basic rules listed earlier says, A compressor is a candidate for loading or stopping if it is running and in the unloaded state (Unloaded, Unloading, or Autodual Unloaded). This basically answers the question of which compressor to unload next. The requirements of when to automatically stop are: There is a compressor running unloaded Pressure rises above the Unload/Stop Pressure The Stop Timer starts If the Stop Timer finishes and the pressure is still high then the compressor is commanded to stop. (See the next graph) Rev. D Date of Issue: 01/05/05

79 Figure 5-12: Compressor Stops Ingersoll-Rand ASC User's Manual 5.3 MACHINE CONTROL OF ROTARY AND RECIP. COMPRESSORS Automatic control of rotary and reciprocating compressors is similar to centrifugal compressors. Automatic control will load and unload compressors based on how the user chooses to operate the system. Automatic control will not start and stop the compressors. The Intellisys panel handles starting and stopping. Therefore careful attention of both system parameters and individual compressor parameters is required. Settings in the local controller may stop the compressor when the ASC needs it to be online. Coordination of compressor parameters with system parameters is critical. Consult with the controller manual supplied with the compressor prior to configuring the system Automatic Loading In a system that is designed to maintain pressure, compressors may need to load in order to compensate for a drop in pressure. A compressor is a candidate for loading if it is in an unloaded state. The requirements of when to automatically load are: A compressor is running unloaded Pressure level falls below ASC Online Pressure The Load Delay Timer starts. If after the Load Delay Timer expires and pressure remains below the ASC Online Pressure then the next compressor in sequence will be commanded to load Automatic Unloading The compressed air system may now be able to maintain a minimum pressure, but running the compressors while demand decreases may result in an elevation in pressure. Compressors need to unload in order to prevent high pressures. A compressor is a candidate for unloading if it is running and in a loaded state. The requirements of when to automatically unload are: A compressor is in a loaded state Pressure rises above ASC Offline Pressure Rev. D Date of Issue: 01/05/05 79

80 The Unload Delay Timer starts. If after the Unload Delay Timer expires and pressure remains above the ASC Offline Pressure then the next compressor in sequence will be commanded to unload. Furthermore, a special case exists where all compressors may be commanded to unload at once. If the pressure level exceeds the ASC Offline Pressure by 5 or more PSI then all loaded, rotary or recip. compressors will be commanded to unload. The System Recovery Time timer starts. No compressor will be commanded to load until pressure falls to ASC Offline Pressure. If the pressure falls prior to the timer expiring then all but one of the previously loaded compressors will be commanded to load. If pressure falls after the timer expires, then only one compressor will be commanded to load. 5.4 LOADSHARING OF CENTRIFUGAL COMPRESSORS Definition: A method of making air compressors in a system share the load more equally. Load sharing utilizes the maximum available throttle of each compressor to minimize costly air bypass to atmosphere, and automatically takes unnecessary air compressors out of the air system. This principle is illustrated below. Figure 5-13: Example of Operation Without Loadsharing Assume a system has three centrifugal compressors. This typical behavior of the compressors in a system with no load sharing is shown above Rev. D Date of Issue: 01/05/05

81 Note that Compressor #1 is fully loaded with its bypass valve closed. Note also that Compressor #2 is loaded and its bypass valve is closed. Compressor #3, on the other hand, is at its minimum load inlet valve position and its bypass valve is 100% open. This system could enjoy the benefits of Load Sharing: Reduce waste air More efficient operation of system Save money To eliminate the above waste, a system is needed to make the air compressors share the load more equally. The ASC software causes the air compressors to balance the load among themselves. The feedback from the system pressure transducers must be very close or the air compressors will behave differently and tend to wander away from each other, with a possible decrease in the amount of energy savings Anti-Blowoff One way Load Sharing forces the compressors to share the load is through Anti- Blowoff. Before getting into how it works, a word should be said about BV Load-sharing Gain. BV Load-sharing Gain is defined as the ratio of a change in the output (of internal pressure setpoint) to a change in the variable (bypass valve position). If the Target Pressure is 125 psig and gain is 6, when the bypass valve is open 20% the internal pressure setpoint will be reset to psi. Internal SP = (Bypass Vlv % Open / 100 BV Load-Sharing Gain) + Target Pressure Anti-Blowoff is a type of load sharing that works on bypass valve position. The operation is as follows: The control system sends the BV Load-sharing Gain to all running-loaded compressors every 25 seconds. (The value will expire after 30 seconds if no new gain is received) This command will only have a direct effect on compressors that are bypassing The internal (not visible) pressure setpoint of these compressors is raised This leads to less bypassing, and an increasing system pressure This causes the compressors that are full loaded or modulating to reduce their output (to their inlet valves). This reduces the system pressure back to near the normal User_PSP value If a compressor stops receiving the load sharing commands it will return to its own local control. The next graph illustrates the three earlier compressors but now with load sharing Rev. D Date of Issue: 01/05/05 81

82 Figure 5-14: Anti-Blowoff As a result of Anti-Blowoff Load Sharing the following benefits will be realized: The amount of bypassed air will be reduced, or eliminated The situation of one or more compressors operating at full load while the others are at minimum load will be eliminated No compressors are at full load No compressors are at 100% blowoff All compressors are dynamically controlling the system Total power is reduced for a given air demand Total waste (blowoff) is reduced Inlet Valve Load-Sharing Inlet Valve Load-Sharing encourages compressors in the system to distribute the load more evenly. Inlet Valve Load-Sharing is active only when no controlled compressor is at Minload. The operation is as follows: The control system sends the IV Load-Sharing Gain to the local controller of all compressors running at Minload every 25 seconds The internal (not visible) pressure setpoint of these compressors is raised. This causes the compressors that are full loaded or modulating to increase their output by opening inlet valves. This may result in a temporary increase of system pressure Rev. D Date of Issue: 01/05/05

83 The equation for the internal pressure set point change is: Ingersoll-Rand ASC User's Manual Internal SP = (100 -Inlet Vlv % Open / 100 IV Load-Sharing Gain) + Target Pressure For example, take the case where Target Pressure is 125 psig, gain is 2 psi, and bypass valve is closed, and the inlet valve is 40%. The internal pressure setpoint will be reset to psi. If all other parameters remain constant, the local controller will need a higher volume output to increase the pressure 1.2 psi. It will increase the output by opening the inlet valve. The IV Load-Sharing Gain that is received by the local controller expires after thirty seconds. If a new value is not received within thirty seconds then the pressure set point of the controller will revert to Target Pressure. Figure 5-15: Inlet Valve Loadsharing Rev. D Date of Issue: 01/05/05 83

84 Rev. D Date of Issue: 01/05/05

85 6.0 TROUBLESHOOTING 6.1 CONFIGURATION ERROR DURING INSTALLATION The following message may be displayed during installation: Figure 6-1: Password Complexity Issue During installation a user is automatically added to the computer. This account is used, among other things, to start the ASC Service. The account has a default name and password. The default password was selected to meet the minimal password complexity requirements. Windows may be setup to require stronger passwords by means of custom password filters. ASC will not install properly on a computer that uses custom password filters. Consult the LAN administrator to disable custom password filters. If the computer does not use custom password filters and the message in Figure 6-1 is displayed during installation then contact your Ingersoll-Rand Representative to receive the latest copy of the setup program Rev. D Date of Issue: 01/05/05 85

86 6.2 TESTING THE ETHERNET WIRING If the IP address of the Modbus/Ethernet bridge has been programmed into the bridge then the TCP/IP settings can be tested to insure connectivity. 1) Click on Start on the taskbar 2) Click Run 3) Type "cmd" 4) Click OK 5) At the prompt, type "PING x.x.x.x" where x.x.x.x is the IP address that was programmed into the bridge. If the test yields a reply then the connection was successful. If the test yields "Request timed out" then the bridge and server parameters (IP address, subnet mask, etc.), wiring, and output voltage of power supply (24 VDC required by Bridge) need to be inspected. 6.3 TESTING THE MODBUS WIRING A certified Ingersoll-Rand Technician using a PC running Service Tool may test Modbus wiring on the RS-422/485 side or the Ethernet side. Connect a RS-232 to RS-422/485 Converter to the RS-232 port of the PC. Connect the Modbus wiring to the converter. Use the Modbus protocol on the Service Tool to connect to each CMC controlled compressor. If the IP address of the Modbus/Ethernet bridge has been programmed into the bridge and is known then the Modbus wiring may be tested using the Service Tool. Plug a crossover cable into the Ethernet port on the bridge and to the Ethernet port of the PC. Set the IP and subnet mask of the PC so that the PC is on the same subnet as the Bridge. Use the ModbusTCP protocol on the Service Tool to connect to each CMC controlled compressor. 6.4 SCHEDULER SKIPS JOB AT MIDNIGHT This is an issue with how the scheduler calculates when a job is supposed to run. If you want a job to run at midnight and re-occur throughout the day, then schedule the job to start at 1 minute after midnight Rev. D Date of Issue: 01/05/05

87 7.0 APPENDIX A: QUICK START This section provides a list of steps to install the ASC. This is intended as a reference for personnel who have read the ASC Manual. These steps are not required to be completed in order. Refer to the section of the manual listed to the left side for additional information. Section Items 1) Material Required a) System PC or Server with Windows 2000 Server or Windows 2003 Server Software (Standard Edition) b) Modbus to Ethernet Bridge c) Network Wire d) List of users and passwords e) ASC Application CD f) CMC with Universal Communication Module (UCM) if applicable g) Intellisys with Intellisys Remote Interface (IRI) if applicable h) I/O Box with UCM if applicable i) CMC Technical Reference Manual and/or the Intellisys Remote Interface operators/instruction manual parts list. 2) Configure Communications Modules in Each Panel a) CMC - Use UCM Wizard to configure each UCM b) Intellisys Use pushbutton on rear of device to configure each IRI c) Wire the Modbus Network in a daisy chain using Belden 9842 or equivalent. d) Do not connect to Modbus to Ethernet Bridge at this time 3) Confirm Network Wiring Continuity a) Unplug the wiring connectors from the UCM and/or IRI b) Ties ends together on one of the twisted pair c) Using a meter check continuity of wires and connections d) Repeat for other twisted pair 4) Reconnect all panel wiring 5) Connect Bridge to PC a) Requires Category Five (Cat5) or better wire b) Ethernet cable must be a crossover if connecting directly to the PC 6) Apply power to Bridge 7) Configure the Bridge using HyperTerminal or Telnet 8) Terminate Modbus network wiring to Bridge 9) Check Modbus network communications with the Modbus or Modbus/TCP Service Tool(may require a RS232-RS422/485 converter or crossover cable) 10) Power up ASC computer 11) Install and activate the ASC software. 12) Double click the ASC Configuration icon on the desktop. 13) Verify IP address (This is IP address of bridge) 14) Verify Modbus address for each component (number shown in decimal) 15) Exit (if IP address was changed, logout of ASC and reboot computer) 16) Right click the ASC Service icon on the tray and Start Rev. D Date of Issue: 01/05/05 87

88 ) Launch Microsoft Internet Explorer 6.0 or greater 18) Complete the login screen (login name and password) 19) Go to the Communication and Control page and verify components are not in Auto Control. 20) Go to the System Communication page and check the communication block for each component. 21) Data should display. 22) Go to System Settings and enter initial settings. 23) Go to System Communcation and Control page and move units to Auto Control side of screen. 24) Place a check mark in Auto Control / Loadshare block 25) System is operating in Auto Control Rev. D Date of Issue: 01/05/05

89 8.0 APPENDIX B: ACCESSING THE DATA Ingersoll-Rand ASC User's Manual ASC uses a Microsoft SQL Server database to store the data it reads from the control panels and I/O boxes. Microsoft SQL Server is an ODBC compliant database, so any tool can be used to query the database that can connect to ODBC databases. This includes popular programs like Microsoft Excel or Microsoft Access. During the installation of ASC a username and password is created and given read-only rights to the ASC database to be used for querying the ASC database. Several recent viruses have targeted Microsoft SQL Servers. In response to security concerns, TCP/IP connections for the database are disabled by default. If you intend to view the data through programs utilizing ODBC then this will need to be enabled. If SQL Server program files are installed at the default locations then open the following program at C:\Program Files\Microsoft SQL Server\80\Tools\Binn\Svrnetcn.exe. The following screen will appear. Figure 8-1: Configure SQL Server Network Parameters Select TCP/IP from the list of Disabled Protocols. Select Enable. Click on OK. You will now need to restart SQL Server in order for this change to be in effect. Right click on the SQL Server icon on bottom right of the screen. Choose MSSQLServer Stop. When the icon shows that the service has stopped then right click on the icon again. Choose MSSQLServer Start. SQL Server should now be configured to work with ODBC connections Rev. D Date of Issue: 01/05/05 89