Neuron II Manual

Index
1.0 Technical Features 23.0
2.0 Controller terminal configuration 24.0
3.0 Main Menu Screen 25.0
4.0 Menu Structure 26.0
4.1 View 26.0
4.1.1 Operator 26.1
4.1.2 Fault Report 26.1
4.1.3 Day Report 26.2
4.1.4 Service Time 26.2
4.1.5 Cumulative Time 26.3
4.1.6 VFD 26.3
4.2 Operator 26.4
4.2.1 Machine 26.5
4.2.2 Schedule 26.7
4.2.3 Maintenance 26.7
4.2.4 Language 26.8
4.2.5 Change Password 26.8
4.3 Service 26.9
4.3.1 Calibration 26.9
4.3.2 Relay 26.10
4.3.3 Change Password 26.10
4.3.4 Maintenance 26.10
4.3.5 Clock 26.11
4.3.6 Self Test 26.11
4.3.7 Change Password 26.11
4.4 Factory menu 26.12
4.4.1 Machine 26.13
4.4.2 Change Password 26.14
4.4.3 Integrator Dryer 26.14
4.5 Customer care 26.14
5.0 Data Interface 27.0
5.1 Analog output 27.0
5.2 DCS Port 27.0
6.0 Construction & Dimension Drawing 28.0
7.0 Controller Identification 29.0
8.0 Revision Details 29.0
APPENDIX A: Mimic LED Table 30.0
APPENDIX B: Short Cut Key Functions 31.0
APPENDIX C 32.0
APPENDIX-D 33.0

21.0
21.1
Technical Features

8 no’s of Optically Isolated Digital Inputs of 24VDC

01 = Emergency Stop
02 = Differential Pressure Oil Filter - DPOF
03 = Reverse Rotation
04 = Differential Pressure Air Filter - DPAF
05 = Remote Start/Stop
06 = High Sump Pressure
07 = Cooler
08 = Main Motor Overload

8 no’s of Output Relay (SPDT 250V AC 10A, 1,00,000 cycle electric life)

01 = Main contactor
02 = Star contactor
03 = Delta contactor
04 = Load Valve
05 = Fan
06 = Auto Drain Valve
07 = Dryer (if Dryer is Connected- else Programmable -Load,
Service, Standby, Warn, Trip, Remote, Ready)
08 = Programmable [Load, Service, Standby, Warn, Trip, Remote,
Ready]

22.0
Technical Features

4 no’s of Analog Input Channels

1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure
1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature
1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure
1 no of RTD (Pt-100) channel, -50 to +90 degree C for Drier Dew Point or
Ambient Temperature

2 no’s of Analog Output Channels

1 to 5 VDC, One for Discharge Pressure and One Programmable (Sump
Pressure, Discharge temp, Dew point/Ambient)

9 no’s of Function keys

Up, Down, Left, Right, Enter, Escape, Start, Stop and Reset.

1 no of Display
128X64 White Backlight Graphical LCD

9 no’s of LED’s for Visualization Alarm & Machine Status

Auto
Air Filter
Main Motor Overload
Reverse Rotation
Cooler
Pressure
Temperature
Differential Pressure Oil Filter
Differential Pressure Separator Element

1 no. of Dual LED for Start/Stop Indication

Green for start and Red for stop

1 no. of Non – Volatile Memory

For storage of 30 Day’s reports & 99 Fault Reports

1 no. of Real Time Clock

With Battery life of about 10 years

22.1
Technical Features

4 no’s of Communication Port (RS485, 2 wire)

Serial Port 1: MODBUS-RTU or SCADA Port
Serial Port 2: Dedicated FPD Port (For future use)
Serial Port 3: Add-On I/O Interface Port (expansion possibility)
Serial Port 4: VFD Interface Port

1 no. of In System Programming (ISP) Port –For program / Data down loading
and data uploading

Power Supply Input: 24VAC +/- 25%, 50Hz / 60Hz, 1A (In built Protection
present for Surge, Over Current)

22.2
Controller Terminals Configuration

X01: Power supply

Connector type: 3 pole combicon

Pin Function Id Active state

1 24V AC Phase 24 VAC P -
2 Earth Earth -
3 24V AC Neutral 24 VAC N -

X02: Relays
Connector type: 10 pole combicon

Pin Function Id Active state

1 Common - Load Relay Common
2 Load Relay L / UL Load when
Energised
3 Common - Fan Relay Common
4 Fan Relay Fan Energised
5 Common - Auto Drain Valve Relay Common
6 Auto Drain Valve Relay ADV Energised
7 Common – Dryer Relay Common
8 Dryer Relay/ programmable relay Dryer / Pr2 Energised
9 Common - Programmable Relay Common
10 Programmable Relay Pr1 Energised

X03: Main Motor Relays

Connector type: 4 pole combicon

Pin Function Id Active state

1 Common for Main, Star and Delta Common -
contactors
2 Main Contactor Main Energised
3 Star Contactor Star Energised
4 Delta Contactor Delta Energised

23.0
Controller Terminals Configuration

X04: Digital Inputs

Connector type: 11 pole combicon

Pin Function Id Active state

1 Digital Inputs Common – 24VDC 24VDC -
2 Emergency Stop Emergency Fault if open
3 Differential Pressure Oil Filter DPOF Fault if open
4 Reverse Rotation Rev. Rot Fault if closed
5 Differential Pressure Air Filter DPAF Fault if open
6 Remote Start Stop Control Remote Stop if open/
start on Closure
7 High Sump Pressure HSP Fault if open
8 Cooler Fault Input Cooler Fault if open
9 Main Motor Overload MMOL Fault if open
10 24V Supply Ground -24V DC (provision for
check DI
voltage)
11 No Connection - -

X05: Analog Inputs

Connector type: 8 pole combicon

Pin Function Id Type Range

1 Discharge pressure Dis. Pr 4-20 ma 0 to 16 bar
2 15 to 24VDC 18V
3 Discharge Temperature Dis. Tr + KTY10 0 to 150°C
4 Discharge Temperature Dis. Tr -
5 Sump Pressure Sump Pr 4-20 ma 0 to 16 bar
6 15 to 24VDC 18V
7 Dryer or Ambient Pt100 + Pt100 -50 to +90°C
temperature
8 Dryer or Ambient Pt100 -
temperature

23.1
Controller Terminals Configuration

X06: Analog Outputs and VFD

Connector type: 5 pole combicon

Pin Function Id Type Protocol/Range

1 VFD Interface VFD A RS485A FC Protocol
2 VFD Interface VFD B RS485 B
3 Supply Ground For 5V 0VDC - -
4 Dis. Pressure Output AO1 Voltage(1-5V) 0 to 16 bar
5 Programmable Analog AO2 Voltage 0 to 160C /
Output (1-5V) 0 to 16 bar /-
65 to 95C

X07: Communication
Connector type: 6 pole combicon

Pin Function Id Type Protocol/Range

1 DCS Interface-Modbus
RTU DCS A RS485 A Modbus-RTU
2 DCS Interface –Modbus -
RTU DCS B RS485 B
3 FPD Interface FPD A RS485 A ASCII
4 FPD Interface FPD B RS485 B
5 Add On Interface Add-On A RS485 A Modbus
6 Add On Interface Add-On B RS485 B

23.2
Main Menu Screen

Dis. Pr : 6.0 bar

Dis. Tr : 32°C
Message 1
Message 2
Warning
HH:MM:SS 1 2 DD/MM

Message 1: Based on the short cut keys pressed (refer APPENDIX B)

Message 2: Compressor Status or fault message

1 - Pressure schedule
- If Blank → Pressure schedule is disabled
- If “PS” → Pressure schedule is enabled
- If “PS” blinking → Waiting for pressure schedule acknowledgement

2 - Control Mode (*/$)

- *L → Local, ON/OFF control from local keypad
- *R → Remote, ON/OFF control from remote input
- *D → DCS, Control is from DCS System
- $M → Manual, Start command given after power failure
- $A → Auto, Compressor will automatically restart after power failure

24.0
Main Menu Screen

Message 2 - Compressor Status or Fault message

Status Description
Ready Ready for start
Star Motor running in Star
Run Motor running in Delta
Run load Compressor in load
Run unload Compressor in unload
Stop busy Stop sequence in progress
Idle When the controller is in idle, User interface will not
function during this period for 5 seconds
Emergency stop Emergency Stop Push Switch is ON
Start inhibit xx.x During the start, if sump pressure is higher than the
set sump pressure value for starting, this message is
displayed XX.X denotes the live sump pressure value.
The compressor starts only if the pump pressure value
is below the set value.
Start inhibit If the sump pressure is not used (Disabled) then the
“seconds” controller will ensure a minimum of 60 seconds
delay between the stop and the start. Count stops if
“STOP” key is pressed
Auto restart If the compressor is in Auto Mode, the controller
“seconds” will ensure a minimum delay (user set, e.g. 90 sec)
between the stop and the start operations. Count stops
if “STOP” key is pressed
Start ack wait This message is displayed when the compressor waits
for user acknowledgement, after fault clearance. By
pressing “START” key user can acknowledge

24.1
Main Menu Screen

Status Description
Pr. Probe failure Discharge pressure sensor probe failure
Tp. Probe failure Temperature sensor probe failure
Sump Pr. probe Sump pressure sensor probe failure
Failure
HSP (A) Case 1: Sump pressure is enabled when the sump
pressure exceeds the set high sump pressure value.
Case 2: Sump pressure is disabled when the discharge
pressure exceeds the set high sump pressure value.
HSP (D) HSP digital input opens due to high sump
pressure
Cooler Cooler digital input opens due to cooler fault
Main motor MMOL digital input opens due to main motor
overload overload.
Rev Rot / Ph fail If the Rev Rot input closes, when the motor is running,
due to motor reverse rotation or phase failure.
Trip temperature Discharge temperature exceeds the set trip
temperature value
Sump pressure This function is displayed when the sump pr sensor is
not developing activated. After the Start, the sump pressure should
be at least 1.0 bar in 10 seconds. If this is
not achieved fault may occurs.
Power failure Mains supply is interrupted for more than 30 msec
Low voltage Mains supply voltage is less than the 67% of rated
voltage, compressor is tripped and the controller
operation is stopped until the Mains supply returns to
normal (at least 75% of the rated)

24.2
Menu Structure

From the default screen, press shortcut keys to view the following (Refer
Appendix B)
S Set load, unload, start sump & maximum differential pressure values
T Current day report
W Warning messages (All warning messages can be viewed)
X Current sump pressure, diff pressure & ambient temperature or dew point

Press “Enter” Key to display main menu

Main Menu

Dis. Pr : 6.0 bar

Dis. Tr : 32°C Status
X View
Operator
Service
Factory
Customer Care

Scroll up or down by using up and down keys to select the menu. Then press
Enter to enter the selected menu.

View

Fault Day Service Cumulative

Operator VFD
Report Report Time Time

4.1 View
No password required.
On view parameters, the preset parameters like mode, pressure values,
temperature values, timer settings, DCS parameters, last 99 fault reports, last
30days report, remaining service hrs due, cumulative time details and VFD
parameters can be viewed. The values cannot be altered through this menu.

25.0
Menu Structure

4.1.1 Operator

LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4

View Operator Mode Control mode Local / Remote / DCS
Unload mode Enable / Disable
Auto restart ON/ OFF
Pressure unit PSI / Bar
Temperature unit Fahren / Centi
Pressure Unload pressure X X . X b or p (bar or
psi)
Load pressure X X . X b or p
Pr. schedule ON/ OFF
Start sump pressure X X . X b or p
Max .diff pressure X X . X b or p
Delay Warn RST delay X X X s(second)
Star delay XXs
DTR delay XXs
RTS delay XXs
Standby time Sby X X m minute)
St/Sp PH X X
DCS port Type Modbus / SCADA
Compr. ID XX
Baud rate 9600/19200
Parity None / Even
Length 8/7
Stop bit 2/1
Temperature Trip temperature X X X C or F
Warn temperature X X X C or F
Fan temperature X X X C or F
Low dew Pt X X C or F
High dew Pt X X C or F

4.1.2 Fault Report

Use S ,T to select the Fault record number (1 to 99).
LEVEL 1 LEVEL 2 LEVEL 3
View Fault report Fault code: XX, Message
Time: HH:MM:SS
Date: DD/MM/YY
Dis.Pr: X X .X
Dis.Tr: XXX
Status: Load/ UnLoad /OFF

25.1
Menu Structure

Fault Code:
01 & 09 – Reserved
02-Main motor overload, 03-Cooler, 04-HSP(Analog), 05–Trip temperature, 06-
Reverse rotation, 07-Pressure probe failure, 08-Temperature
probe failure, 0A-HSP(Digital), 0B-Power failure( Short Power Interrupt), 0C-
Sump pressure not developing , 0D-Sump pressure probe failure.
On the fault report, parameters such as line pressure, discharge temperature and
status of compressor will be displayed. This will help to troubleshoot the failure.

4.1.3 Day Report

Use S ,T to select the Record number (1 to 30).

LEVEL 1 LEVEL 2 LEVEL 3

View Day report Date: DD/MM/YY
L: X X Hours St: X X Hours
UL: X X Hours F: X X Hours
R: X X Hours Sby: X X Hours
STC: X X X LDC: X X X X X

L- Load, St – Stop, UL – Unload, F- Fault, R- Run, Sby- Standby,

STC – Start Count, LDC Load Count
On the fault report, parameters such as line pressure, discharge temperature
and status of compressor will be displayed. This will help to troubleshoot the
failure.

4.1.4 Service Time

LEVEL 1 LEVEL 2 LEVEL 3

View Service time Remaining AFCT: X X X X X X hours
Remaining OFCT: X X X X X X hours
Remaining OSCT: X X X X X X hours
Remaining OCT: X X X X X X hours
Remaining RGT: X X X X X X hours

The remaining service hours for the consumable parts can be viewed and the
service due is completed. The countdown then will be shown in negative
(- hrs).

25.2
Menu Structure

4.1.5 Cumulative Time

LEVEL 1 LEVEL 2 LEVEL 3

View Cumulative time Load X X X X X X hrs: X X Min
Unload X X X X X X hrs: X X Min
Run X X X X X X hrs: X X Min
Stop X X X X X X hrs: X X Min
Fault X X X X X X hrs: X X Min
Standby X X X X X X hrs: X X Min
Start Count XXXXXX
Load Count XXXXXXXXX
Utilisation XX%
On this menu, the cumulative hours including number of start/stops, number of
load/unloads and percentage of utilization can be viewed. With this Cumulative
Time feature, the Emergency stop hours will be accounted in stop hours, and
not under fault hours. This enables the user to view the real fault hours. These
details will further guide for energy savings in compressed air.
4.1.6 VFD
When the VFD is connected to the compressor, user can view the following
parameters of VFD on Neuron II.
1. Voltage in V
2. Current in A
3. Frequency in Hz
4. Power in KW
5. Run Hours
6. Kilowatt Hour (Multiply the value shown by 100 to get the real KWH)
7. Status of the VFD

25.3
Menu Structure

4.2 Operator
Password protected. The operator has to receive the password from the
compressor commissioning engineer

Operator

Change
Machine Schedule Maintenance Language
Password

Set DCS Auto Drain Set Dew

Mode Pressure
Delay Port Valve Point

With this menu, the operator parameters can be adjusted to match the
requirement. Minimum and maximum limits are fixed for all the value adjustment
parameters. When the setting exceeds these values, there will be an indication
of ‘out of range’.

25.4
Menu Structure

4.2.1 Machine
# Item Min Max Option Default Unit
1 Auto restart - - on / off off -
2 Pr unit - - bar / psi bar -
3 Tr unit - - cen / fah cen -
4 Control mode - - loc/rem/dcs loc -
5 Unload mode - - en/dis dis -
6 Analog output 2 - - Tmp / Sp /
Pt / off off -
Pressure
7 Unload > load < max - 7.5 bar bar/psi
pressure pressure unload (Varied
+0.5 pressure according
(bar) (bar) to pr
model)
8 Load 4.0 (bar) < unload - 5.5 bar bar/psi
pressure pressure- (Varied
0.5 (bar) according
to pr
model)
Set Delay
9 Warn RST 90 300 - 90 second
10 Star 6 10 - 6 second
11 DTR 10 60 - 10 second
12 RTS 5 30 - 5 second
13 Standby 1 99 - 5 minute
14 St/Sp per hr 3 10 - 5 -
DCS Port
15 Type - - Modbus / modbus -
SCADA
16 ID 01 99 - 01 -
17 Baud rate - - 9600/19200 9600 bps
18 Parity - - None /Even None -
19 Length - - 8/7 8 -
20 Stop bit - - 2/1 2 -
Auto Drain Valve
21 Off time 1 150 - 4 minute
22 On time 1 15 - 5 Second
Set Dew Point
23 Low dew point -6 C +2 C - -2 C C/F
24 High dew point 6C 12 C - 8C C/F

25.5
Menu Structure

Important Function Keys:

Auto restart ON: Switches On the compressor automatically after a power

failure. The internal timer counts the power Off period and the period when
power resumes. The compressor starts after elapsing the set time by this
function, ensuring the compressor availability immediately after a power failure.
On the screen A will be displayed and the Auto lamp is On, indicating that the
compressor can be automatically started. If it doesn’t, M (manual) will be
displayed. This mode indicates that a manual start is required after power failure.
Local: The compressor is switched On/ Off through the start and stop buttons
in the controller.
Remote: The compressor is switched On/Off only through Digital input (Remote),
and cannot be operated through the controller push buttons.
DCS : The compressor is operated only through modbus.
In Remote and DCS modes, the compressor can be stopped through the
Emergency stop. The Auto LED will glow, in both these modes, indicating that
the compressor can be automatically started.
Unload mode: This key verifies the functions of the compressor with out loading.
If this mode is selected, the relay out put (load / unload) will be de energized.
During this mode, the compressor runs continuously in Unload mode. If the
function is disabled, then the compressor operates as per the pressure set in
the controller.
Load pressure & unload pressure: The user can adjust these values within
the limits of the factory. The value is set at a minimum load pressure of 4 bar.
The maximum unload pressure is set as per the indication on the compressor
name plate. The minimum differential is 0.5 bar.

25.6
Menu Structure

4.2.2 Schedule
Enable Pressure Schedule, and use ²%, ¼% to select the schedule number
(1 to 32).
Then Press “Enter” to set the following
# Item Min Max Option Default Unit
1 Day - - Sun to Sat /
-- (means no
schedule) -
2 Action - - on / off —- -
3 Time HH 00 23 - —- Hour
4 Time MM 00 59 - —- Minute
5 Unload > Load < Max - bar/psi
Pressure Pressure Unload
+0.5 Pressure
(bar) (bar)
6 Load Pressure 4.0 bar < Unload - —- bar/psi
Pressure –
0.5 (bar)

Once the pressure scheduler is selected, PS blinks on the screen. To

acknowledge this, press “START” button. When pressed, the compressor starts
and stops as per the pressure scheduler. The start / stop keys are not activated
in this mode, after the user acknowledges it.
The controller is designed to accommodate changes in the schedule in between
periods. It avoids the necessity of marking changes in schedules in an order.
For example, consider the two periods: Monday schedule (1-4) and Tuesday
schedule (5-8). If the user wants to make changes to the Monday schedule, he
can enter the changes in the 9 schedule (that follows after the Tuesday schedule).
4.2.3 Maintenance

# Item Min Max Option Default Unit

1 AF changed - - no/yes no -
2 OF changed - - no/yes no -
3 OS changed - - no/yes no -
4 Oil changed - - no/yes no -
5 Re Grease - - no/yes no -

Once the consumable part is replaced, enter in to the maintenance menu. Type
the changed part as Yes. Set the remaining service hours as per the 100%
service hours.

25.7
Menu Structure

4.2.4 Language

# Item
1 English
2 Hindi
3 Portuguese

The user language can be selected, Default is in English.

4.2.5 Change Password

Procedure for changing the password

1. Enter the old password

2. If old password is correct, next screen is displayed. If wrong, the control
comes out of the ‘change password’ screen
3. When the ‘next’ screen is displayed, enter the new password
4. Re-enter new password
5. If new password matches both the entries, the password will be updated.
If mismatch occurs, the control goes back to step 3.
Pressing Esc will bring the control back to the main menu screen

25.8
Menu Structure

4.3 Service
Password protected. Only Elgi Service engineers are authorized to change the
menu.

Service

Fan Self
Calibration Relay Maintenance Clock
Temp Test

4.3.1 Calibration
Select the parameter needed for calibration using the ²%, ¼%keys. Then Press
“Enter” to calibrate.
Discharge Pressure/ Discharge Temperature/ Sump Pressure Calibration
Run the compressor. Measure the value using a standard and recently calibrated
meter, when the value is stable. Enter the meter reading in the set value field
displayed on the Neuron II. Set Value should not exceed +/- 1 bar and +/- 10 C
the actual value.
Pt 100 Calibration
Measure the value using a standard and recently calibrated meter, when the
dew point/ ambient temperature is stable. Enter the meter reading in the set
value field displayed on the Neuron II. Set Value should not exceed +/- 3 C the
actual value.
Note:
Calibration should be done when the compressor is switched Off , and ensure
the digital outputs (relay terminals) are disconnected from the controller.
Calibration for pressure should be done for the pressure sensor at 8 bar (in bar
only), and at 100 Deg C (in Centigrade only).
(3.3k resistor=100Deg C)

Analog Output 1 & 2

Calibration for analog output is done for two values: one at zero and the other
at 8.0 bar / 80 degree C. These values are set by connecting a Variable Resistor
(TRIM POT) to the analog input channel. Measure the analog output value (can
be viewed in the DCS/VFD / or any master unit where this output is connected).
Enter this value in “set pressure:”

25.9
,

Menu Structure

4.3.2 Relay
Select the Programmable Relay 1 or 2 using the S,Tkeys. Then Press “Enter”
to assign any of the following functions for the relay.

# Item
Default:
1 Warn
Relay 1 = Warn
2 Load
Relay 2 = Trip
3 Service
Note: If Dryer is enabled, the Programmable Relay
4 Standby
2 is not user programmable. It is used for automatic
5 Trip dryer control.
6 Remote
7 Ready

4.3.3 Change Password

The fan temperature set point is used to start the fan when set temperature is
reached. Stop the fan when the temperature reaches 10 Deg C or lesser than
the set temperature. This setting is used to control On / Off settings of the fan,
based on the discharge oil temperature.
# Item Min Max Option Default Unit
1 Fan temperature 60 C 85 C - 85 C C/F

4.3.4 Maintenance
# Item Min Max Option Default Unit
1 Set AFCT 000000 999999 - 001500H Hour
2 Set OFCT 000000 999999 - 001000H Hour
3 Set OSCT 000000 999999 - 004000H Hour
4 Set OCT 000000 999999 - 001000H Hour
5 Set RGT 000000 999999 - 001500H Hour

The maintenance due is fixed by Elgi Service Engineer based on the spare
parts used.

25.10
 Menu Structure

4.3.5 Clock

# Item Min Max

1 Hour 00 23

2 Minute 00 59

3 Second 00 59

4 Date 01 31

5 Month 01 12

6 Year 00 99

7 Day Sun/Mon/Tue/Wed/Thu/Fri/Sat

The clock setting of the controller is not changed, if used in India. When used
overseas, the time is set according to the local timings, at the time of
commissioning

4.3.6 Self Test

Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output,
Memory & Communication Ports working.
Follow the instructions displayed on the screen.

Warning
Self-Test should be conducted only after disconnecting the compressor from
the controller. (Use connect power supply X01 3 pin connector) DO NOT perform
self-test when the controller is connected to the compressor. Doing so will cause
severe damage to the compressor.

4.3.7 Change Password

1. Enter the old password
1. Enter the old password
2. If old password is correct, next screen is displayed. If wrong, the control
comes out of the ‘change password’ screen
3. When the ‘next’ screen is displayed, enter the new password
4. Re-enter new password
5. If new password matches both the entries, the password will be updated. If
mismatch occurs, the control goes back to step 3.
Pressing Esc will bring the control back to the main menu screen

25.11
Menu Structure

4.4 Factory menu

Password protected. Only Elgi authorized persons are allowed to change the
setting.

Factory

Change
Machine Dryer
Password

Max.
Compressor Temperature
DPAF DPOF Pressure
Info Settings
Settings

25.12
Menu Structure

4.4.1 Machine

# Item Min Max Option Default Unit

1 Rating - - 11 to 315 22 KW
2 Pressure - - LP/ 7.0to12.5 LP bar
3 Fab no Alpha:A Alpha:Z - AAAA -
(10 digit) num:0 num:9 000000
4 DPAF - - on/off off -
5 DPOF - - on/off off -
Max. Pressure Settings
6 Max UL > Unload <13.5bar - 7.5 bar bar
Pressure Pressure /psi
7 High sump > Max < Max - 10.5 bar bar
pressure Unload Unload /psi
pressure pressure
+0.5 +3
8 Sump - - enable/ disable -
pressure disable
9 Start sump 0.0 bar 16.0 bar - 1.0 bar bar
pressure /psi
10 Max. 0.0 bar 2.0 bar - 1.5 bar bar
differential /psi
pressure
Temperature Settings
11 Trip 80 C 120 C - 110 C C/F
temperature
12 Warn 70 C 110 C - 105 C C/F
temperature

If the sump pressure sensor is enabled, the Star sump pressure and the
maximum differential pressure values will function. In this mode, the high
sump pressure is activated based on the sump pressure in the Air oil
sump.

25.13
Menu Structure

4.4.2 Change Password

1. Enter the old password
2. If old password is correct, next screen is displayed. If wrong, the control
comes out of the ‘change password’ screen
3. When the ‘next’ screen is displayed, enter the new password
4. Re-enter new password
5. If new password matches both the entries, the password will be updated.
If mismatch occurs, the control goes back to step 3.
Pressing Esc will bring the control back to the main menu screen

4.4.3 Dryer

# Item Min Max Option Default Unit

1 Dryer mode - - on/off off -
2 Dryer Delay 2 10 - 3 Minute

This mode is enabled, if dryer is part of the compressor. The dryer is switched
on and off through the controller, provided the compressor is switched On.
When the compressor is On, dryer is switched On; and the dryer is switched
Off when the compressor is on Off mode. The time interval between the stop
and start operations is decided by dryer delay time setting, which enables the
safe operation of dryer and compressor.

4.5 Customer Care

Dis. Pr : 6.0 bar

o
Dis. Tr : 32 C
Status
Toll Free No
1800-425-3544
e-mail ccs@elgi.com

25.14
Data Interface

Neuron II has two types of Data Interface

N Analog output

N DCS Port

5.1 Analog output

Two channels are available for analog output. The first channel will output the
current discharge pressure value from 0.0 -16.0 bar, converted from 1 - 5V.
The Second channel is programmable. User can select any one of the following
menu: “Operator/ Machine/ Mode/ Analog output”

a. Dis. Temperature 0 -160 C, converted from 1 - 5V

b. Sump Pressure 0 - 16.0 bar, converted from 1 - 5V

c. Pt100 Temperature -65 - 95 C, converted from 1 - 5V

Note: Analog output will be 0V, in case of probe failure.

5.2 DCS Port

DCS port can be of Modbus RTU type to interface to Generic DCS system or
SCADA type to interface to ELGI SCADA software.
User can select the Port type in menu “Operator/ Machine/ DCS Port”. The
ID, Baud Rate, Parity, data Length, Stop Bit are also user settable. The Modbus
data table will be provided based on the request (A CD contains address table
and activation key)

26.0
Construction

N Corrosion & dust protected back cover

N IP65 polyethylene front keypad
N Inputs and outputs through terminal block, board to wires, disconnect
able, screw terminals
N Front plate dimensions 260 x 145mm
N Enclosure dimensions 235 X 120 X 70 mm
N Operating temperature - 0ºC to +75ºC
N Relative humidity <85% RH non-condensing @ 40ºC

6.1 Dimension Drawing

Panel Front Plate

260

100
133

145

Panel Cut out Dimension

70 235

X01 X06
120

X04
120

X07
X05 ISP X03 X02

All dimensions are in mm

27.0
Controller Identification

While Communicating to Elgi, please mention the following:

Type of controller

SL no

Batch NO

Revision Details
Version Date Changes

1.0 2 April 2009 Initial Draft

1.1 13 July 2009 Pilot Batch S/W Version 1.1

1.2 01.02.2010 Pilot batch SW version 1.1D

For any other clarification in the controller please contact ELGI

Toll Free No : 1800-425-3544

e-mail ccs@elgi.com

28.0
Appendix A
Mimic Led Table
# LED
1 Auto
2 Air Filter
3 Main Motor Overload
4 Reverse Rotation
5 Cooler fault
6 Pressure
7 Temperature
8 Differential Pressure
9 Differential Pressure
10 Start & Stop
Description
Indicates the machine is in Automatic
on/off mode. LED glows in Amber
Colour when
1. Pressure Schedule is enabled (or)
Auto Restart is enabled
Glows in Amber colour when 1.
Air Filter Service is due based on
service hours2. Air Filter Digital Input
(DPAF) is Open & DPAF is enabled
Glows in Red when the Main Motor
Overload Digital Input is Open.
Glows in Red when the Reverse
Rotation Digital Input is Closed
Glows in Red when the cooler Digital
Input is Open
Glows in Red when 1. HSP Digital
Input is Open 2. Analog Pressure
Input is Open (Probe Failure) Dis.
Pressure is higher than set HSP
Glows in Red when 1. Analog
Temperature Input is Open (Probe
Failure) 2. Dis. Temperature is higher
than set Trip temp.
Glows in Amber when 1. DPOF
Digital Input is Open & DPOF is
enabled Oil Filter Service is due
Glows in Amber when 1. Oil Separator
Filter Service is due 2. On High
Differential Pressure (Only if Sump
Pressure enabled)
1. Glows in Red when machine is
stopped / idle 2. Glows in Green
when machine is running
29.0
Appendix B

APPENDIX B: Short Cut Key Functions

Note1: All shortcut key functions only when the display is on Main Screen.
Note2: On every press of the key NEXT message is displayed.

W“LEFT” – Warning messages

Warning Description
DPAF Differential Pressure Air Filter Due For
Service
DPOF Differential Pressure Oil Filter Due For
Service
Dryer Probe Failure Pt100 Sensor Probe Failure
Low Dew Point Live Dew Point less than the Set Low
Dew Point
High Dew Point Live Dew Point greater than the Set High
Dew Point
High Differential pressure Difference Between the Sump & Discharge
Pressure is greater than the set max
Differential Pressure value.
Warn Temperature Discharge Temperature exceeds the set
Warn value
Change Air Filter Air Filter Due For Service
Change Oil Filter Oil Filter Due For Service
Change Oil Separator Oil Separator Due For Service
Change Oil Oil Change Due For Service
Change Grease Re Grease Due For Service
Start Stop Exceeded No. of Start and Stop per hour exceeded

30.0
Appendix B

X“RIGHT” - Live analog values

1. Live differential pressure
2. Live sump pressure
3. Live Pt100 temperature

S “UP” – Set analog values

1. Set load pressure
2. Set unload pressure
3. Set start sump pressure
4. Max differential pressure

d“DOWN” – Today report

1. Date
2. Load and stop hours
3. Unload and fault hours
4. Run and standby hours
5. Start count and load count

30.1
Appendix C

APPENDIX C: Modbus Table [Function Code: 0x03(Read) & 0x10(Write)]

# Data Address Type Bytes Example/ Access
Description Format
Cumulative Time & Count Registers
1 Load Hours 1010 BCD 4 HHHHHH:MM R
2 Unload Hours 1012 BCD 4 HHHHHH:MM R
3 Run Hours 1014 BCD 4 HHHHHH:MM R
4 Stop Hours 1016 BCD 4 HHHHHH:MM R
5 Fault Hours 1018 BCD 4 HHHHHH:MM R
6 Standby Hours 101A BCD 4 HHHHHH:MM R
7 No of Start 101C BCD 4 NNNNNNNN R
8 Load Count 101E BCD 6 NNNNNNNNNNNN R
9 Utilization % 1022 BCD 2 XXXX R
Service Remaining Time Registers
10 Rem AFCT 1029 ULong 4 H800927BF = R
Minutes -599999
11 Rem OFCT
Minutes 102C ULong 4 H800927BF = R
-599999
12 Rem OSCT 102F ULong 4 H800927BF = R
Minutes -599999
13 Rem OCT 1032 ULong 4 H800927BF = R
Minutes -599999
14 Rem RGT 1035 ULong 4 H800927BF = R
Minutes -599999
Mode Registers

15 Control Mode 1040 BCD 2 0001-DCS

0002-Local
0003-Remote R/W
16 Unload Mode 1041 BCD 2 0001-Disabled
0002-Enabled R/W
17 Auto Restart 1042 BCD 2 0001-OFF
0002-ON R/W
18 Pr Unit 1043 BCD 2 0001-BAR
0002-PSI R/W

31.0
Appendix C

# Data Address Type Bytes Example/ Access

Description Format
19 Tr unit 1044 BCD 2 0001-Centi
0002-Farhen R/W
20 Pr. Schdl 1045 BCD 2 0001-OFF
(on/off) 0002-ON R
Analog Registers
27 Dis. Pressure 104A BCD 2 1200 (/100) =
12.0 bar R
28 Dis. 104B BCD 2 1100 (/10) =
Temperature 110 C R
29 Dew Point /
Ambient
Temperature 104C BCD 2 MSB 01 = +
MSB 02 = -
LSB = 30 R
30 Sump Pressure 104D BCD 2 1200 (/100) =
12.0 bar R
31 Diff Pressure 104E BCD 2 0100 (/100)
=1.0 bar R
32 Set Unload 104F BCD 2 0120 (/10)
Pressure = 12.0 bar R/W
33 Set Load 1050 BCD 2 0080 (/10) =
Pressure 8.0 bar R/W
34 Set Diff 1051 BCD 2 0010 (/10) = R/W
Pressure 1.0 bar
35 Trip Temp 1052 BCD 2 0110 = 110 C R
36 Warn Temp 1053 BCD 2 0105 = 105 C R/W
37 Low Dew Point 1054 BCD 2 MSB 01 = +
MSB 02 = -
LSB = 30 R/W
38 High Dew Point 1055 BCD 2 MSB 01 = +
MSB 02 = -
LSB = 30 R/W
39 Fan Temp 1056 BCD 2 0070 = 70 C R/W

31.1
Appendix C

# Data Address Type Bytes Example/ Access

Description Format
21 Auto Restart 1060 BCD 2 0100 R/W
Delay (Sec)
22 Star Delay (Sec) 1061 BCD 2 0005 R/W
23 DTR Delay (Sec) 1062 BCD 2 0010 R/W
24 RTS Delay (Sec) 1063 BCD 2 0010 R/W
25 Standby Time 1064 BCD 2 0005 R/W
(Min)
26 Max. No of Start 1065 BCD 2 0005 R/W
per hour
RTC Registers

40 Hour 106A BCD 2 0023 R

41 Minutes 106B BCD 2 0059 R
42 Seconds 106C BCD 2 0059 R
43 Date 106D BCD 2 0031 R
44 Month 106E BCD 2 0012 R
45 Year 106F BCD 2 0009 R
46 Day 1070 BCD 2 0001Sunday -1 R
Status Registers
47 General Status 1071 UInt 2 Refer table R
48 Warning Status 1072 UInt 2 Refer table R
49 Fault Status 1073 UInt 2 Refer table R

31.2
Appendix C

Function Code: 0x01(Read Coil) & 0x05(Write Coil)

0x01 Read Coil (Start / Stop)
Frame Type ID Function Address Quantity of Data
Code coils
Request XX 01 2000 0001 —
Response XX 01 — Byte count: 01 ON Æ 0x01
OFF Æ0x00

0x05 Write Coil (Start / Stop)

Frame Type ID Function Address Quantity of Data
Code coils

Request XX 01 2000 0xFF00 Æ Start

0x0000 Æ Stop
Response XX 01 2000 0xFF00 Æ Start
0x0000 Æ Stop

31.3
Appendix C

Note: Function Code 0x10 (Write), 0x05 (Start/Stop) and 0x01 (read Start/Stop)
will function only if “Control Mode” is set to “DCS”. Refer: Operator/Machine/
Mode (Chapter 5.2.1)
On improper master request, any one of the following exception response
is sent
Code 01: Illegal function
Code 02: Illegal data address
Code 03: Illegal data value
Status Register Bit Definition:

Bit Position General Warning Fault

0 Ready DPAF HSP
1 Star DPOF Cooler
2 Run Dryer probe failure Main motor
overload
3 Run load Low dew point Reverse rotation
4 Run unload High dew point Pressure probe
failure
5 Stop busy High differential Temperature probe
pressure Failure
6 Idle Warn temperature Trip temperature
7 Emergency Change air filter Sump pressure not
stop developing
8 Start inhibit Change oil Sump pressure
filter probe failure
9 Start Change oil Power failure
ack wait separator
10 Standby Change oil Reserved
11 Reserved Change grease Reserved
12 Reserved Reserved Reserved
13 Reserved Reserved Reserved
14 Reserved Reserved Reserved
15 Reserved Reserved Reserved

31.4
Appendix D

Appendix-D Flow charts (Start, Stop, Load /unload /standby

sequence)
Start Sequence:

Start Sequence

STAR
ON

Delay for 100msecs

(Fixed)

MAIN ‘ON’

NO. OF. START

INCREMENT

STAR TO DELTA delay ‘x’ sec

(Star delay)

STAR OFF

DELTA ON

Delta to run delay ‘x’ sec

(DTR)

Return

32.0
Appendix D

Stop Sequence:
Stop

Is Yes
STAR ON?

No

Is No
Return
MAIN ON?

Yes

(RTS delay)
LOAD “OFF”
Run to stop ‘x’ sec

DELTA & MAIN

OFF

“IDLE” delay for 5 secs

Fixed delay

READY

32.1
Appendix D

RUN LOAD/UNLOAD/STANDBY

Is
Delta Return
ON? NO

Yes

No
Is Is
DIS Pr DIS pr. Return
< Load pr >UL pr
NO

Yes
Yes

Load ‘ON’ Load ‘OFF’

Increment
Load Count

Standby mode: In unload mode, if the pressure exceeds the set load pressure
in the preset standby time, and is less than number of start/stop cycles during
that time, the compressor goes into the standby mode ( or the compressor
stops as per the stop sequence).

In standby mode, if the pressure drops below the set load pressure, the
compressor starts automatically as per the start sequence.

32.2