INTRODUCTION TO CALMS DEVICES

CAL-PM-X

Presenter:

Amina Grosic

CALMS Air Inc

amina@calms.eu

info@calms.com

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What is CAL-PM-X?

• Installed in compressor station
• Gather data from all connected sensors and equipment and sends it to CALMS web application through mobile network!
• Upload interval: 5minutes
• Sampling interval: 5sec

Input power supply cable (recommended: 3x1,5mm2, fused with B10 circuit breaker)

Fuses, C4 (line and neutral)

Surge protection device

Power supply unit 100-240VAC/24VDC, 100W

CAL-edge gateway – for sending data packages,

LAN port – connected to PLC X101 port,

Power supply: 24 VDC

PLC and all terminals (DI, AI, DOR, special…)

Operator touch panel

4 screws to demount the HMI from cabinet

Input power supply 24VDC

RJ45 socket for communication with PLC and router. Connected to PLC port X102

OP-HMI. Operator touch panel

Nameplate of CAL-PM-X box. Here you can Find its SERIAL NUMBER, TYPE and MAC ADDRESS.

When referring to certain box, always use SERIAL NUMBER!!!

CS-x BASE

Main PLC (2x network adapters, X001 is separate.

X101 and X102 depends on DIP switches.

Micro SD card and internal battery are under front lap.

X1 – power distribution terminal

(left side: 8x 24VDC. Right side: 8x 0VDC.

DI1 – 8x digital input terminal

DOR1 – 4x digital output terminal

13-14, 23-24, 33-34 are reserved for SOV.

43-44 is reserved for alarm relay output -general alarm

AI1 – 4x analog input terminal (4-20mA)

AO1 – 2x analog output terminal 4-20mA

BC1 – 2x EtherCAT junction terminal for connecting interface modules

CS-x BASE

Main PLC (2x network adapters, X001 is separate.

X101 and X102 depends on DIP switches.

Micro SD card and internal battery are under front lap.

X1 – power distribution terminal

(left side: 8x 24VDC. Right side: 8x 0VDC.

DI1 – 8x digital input terminal

DOR1 – 4x digital output terminal

13-14, 23-24, 33-34 are reserved for SOV.

43-44 is reserved for alarm relay output -general alarm

AI1 – 4x analog input terminal (4-20mA)

AO1 – 2x analog output terminal 4-20mA

BC1 – 2x EtherCAT junction terminal for connecting interface modules

Cable entry system

• Makes your work easier
• Better transparency

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Power supply unit

• Input power: 100-240 VAC, 50/60Hz, 100W;
• Output power: 24 VDC;
• Supplies: CAL-EDGE-4G device,PLC, modules and HMI.

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Surge protection device (SPD)

• Used to protect against transient surge conditions
• We are using Phoenix Contact VAL-SEC-T2-1S-350 (no backup fuse required)
• Connection schematic:

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Compressor interface modules

• CAL-C-ON/OFF – module for ON/OFF compressors;
• CAL-C-VSD – module for VSD compressors;
• Mounted in compressor closure;
• Power supply: 24VDC;
• Input power supply is taken from compressor;
• EtherCAT communication with main CAL-PM-X box

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CS-C-ON/OFF interface module

• Interface module for ON/OFF compressors;
• Mounted in compressor closure;
• Power supply: 24VDC;
• Input power supply is taken from compressor;
• EtherCAT communication with main CS-X box;
• Includes: 4x DI, 4x DO, 1x AIP.

CS-C-VSD interface module

• Interface module for VSD compressors;
• Mounted in compressor starter closure;
• Power supply: 24VDC;
• Input power supply is taken from compressor;
• etherCAT communication with main CS-X box;
• Includes: 4x DI, 4x DO, 1x A0, 1x AIP.

• DI‘s are used for compressor feedback signals;
• DOR – 4x digital output relay terminal, used for compressor regulation. Remote start/stop, remote load/unload;
• AO – analog output terminal for speed regulation can be added.
• AIP‘s are power analyzer terminals. Used for measuring power of the compressor (can take X/5A CT, optionally X/333mV);
• BC1 – bus coupler for CAL-X modules. 2x RJ45 ports (INPUT: connection with BC terminal in main CAL box, OUTPUT: used in case of daisy chain connection to second CS-C module.
• X1 – power distribution terminal (left side: 8x 24VDC, right side: 8x 0VDC)

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End terminal

AIP1 terminal

DOR1

X1

BC1

Power supply unit 230VAC/24VDC, 24W

FC1 –C2 circuit breaker

Sensors wiring

• Any sensor can be connected to device. Most common are:
• Pressure transmitters,
• Flow meters,
• Temperature sensors,
• Vibration sensors,
• Dew point sensors,
• Other 4-20mA sensors,
• Optionally also 2-10V sensors…

Pressure transmitter – SML 10

• Range: 0-16 barg,
• Usually connected to AI1,
• 2 wire connection,
• Should be connected after air treatment equipment (filter, dryers) for regulation purpose,
• Two sensors can be used: �one before dryer and second after dryer (for measuring the air treatment pressure drop)…

Flow meter – FS10A

• Range: 0-122 Nm/s,
• Usually connected to AI2,
• 3 wire connection,
• Special connector,
• Direction of flow meter must be checked!,
• Sensor must be installed in the center of the pipe!

Sensor wiring – electrical scheme

Operator touch panel

• Operator touch panel works on „Touch screen“ principle;
• Allows to view the status of compressor room without logging into the system;

Types of CALMS touch panels

CAL-PM-2 and CAL-PM-4

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MT8050iE / MT8051iE

Dimensions: 480x272

CAL-PM-8 – bigger panel

MT8071iE / MT80101iE

Dimensions: 800x480

Home page

Overview page

Login for different users

Setup page - Login

User of the touch panel

Manager

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• Password: 321
• Manager can set up ranges of digital and analog inputs and can do the basic settings for CFC and EMCS

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Operator

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• Pasword: 111
• Operator can‘t change anything
• Only monitors the compressor room

Admin

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• Advanced user
• Has access to every part of the panel (settings, advanced settings)

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Calms flow controller (CFC)

• Separates air production (compressors) and demand (end users);
• Main purpose: maintain constant and stable system pressure, no matter on system demand;
• Goal of CFC: lower the pressure on demand side to its lowest acceptable point, what leads to maximum energy efficiency (reduced apparent air consumption – reduced system flow – reduced air leaks and inappropriate use of compressed air);
• Goals are achieved by using PI(D) regulator, which is the most common control algorithm used in industry;
• To activate CFC function customer has to purchase this option;

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CFC hardware details

CFC is supplied with its standard elements such as:

• Actuator with a valve:
• Special designed disc valves
• Flow direction indication on the valve,
• Valve opens in case of 4-20mA control loop fault,
• Dimension and shape of the valve is selected for each project individually.
• Pressure transducers:
• PT.01: Pressure transducer with 4-20mA output which measures CFC inlet pressure,
• PT.02: Pressure transducer with 4-20mA output which measures CFC outlet pressure.

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Installation example

NOTE: It is mandatory that CFC is connected to CALMS CAL-PM-X device!!!

Installation recommendations:

• Try to mount CFC in a way CFC is easy to access in case of service or overview,
• Ambient temperature should not exceed 60°C

CFC configuration and HMI settings

• CFC must be connected to CAL-PM-X box, which consists program for CFC regulation!
• When CFC is properly mounted and connected to box we can start with configuration through HMI.
• For adjusting settings a „manager“ login is required.
• On setup menu of HMI you can find CFC page.
• Operation mode: AUTO or MANUAL mode.

Operator can manually open the CFC from 0% to 100%.

Used while testing or when customer want that CFC is constantly opened at specific %.

In this mode algorithm does not regulate the CFC and there is a risk of outlet pressure drop!

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MANUAL MODE

CFC operates automatically.

It always compare the CFC outlet pressure with pressure setpoint:

When CFC outlet pressure is higher than SETPOINT, CFC starts moving toward closed position!

When CFC outlet pressure is lower than SETPOINT, CFC starts moving toward opened position!

Actual valve position: CFC gives feedback position (as 4-20mA signal) and we exactly know at what position CFC currently is;

Demanded valve position: Demanded position of the CFC. This is a 4-20mA signal box is giving the CFC.

NOTE: If normal conditions those two values should be close each other!

AUTO MODE

CFC status screen

To check CFC status screen login is not required. On the upper left side of the screen is displayed in which operation mode CFC currently is!

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Most important process variables for proper CFC operation:

• Normal operation in AUTO/MANUAL mode
• Setpoint is 0 bar: in this situation CFC closes to its close position!
• Low inlet pressure: System detected low inlet pressure. Below “Close pressure” setting
• Low outlet pressure: System detected low outlet pressure. Below “Setpoint- open tolerance”

CFC status page

Troubleshooting

The most common troubles when commissioning CFC or during operation of CFC:

1. CFC inlet/outlet pressure is 0 barg:
1. check the wiring of PT.01 and PT.02.
2. Check and adjust range of pressure transducers;
3. Faulty analog input: try another analog input.
1. Actual valve position does not change even valve is moving:
1. Check the CFC settings
2. Check the wiring
3. Check the mA signal loop with mA meter
4. Try another analog input

For more information check our user manual “CFC detail explanation”!

THANK YOU!

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• info@calms.com

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