EasyManua.ls Logo

Altronic DE-2500 - User Manual

Default Icon
70 pages
Print Icon
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Loading...
-1-
ALTRONIC CONTROLLER SYSTEM INSTALLATION & OPERATING INSTRUCTIONS
MODEL DE-2500 FORM DE-2500 IOI 3-04
WARNING: DEVIATION FROM THESE OPERATING INSTRUCTIONS MAY LEAD TO
IMPROPER ENGINE/MACHINE OPERATION WHICH COULD CAUSE PERSONAL
INJURY TO OPERATORS OR OTHER NEARBY PERSONNEL.
1.0 OVERVIEW
1.1 For help locating subjects in this document, a section index is provided on page 57. A
glossary of technical terms is also provided which begins on page 52.
1.2 The Altronic DE-2500 controller system is an electronic, microprocessor-based system
designed to sense various analog and digital input points to control and monitor industrial
compressors. The system is field-programmable using a PC (personal computer) and the
supplied DE-2500 terminal program and contains a non-volatile memory to store the setup.
Serial communications provide an interface to PC’s, PLC’s, modems and satellite uplinks for
remote communication. A backlit 4x20 LCD character display shows system status,
programmed engine/motor and compressor parameters and channel labels. A front mounted
keypad serves as the user interface. The DE-2500 provides for both the safety shutdown
functions needed to prevent unnecessary damage to remote operated equipment and the
closed loop automatic control functions needed to optimize their efficiency of operation.
Additionally, the DE-2500 provides for remote data acquisition and supervisory control in a
compact, low cost package dedicated to industrial compressor applications. The optimization
strategies available for the management of compressor throughput include automatic prime
mover speed setting as well as capacity control. On rotary screw compressors, capacity
control can be done via suction throttling, or using an internal gas bypass technique
employing poppet valves, turn valves or slide valves. On reciprocating compressors, capacity
can be controlled using external gas bypass loops or pressure regulation techniques. A wide
range of output options, including both analog current loops and digital outputs, are provided
to interface with the large variety of actuation systems currently in use. In addition, automatic
load limiting based upon prime mover power capabilities or other application specific
limitations, such as cooling capacity, are readily implemented. There is also an AUTO START
option that is enabled using the terminal program.
1.3 The system consists of three main parts: a panel mounted Display Module DE-2500, a
Power Supply Module 691122-1, and a Terminal Module 691127-1. These components are
interconnected by means of Cable assembly 693115-1.
WARNING: THE CONTROLLER SYSTEM MUST BE CONFIGURED PRIOR TO USE ON A
COMPRESSOR SYSTEM. REFERENCE DE-2500 PI PROGRAMMING
INSTRUCTIONS, FOR INSTRUCTIONS DESCRIBING HOW TO CONFIGURE THE
CONTROLLER FOR THE SPECIFIC APPLICATION. VERIFY THE PROGRAM IN
NONVOLATILE MEMORY (THE EEPROM) PRIOR TO STARTING THE SYSTEM.
REFER TO SECTION 10.0 ON HOW TO VIEW THE CURRENT CONFIGURATION.
Question and Answer IconNeed help?

Do you have a question about the Altronic DE-2500 and is the answer not in the manual?

Summary

Overview of the Altronic DE-2500 Controller

Altronic DE-2500 Controller System Description

Details the DE-2500 controller system's capabilities, features, and applications in industrial compressors.

DE-2500 System Components

Outlines the three main parts of the DE-2500 system: Display Module, Power Supply Module, and Terminal Module.

Display Module Functions and Operation

Display Module Interface and Components

Describes the physical components and user interface of the DE-2500 Display Module.

Keypad Functions for Navigation and Control

Explains the functions of the DE-2500 keypad keys used for navigation, control, and editing.

LCD Display Screen Navigation

Describes the different screens displayed on the LCD, including home and view screens.

Keypad Navigation and Configuration Saving

Explains how to navigate menus, select channels, and save configurations using the keypad.

Power Supply Module Details

Power Supply Module Mounting and Connections

Describes the rail mounting and interface connections for the Power Supply Module.

Power Supply Module Output Modules

Details the industry standard output modules supported by the Power Supply Module.

Power Input and System Protection

Explains the 12-24 Vdc power input and the system's overcurrent protection.

RS-485 Communication Ports

Describes the external RS-485 communication ports for PC or PLC interfacing.

IGN and PU Input Terminals

Explains the function of IGN IN and PU IN terminals for engine monitoring.

Terminal Module Functionality

Terminal Module Interface and Sensor Inputs

Describes the Terminal Module's role as sensor interface and its discrete/analog inputs.

Pressure Transducer Specifications and Connections

Details Altronic pressure transducers, their ranges, and wiring connections.

Temperature Transducer Specifications and Connections

Details Altronic temperature transducers, their ranges, and wiring connections.

Thermocouple Input Configuration

Explains how to configure and use thermocouple inputs for temperature monitoring.

Mounting Guidelines for DE-2500 System

Display Module Mounting Instructions

Provides instructions for mounting the Display Module for optimal viewing.

Power Supply Module Mounting

Instructions for mounting the Power Supply Module, including DIN rail usage.

Terminal Module Mounting and Interconnection

Instructions for mounting the Terminal Module and connecting it to the Power Supply Module.

Pressure Transducer Mounting Considerations

Guidance on mounting pressure transducers and avoiding overloads.

Temperature Transducer Mounting Considerations

Guidance on mounting temperature transducers and protecting wiring.

DE-2500 System Wiring Procedures

System Component Wiring Connections

Explains how to connect the Display, Terminal, and Power Supply modules.

Power Wiring Connections

Instructions for connecting the 12-24 Vdc power supply to the DE-2500 system.

Discrete Sensor Input Wiring

Details wiring procedures for normally open and normally closed discrete sensor inputs.

Additional Wiring Procedures

Analog Sensor Wiring

Instructions for wiring analog sensors and transducers to the Terminal Module.

Thermocouple and Extension Wire Wiring

Details wiring procedures for thermocouples and extension wires.

Output and Communication Wiring

Output Switch Wiring

Describes wiring for various output modules, including custom ignition/fuel valve modules.

RS-485 Communications Wiring

Instructions for wiring RS-485 communication ports to PCs or PLCs.

Sense Rotation Input Wiring

Explains the use of IGN IN and PU IN terminals for engine rotation sensing.

Hazardous Area Operation and Keypad Functions

Hazardous Area Operation Requirements

Details CSA certification and specific requirements for Class I, Division 2 areas.

Keypad Overview and Basic Functions

Provides an overview of the keypad and the basic functions of key buttons.

STOP Key Functionality

Explains the function of the STOP key for manual stop operations.

RESET Key Functionality

Explains the function of the RESET key for clearing faults and timers.

TEST Key Functionality

Explains the function of the TEST key for testing sensors without tripping outputs.

VIEW CHAN Key Functionality

Explains the function of the VIEW CHANNELS key for channel status.

NEXT Key Functionality

Explains the function of the NEXT key for navigating screens and values.

VIEW Key Functionality

Explains the function of the VIEW key for accessing process information screens.

ENTER Key Functionality

Explains the function of the ENTER key for accepting selections and saving values.

ESC Key Functionality

Explains the function of the ESCAPE key for exiting screens without changes.

Menu and Home Screen Navigation

MENU Key Functionality

Explains the function of the MENU key for accessing edit menus.

UNITS and TENS Key Functionality

Explains the function of UNITS and TENS keys for adjusting values.

Home Screen Content and Status Words

Describes the content and status words displayed on the home screens.

Manual Engine Start Procedure

Details the procedure for manually starting the engine using the RESET button.

AUTO START and Running Status

AUTO START Sequence Operation

Explains the sequence and features of the AUTO START option.

RUNNING Status Screen

Describes the RUNNING status screen indicating normal system operation.

Servicemeter Alerts and Messages

Servicemeter Alerts and Viewing Messages

Explains how servicemeter alerts are indicated and how to view service messages.

Capacity Control Screens (Older Versions)

Accessing and Interpreting Capacity Control Screens

Guides the user on accessing and understanding the Capacity Control screens.

Advanced Capacity Control Features

Load Inhibit and Force Unload Conditions

Explains how load inhibit and forced unload conditions affect capacity control.

Manual Override for Capacity Control

Describes how to switch to MANUAL mode for capacity control.

Control Loop #1 Operation (Version 2.0+)

Accessing and Interpreting CONTROL LOOP #1

Guides the user on accessing and interpreting the CONTROL LOOP #1 screen.

Control Loop #2 Operation

Understanding the Second Control Loop

Describes the second control loop (CONTROL LOOP #2) and its configuration.

Pulse Control Using Digital Outputs

PULSE CONTROL with Digital Outputs #1 and #2

Explains the PULSE CONTROL feature using digital outputs for valve control.

PID Deadband and Test Mode

PID Deadband Adjustment for Stability

Details how to set or edit PID deadband values for system stability.

Entering and Using TEST Mode

Guides the user on entering and operating the TEST mode for sensors.

Fault Handling and Manual Stop

Fault Condition Display and Acknowledgment

Explains how the system displays and handles fault conditions.

MANUAL STOP Message Functionality

Describes how the MANUAL STOP message is displayed and its purpose.

Viewing Process Information Screens

Accessing and Displaying Process Information

Explains how to access and view various process information screens.

Viewing Channel Status Screens

Viewing Channel Status and Navigation

Guides the user on viewing input channel status and navigating through channels.

Shutdown and Fault Status Screens

First Fault Detection and Acknowledgment

Details how the system indicates the first fault detected and how to acknowledge it.

Test Mode Screens Operation

High;Low Setpoint Faults on Analog Channels

Explains how high/low setpoint faults are indicated on analog channels.

Entering and Operating TEST Mode

Guides the user on entering and operating the TEST mode for sensors.

Configuration via Menu Mode

Menu Access and Editable Parameters

Overview of accessing menu screens and parameters that can be viewed or edited.

Menu Navigation and Editing Procedures

Viewing and Editing Controller Configuration

Steps to view and edit the controller configuration using the menu system.

Menu Screen Key Functions

Explains the functions of keys used for navigation within menu screens.

Menu Screen Navigation Levels

Describes the two levels of menu screens and how to navigate them.

Editing Control Values and Setpoints

Editing Setpoint Values

Details how to edit setpoint values for channels via the menu.

Editing Primary Controls

Details how to edit primary control parameters via the menu.

Editing Safety Shutdowns and Input Classes

Editing Safety Shutdown Values

How to view or edit safety shutdown values and setpoints.

Viewing and Editing Input Class

Guides on viewing and editing input class configurations for channels.

Editing Global Values and Output Configurations

Editing Global Values

Details how to view and edit global values like test time and node number.

Editing Output Configurations

Editing Output Configurations

How to edit output configurations, including delay times and output states.

Editing Time, Date, and Communications

Viewing and Editing Time and Date

Guides on viewing and editing the system's time and date settings.

System Settings and Maintenance Data

Configuring Communications Setup

How to configure communication settings like node number and port protocols.

Viewing Hourmeter and Servicemeter Messages

Explains how to access and view Hourmeter and Servicemeter messages.

Firmware Revisions and First Fault Time

Viewing Firmware Revisions

Details how to view firmware revisions for the Display and Terminal modules.

Viewing First Fault Timestamp

Explains how to view the timestamp of the first detected fault.

Contrast Adjustment and Data Logging

Adjusting LCD Contrast Ratio

Instructions for adjusting the LCD display contrast ratio for optimal readability.

Data Logging Feature Overview

Explains the DE-2500's data logging capability and its purpose.

Node Number Configuration

Details on how to view or edit the node number for controller addressing.

Communication Parameters for PC;PLC

Lists the required communication parameters for PC/PLC interaction.

Data Logging and Remote Data Access

Data Logging Memory and Periods

Details data logging memory capacity and how to set logging periods.

ASCII Commands for Data Retrieval

Explains the ASCII commands used to read collected data from the system.

Data Record Information and Remote Access

Data Record Content Description

Describes the information contained within a single data log record.

Reading Multiple Data Records

Instructions on how to read multiple data records sequentially.

Reading First Fault Data Remotely

Explains how to remotely read the first fault data log record.

Reading Most Current Data Remotely

Explains how to remotely read the most current data log record.

Remote Communication Features

DSM Parameter Retrieval

Details retrieving parameters from auxiliary DSM devices via serial command.

Remote Stop and Reset Commands

Explains commands for remotely resetting or stopping the DE-2500 system.

Modbus RTU Compliance and Registers

Details Modbus RTU standard compliance and register read limitations.

Identification Query Response

Explains how the DE-2500 responds to identification queries.

Remote Stop;Reset Register Configuration

Details the register for remotely triggering stop and reset functions.

Remote Operator Interface (ROI)

Remote Operator Interface Functionality

Details the Remote Operator Interface (ROI) feature and its keypad commands.

Automatic Call Out Using External Modem

Automatic Call-Out Feature Overview

Explains the automatic call-out feature for remote fault reporting.

External Modem Requirements

Details the requirements for connecting and using an external modem with the system.

Modem Configuration Settings

Provides modem configuration settings required for DE-2500 communication.

Dialing and Fault Report Procedure

Procedure for the controller to dial numbers and send fault reports via modem.

Troubleshooting the DE-2500 Controller System

Troubleshooting Blank LEDs and LCD

Steps for troubleshooting blank power LEDs and the LCD display.

Troubleshooting Normally Open Sensor Faults

Troubleshooting steps when normally open sensors do not cause a fault.

Troubleshooting Output Relays Not Tripping

Steps for troubleshooting when output LEDs change but relays do not trip.

Troubleshooting Blank LCD with Lit LEDs

Troubleshooting a blank LCD despite lit power LEDs, indicating a configuration issue.

Troubleshooting NO COMM. Message

Steps for troubleshooting the 'NO COMM.' message on the home screen.

Troubleshooting Parameter Dashes

Steps for troubleshooting when dashes appear for parameters on the home screen.

Troubleshooting Fuel;Ignition Tripping Issues

Troubleshooting problems with fuel valve and ignition shutdown outputs.

Troubleshooting Incorrect Time and Date

Troubleshooting incorrect time and date settings after power cycling.

Troubleshooting LCD Contrast Issues

Steps for troubleshooting LCD contrast that is too light or too dark.

External Modem Dialing Issues

Troubleshooting External Modem Dialing

Steps for troubleshooting issues where the external modem does not initiate dialing.

AUTO START Option Configuration and Operation

AUTO START Initiation and Sequence

Explains the initiation and sequence of the AUTO START feature.

Automatic Compressor Load Control

Speed and Capacity Control Strategies

Details speed control and capacity control strategies for compressor throughput.

Selecting a Control Strategy

Control Strategy Guidelines and Definitions

Offers general guidelines and definitions for selecting control strategies.

Speed and Capacity Control Methods

Explains how the DE-2500 controls throughput using speed and capacity.

Speed Control Output Interface

Details how the speed control output interfaces with electronic governors.

Capacity Control Output Formats

Describes the two formats of capacity control output: 4-20mA and digital.

Compressor Load Control Strategies

Primary Input Selection for Load Control

Discusses selecting the primary input for load control based on operating conditions.

Defining Control Input;Output Relationships

Defines direct/inverse acting relationships for control inputs, outputs, and actuators.

Primary and Secondary Control Actions

Primary and Secondary Control Inputs;Actions

Details primary/secondary inputs and control actions like Load Inhibit and Force Unload.

Enhanced Control Setpoint Options

Enhanced Control Setpoint Options (Software 2.0+)

Describes enhanced control setpoint options for newer software versions.

Transducer Calibration Procedures

Initial Connection for Transducer Calibration

Steps for connecting the computer and DE-2500 for calibration.

Using DE-2500 Calibration Software

Guides the user on using the DE-2500 software for transducer calibration.

Selecting Channel and Connecting Voltmeter

Steps to select a channel and connect a voltmeter for calibration readings.

Entering Low Sensor Voltage During Calibration

Procedure for entering the low sensor voltage reading during calibration.

Entering High Sensor Voltage During Calibration

Procedure for entering the high sensor voltage reading during calibration.

Contrast Adjustment and Data Logging Features

Adjusting LCD Contrast Ratio

Instructions for adjusting the LCD display contrast ratio for optimal readability.

Data Logging Feature Overview

Explains the DE-2500's data logging capability and its purpose.

Node Number Configuration

Details on how to view or edit the node number for controller addressing.

Communication Parameters for PC;PLC

Lists the required communication parameters for PC/PLC interaction.

Data Logging and Remote Data Access Procedures

Data Logging Memory Capacity and Periods

Details data logging memory capacity and how to set logging periods.

ASCII Commands for Data Retrieval

Explains the ASCII commands used to read collected data from the system.

Data Record Details and Remote Access Methods

Data Record Content Description

Describes the information contained within a single data log record.

Reading Multiple Data Records Sequentially

Instructions on how to read multiple data records sequentially.

Reading First Fault Data Remotely

Explains how to remotely read the first fault data log record.

Reading Most Current Data Remotely

Explains how to remotely read the most current data log record.

Remote Communication and Control Features

DSM Parameter Retrieval via Serial Command

Details retrieving parameters from auxiliary DSM devices via serial command.

Remote Stop and Reset Commands

Explains commands for remotely resetting or stopping the DE-2500 system.

Modbus RTU Compliance and Register Access

Details Modbus RTU standard compliance and register read limitations.

Identification Query Response Procedure

Explains how the DE-2500 responds to identification queries.

Remote Stop;Reset Register Configuration

Details the register for remotely triggering stop and reset functions.

Remote Operator Interface (ROI) Functionality

Remote Operator Interface (ROI) Features

Details the Remote Operator Interface (ROI) feature and its keypad commands.

Automatic Call Out Setup with External Modem

Automatic Call-Out Feature Overview

Explains the automatic call-out feature for remote fault reporting.

External Modem Requirements for Connection

Details the requirements for connecting and using an external modem with the system.

Modem Configuration Settings for DE-2500

Provides modem configuration settings required for DE-2500 communication.

Dialing and Fault Report Procedure

Procedure for the controller to dial numbers and send fault reports via modem.

Troubleshooting DE-2500 Controller Issues

Troubleshooting Blank LEDs and LCD Display

Steps for troubleshooting blank power LEDs and the LCD display.

Troubleshooting Normally Open Sensor Faults

Troubleshooting steps when normally open sensors do not cause a fault.

Troubleshooting Output Relays Not Tripping

Steps for troubleshooting when output LEDs change but relays do not trip.

Troubleshooting Blank LCD with Lit LEDs

Troubleshooting a blank LCD despite lit power LEDs, indicating a configuration issue.

Troubleshooting NO COMM. Message

Steps for troubleshooting the 'NO COMM.' message on the home screen.

Troubleshooting Parameter Dashes Display

Steps for troubleshooting when dashes appear for parameters on the home screen.

Troubleshooting Fuel and Ignition Tripping Issues

Troubleshooting problems with fuel valve and ignition shutdown outputs.

Troubleshooting Incorrect Time and Date Settings

Troubleshooting incorrect time and date settings after power cycling.

Troubleshooting LCD Contrast Ratio

Steps for troubleshooting LCD contrast that is too light or too dark.

External Modem Dialing Troubleshooting

Troubleshooting External Modem Dialing Issues

Steps for troubleshooting issues where the external modem does not initiate dialing.

AUTO START Option Configuration and Sequence

AUTO START Initiation and Sequence

Explains the initiation and sequence of the AUTO START feature.

Automatic Compressor Load Control Strategies

Speed and Capacity Control Strategies

Details speed control and capacity control strategies for compressor throughput.

Selecting Compressor Control Strategies

Control Strategy Guidelines and Definitions

Offers general guidelines and definitions for selecting control strategies.

Speed and Capacity Control Methods Explained

Explains how the DE-2500 controls throughput using speed and capacity.

Speed Control Output Interface to Governors

Details how the speed control output interfaces with electronic governors.

Capacity Control Output Formats

Describes the two formats of capacity control output: 4-20mA and digital.

Compressor Load Control Approaches

Primary Input Selection for Load Control

Discusses selecting the primary input for load control based on operating conditions.

Defining Control Input;Output Relationships

Defines direct/inverse acting relationships for control inputs, outputs, and actuators.

Primary and Secondary Control Actions

Primary and Secondary Control Inputs;Actions

Details primary/secondary inputs and control actions like Load Inhibit and Force Unload.

Enhanced Control Setpoint Options (Software 2.0+)

Enhanced Control Setpoint Options

Describes enhanced control setpoint options for newer software versions.

Transducer Calibration Procedures

Initial Connection for Transducer Calibration

Steps for connecting the computer and DE-2500 for calibration.

Using DE-2500 Calibration Software

Guides the user on using the DE-2500 software for transducer calibration.

Selecting Channel and Connecting Voltmeter

Steps to select a channel and connect a voltmeter for calibration readings.

Entering Low Sensor Voltage During Calibration

Procedure for entering the low sensor voltage reading during calibration.

Entering High Sensor Voltage During Calibration

Procedure for entering the high sensor voltage reading during calibration.

Altronic DE-2500 Specifications

General IconGeneral
BrandAltronic
ModelDE-2500
CategoryController
LanguageEnglish