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SIERRA CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL (Part No. 80441801) INGERSOLL-RAND  AIR COMPRESSORS
SIERRA CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL (Part No. 80441801) INGERSOLL-RAND  AIR COMPRESSORS

SIERRA ®

CMC TROUBLESHOOTING AND REMOTE COMMUNICATIONS REFERENCE MANUAL

(Part No. 80441801)

INGERSOLL-RANDAIR COMPRESSORS

CMC TECHNICAL REFERENCE MANUAL

Copyright Notice

Copyright 2004 Ingersoll-Rand Company

THIS MANUAL IS SOLD "AS IS" AND WITHOUT ANY EXPRESSED OR IMPLIED WARRANTIES WHATSOEVER.

Printing Date: 15 December 2004

Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air applications. Ingersoll-Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service.

CMC TECHNICAL REFERENCE MANUAL

Table of Contents

References

2

General - CMC Panel

3

Protection and Monitoring

4

Analog Functions

4

Digital Functions

5

Troubleshooting

7

Troubleshooting Example

8

Input/Output (I/O) System

9

Control Power System (CPS)

27

Controller Problems

30

 

_______________________________________________________

Communication

32

Human Machine Interface (HMI) Systems

32

Direct CMC Communications with RS422/485

32

 

__________________________________

The CMC-MODBUS Interface

________________________________________________

33

The CMC-DF1 Interface

52

 

79

_______________________________________________________

Documentation System Information

79

Status Codes

79

81

84

88

Glossary

1

2

CMC TECHNICAL REFERENCE MANUAL

References

The following references were used in creating this document. All of this documentation is recommended for a more detailed understanding of specific control modes and control panel functions.

NEMA STANDARDS PUBLICATION NO. 250, Enclosures for Electrical Equipment (1000 Volts Maximum), Revision 2, May 1988 NFPA 496 Standard for Purged and Pressurized Enclosures for Electrical Equipment, 1986 Edition Doebelin, Ernest O., Control System Principles and Design, John Wiley & Sons, 1985

Rowland, James R., Linear Control Systems Modeling, Analysis, and Design, John Wiley & Sons, 1986

Deshpande, Pradeep B. and Ash, Raymond H., Computer Process Control With Advanced Control Applications, 2nd Edition, Instrument Society of America, 1988

Harrison, Howard L. and Bollinger, John G., Introduction to Automatic Controls, Second Edition, Harper & Row, 1969

CMC TECHNICAL REFERENCE MANUAL

3

General - CMC Panel

The CMC panel is the microprocessor-based control and monitoring system for Sierra. The CMC handles compressor control and monitoring functions; as well as, control of auxiliary equipment such as the main motor starter, condensate solenoid valve and the load solenoid valve.

The CMC panel has a custom computer board called the Base Control Module (BCM). This board has a microcontroller and memory chips that tell the rest of the panel what to do for the various input pressures and temperatures. All hardware for data analysis, number of input and output (I/O) points and system memory are optimally selected for accurately controlling and protecting Sierra compressors.

Features of the CMC system are:

Ease of use

only twelve buttons to push on the operator OUI!

NOTE

For the purpose of consistency and clarity, all of the descriptions and examples that follow refer to "air" for the more generic "gas". Any gas compressed by a Sierra compressor would also apply.

4

CMC TECHNICAL REFERENCE MANUAL

Protection and Monitoring

Each CMC base module has Twenty-three analog inputs, sixteen digital inputs, four analog outputs and sixteen digital outputs for control, protection and monitoring. These input functions provide the CMC with information about the compressor. The CMC board uses the output functions to communicate to the user and perform actions like starting the compressor. All of these inputs and outputs are required to interface physical actions to and from the electronics.

Analog Functions

An analog function is one in which an electrical signal represents a specific pressure or temperature. As these inputs and outputs fluctuate, the electrical signal to and from the microprocessor board also fluctuates proportionally to the amount of change.

Analog Inputs

Twenty-one grounded and two floating analog inputs are used for protection, monitoring and control. Each input used for protecting the compressor can be programmed for alarm and trip indication. Each of these functions is pre-programmed with the function title, engineering units, range, alarm and trip values, so no configuration is required upon receipt by the customer.

The CMC uses pressure transmitters to measure pressure, resistance temperature detectors (RTD), thermistors and transmitters to measure temperature.

The CMC logic used for the protective alarm and trip functions is as follows: if the actual value of the input is greater than or equal to the alarm or trip value, indicate the condition. This logic is used for all inputs except, low oil pressure where the logic is reversed.

Analog Outputs

The Sierra CMC controller does not use any analog outputs.

Analog Input (AI) Fail

If the value of the analog input drops below 2.5mA (low) or exceeds 20.5mA (high) it’s value in engineering units will not be displayed. When the CMC detects an analog value out of range it will indicate that condition on the page that normally displays the engineering units reading. In the example at the right, Package Discharge Pressure, 4APT, has

4 CMC TECHNICAL REFERENCE MANUAL Protection and Monitoring Each CMC base module has Twenty-three analog inputs,

System Page – 4APT Failed

failed as indicate by the OUI System folder and Status Bar. Analog input failures are treated as Trips.

CMC TECHNICAL REFERENCE MANUAL

5

CMC TECHNICAL REFERENCE MANUAL 5 Event Log – 4APT Failed Low The 4APT failure is also

Event Log – 4APT Failed Low

The 4APT failure is also listed on the Event Log. Assuming in our example 4APT failed low, the Event Log entry would indicate the failure was Low. High failures will be shown in a similar manner, with the word High replacing Low.

See the Troubleshooting section of this manual to resolve irregular analog input values.

Digital Functions

A digital function is one in which the presence of an electrical signal indicates ON or YES, and the lack of that signal represents OFF or NO. This is analogous to a light switch that has only two states, ON or OFF. The term "discrete" is also used instead of digital in many instances. The term that will be used throughout this documentation shall be digital.

Digital Inputs

The sixteen digital inputs provide status of motor overloads, remote start/stop, remote load, auxiliary inputs and emergency stop. Any of these inputs can be configured as an alarm or trip. All inputs operate on 24 VDC power.

Digital Outputs

The sixteen digital outputs are used by the CMC to energize the main starter contacts, indicate that an alarm or trip condition exists, activate the condensate and load solenoid valves, indicate that the compressor is stopped in auto restart and to sound the horn. Outputs can operate on 120 VAC, 50/60 Hz, single-phase power or 24 VDC power.

6

CMC TECHNICAL REFERENCE MANUAL

Alarm and Trip Settings

These values determine when the controller will indicate an alarm or trip condition.

 

WARNING

Setting Trip values outside the range specified in the Operator’s/Instruction Manual can result in compressor damage.

Setting Trip values outside the range specified in the Operator’s/Instruction Manual can result in compressor damage.

CMC TECHNICAL REFERENCE MANUAL

7

Troubleshooting

The following procedures provide direction on troubleshooting the CMC System, control panel, and associated instrumentation. Faults are either Event Logged, which means the fault is displayed in the INFO Folder on the OUI, or Non-Event Logged. The distinction helps to expedite the troubleshooting process.

When a control system fault is suspected, the following diagram (figure 1) is used to categorize the fault. The section following the diagram breaks each category down into specific items, which can cause a particular fault.

CMC TECHNICAL REFERENCE MANUAL 7 Troubleshooting The following procedures provide direction on troubleshooting the CMC System,

Figure 1: Troubleshooting Tree

8

CMC TECHNICAL REFERENCE MANUAL

Troubleshooting Example

The following example will serve as a guide to follow when troubleshooting specific problems.

SYSTEM INFO SETTINGS SERVICE Event Name Time Date 1 Low Oil Press Trip 09:18:44 0720 2
SYSTEM
INFO
SETTINGS
SERVICE
Event Name
Time
Date
1
Low Oil Press Trip
09:18:44
0720
2
Low Oil Press Alarm
09:18:43
0720
3
Reset key pressed
09:18:34
0720
4
Low Oil Press Trip
09:08:43
0720
5
Low Oil Press Alarm
08:58:23
0720
6
Load key pressed
08:24:01
0720
7
Start key pressed
08:23:12
0720
Trip
Not Ready
Remote
2/3

Problem Indication:

Plant air pressure is low and the CMC OUI is found as shown.

Probable Cause Determination:

  • 1. The machine Tripped on Low Oil Pressure, which means the oil pressure, was below the Oil Pressure Trip Value. Figure 2 leads to the assumption that the problem is either compressor or I/O related, because the fault is Event Logged. There are two most likely causes for this event.

    • a) Actual oil pressure is low.

      • i) The oil pump is found to be running and installation of a calibrated pressure sensor shows the actual oil pressure to be above the Oil Pressure Trip Value. Therefore, the mechanical system is operating correctly.

    • b) The value read by the CMC is incorrect.

      • i) The oil pressure value displayed on Page 3 of the System Folder shows the oil pressure to be below the test sensor reading and erratic. Additionally, all other analog input readings are normal and not erratic. Therefore, the problem can be isolated to the oil pressure, analog input circuit.

ii)

The Pressure Monitoring System (PMS) troubleshooting table, found in the following section “The Pressure Monitoring System” identifies the probable cause for an erratic reading as a loose wire/terminal/connector and specifies Troubleshooting Procedure PMS #1 and 2 as the appropriate procedures.

Trouble Procedure Execution:

Step 1 of PMS #1 requires disconnecting of the pressure transducer (PT) wires at the terminal strip. When this step is performed, one of the connections is found to be intermittent. When the poor connection is corrected, the erratic reading on the OUI becomes solid.

CMC TECHNICAL REFERENCE MANUAL

9

Input/Output (I/O) System

Temperature Monitoring System (TMS)

Description:

An RTD (Resistance Temperature Detector-2 Wire) with external transmitter is used by the CMC for temperature monitoring. An RTD resistance (ohmic value) varies with temperature. A transmitter for monitoring by the CMC analog input channel converts the resistance to a 4-20 mA signal.

Component specification:

Probe:

100 ohm Platinum resistance at 32 °F (0°C) with Temperature Coefficient Rating (TCR) of 0.00385 Ohm/Ohm/Deg C

Transmitter:

The transmitter is mounted in the control panel enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of 0-500°F (-17.7 to +260°C).

Troubleshooting:

The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:

Typical Problem

Probable Cause

Troubleshooting

   

Procedure

High OUI readout

 

TMS #4

High resistance connection Transmitter not calibrated

TMS #3

RTD failure

TMS #2

Transmitter failure

TMS #3

Low OUI readout

Transmitter failure

TMS #3

RTD failure

TMS #2

Transmitter not calibrated

TMS #3

Erratic OUI readout

Loose terminal connection

TMS #4

RTD internal wire fault

TMS #2

Transmitter failure

TMS #3

Incorrect OUI readout

Transmitter not calibrated

TMS #3

RTD or transmitter failure

TMS #2, 3

Any

TMS #1, 2, 3, 4

10

CMC TECHNICAL REFERENCE MANUAL

Checking for Power to the Temperature Transmitter TMS #1 1. Disconnect the wires at terminals #1
Checking for Power to the Temperature Transmitter
TMS #1
1.
Disconnect the wires at terminals #1 and #2 on the transmitter and connect a voltmeter
to these wires.
2.
With control power on, there should be approximately 24 VDC present at the terminals.
3.
If approximately 24 VDC is not present, see the section titled “Control Power System”.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs,
(4-20mA) Channels 3-23
Pin 25
Pin 1
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
1 23 4
VAC
mA COM
V
RTD
Temperature transmitter

CMC TECHNICAL REFERENCE MANUAL

11

Checking for a Faulty RTD

TMS #2

  • 1. Turn control power off.

 
XXXXX XXXXX XXXXX XXXXX XXXXX XXXXX VDC mA VAC Ω mA COM V Ω
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
VAC
mA COM
V
 
  • 2. Check ohms versus temperature. Use an Ohmmeter and the following tables to determine if the RTD is faulty. Vary the temperature to the RTD and check the ohms around the normal operating range.

Thermometer

RTD

32 DEGF

Ice water

12

CMC TECHNICAL REFERENCE MANUAL

Degrees Fahrenheit versus Ohms value chart for 100 OHM Platinum RTD

 

°F

0

1

2

3

4

5

6

7

8

9

0

 
  • 93.01 93.22

   
  • 93.44 94.32

    • 93.66 93.88

 
  • 94.10 94.54

 

94.76

94.98

10

 
  • 95.20 95.42

   
  • 95.63 96.51

    • 95.85 96.07

 
  • 96.29 96.73

 

96.95

97.17

20

 
  • 97.38 97.60

   
  • 97.82 98.69

    • 98.04 98.26

 
  • 98.47 98.91

 

99.13

99.35

30

 
  • 99.56 99.78

100.00

 
  • 100.20 100.40

 
  • 100.70 100.90

 
  • 101.10 101.50

101.30

 

40

 
  • 101.70 102.00

102.20

 
  • 102.40 102.60

 
  • 102.80 103.00

 
  • 103.30 103.70

103.50

 

50

 
  • 103.90 104.10

104.30

 
  • 104.60 104.80

 
  • 105.00 105.20

 
  • 105.40 105.80

105.60

 

60

 
  • 106.10 106.30

106.50

 
  • 106.70 106.90

 
  • 107.10 107.40

 
  • 107.60 108.00

107.80

 

70

 
  • 108.20 108.40

108.70

 
  • 108.90 109.10

 
  • 109.30 109.50

 
  • 109.70 110.20

109.90

 

80

 
  • 110.40 110.60

110.80

 
  • 111.00 111.20

 
  • 111.50 111.70

 
  • 111.90 112.30

112.10

 

90

 
  • 112.50 112.70

113.00

 
  • 113.20 113.40

 
  • 113.60 113.80

 
  • 114.00 114.50

114.30

 

100

 
  • 114.70 114.90

115.10

 
  • 115.30 115.50

 
  • 115.80 116.00

 
  • 116.20 116.60

116.40

 

110

 
  • 116.80 117.00

117.30

 
  • 117.50 117.70

 
  • 117.90 118.10

 
  • 118.30 118.80

118.50

 

120

 
  • 119.00 119.20

119.40

 
  • 119.60 119.80

 
  • 120.00 120.20

 
  • 120.50 120.90

120.70

 

130

 
  • 121.10 121.30

121.50

 
  • 121.70 122.00

 
  • 122.20 122.40

 
  • 122.60 123.00

122.80

 

140

 
  • 123.20 123.40

123.60

 
  • 123.90 124.10

 
  • 124.30 124.50

 
  • 124.70 125.20

124.90

 

150

 
  • 125.40 125.60

125.80

 
  • 126.00 126.20

 
  • 126.40 126.60

 
  • 126.90 127.30

127.10

 

160

 
  • 127.50 127.70

127.90

 
  • 128.10 128.30

 
  • 128.60 128.80

 
  • 129.00 129.40

129.20

 

170

 
  • 129.60 129.80

130.00

 
  • 130.30 130.50

 
  • 130.70 130.90

 
  • 131.10 131.50

131.30

 

180

 
  • 131.70 132.00

132.20

 
  • 132.40 132.60

 
  • 132.80 133.00

 
  • 133.20 133.60

133.40

 

190

 
  • 133.90 134.10

134.30

 
  • 134.50 134.70

 
  • 134.90 135.10

 
  • 135.30 135.80

135.50

 

200

 
  • 136.00 136.20

136.40

 
  • 136.60 136.80

 
  • 137.00 137.20

 
  • 137.40 137.90

137.70

 

210

 
  • 138.10 138.30

138.50

 
  • 138.70 138.90

 
  • 139.10 139.30

 
  • 139.60 140.00

139.80

 

220

 
  • 140.20 140.40

140.60

 
  • 140.80 141.00

 
  • 141.20 141.40

 
  • 141.70 142.10

141.90

 

230

 
  • 142.30 142.50

142.70

 
  • 142.90 143.10

 
  • 143.30 143.50

 
  • 143.80 144.20

144.00

 

240

 
  • 144.40 144.60

144.80

 
  • 145.00 145.20

 
  • 145.40 145.60

 
  • 145.90 146.30

146.10

 

250

 
  • 146.50 146.70

146.90

 
  • 147.10 147.30

 
  • 147.50 147.70

 
  • 147.90 148.40

148.20

 

260

 
  • 148.60 148.80

149.00

 
  • 149.20 149.40

 
  • 149.60 149.80

 
  • 150.00 150.50

150.20

 

270

 
  • 150.70 150.90

151.10

 
  • 151.30 151.50

 
  • 151.70 151.90

 
  • 152.10 152.50

152.30

 

280

 
  • 152.70 153.00

153.20

 
  • 153.40 153.60

 
  • 153.80 154.00

 
  • 154.20 154.60

154.40

 

290

 
  • 154.80 155.00

155.20

 
  • 155.40 155.70

 
  • 155.90 156.10

 
  • 156.30 156.70

156.50

 

300

 
  • 156.90 157.10

157.30

 
  • 157.50 157.70

 
  • 157.90 158.10

 
  • 158.40 158.80

158.60

 

310

 
  • 159.00 159.20

159.40

 
  • 159.60 159.80

 
  • 160.00 160.20

 
  • 160.40 160.80

160.60

 

320

 
  • 161.00 161.30

161.50

 
  • 161.70 161.90

 
  • 162.10 162.30

 
  • 162.50 162.90

162.70

 

330

 
  • 163.10 163.30

163.50

 
  • 163.70 163.90

 
  • 164.10 164.30

 
  • 164.60 165.00

164.80

 

340

 
  • 165.20 165.40

165.60

 
  • 165.80 166.00

 
  • 166.20 166.40

 
  • 166.60 167.00

166.80

 

350

 
  • 167.20 167.40

167.60

 
  • 167.80 168.10

 
  • 168.30 168.50

 
  • 168.70 169.10

168.90

 

360

 
  • 169.30 169.50

169.70

 
  • 169.90 170.10

 
  • 170.30 170.50

 
  • 170.70 171.10

170.90

 

370

 
  • 171.30 171.50

171.80

 
  • 172.00 172.20

 
  • 172.40 172.60

 
  • 172.80 173.20

173.00

 

380

 
  • 173.40 173.60

173.80

 
  • 174.00 174.20

 
  • 174.40 174.60

 
  • 174.80 175.20

175.00

 

390

 
  • 175.40 175.60

175.80

 
  • 176.00 176.30

 
  • 176.50 176.70

 
  • 176.90 177.30

177.10

 

400

 
  • 177.50 177.70

177.90

 
  • 178.10 178.30

 
  • 178.50 178.70

 
  • 178.90 179.30

179.10

 

410

 
  • 179.50 179.70

179.90

 
  • 180.10 180.30

 
  • 180.50 180.70

 
  • 180.90 181.30

181.10

 

420

 
  • 181.50 181.80

182.00

 
  • 182.20 182.40

 
  • 182.60 182.80

 
  • 183.00 183.40

183.20

 

430

 
  • 183.60 183.80

184.00

 
  • 184.20 184.40

 
  • 184.60 184.80

 
  • 185.00 185.40

185.20

 

440

 
  • 185.60 185.80

186.00

 
  • 186.20 186.40

 
  • 186.60 186.80

 
  • 187.00 187.40

187.20

 

450

 
  • 187.60 187.80

188.00

 
  • 188.20 188.40

 
  • 188.60 188.80

 
  • 189.00 189.40

189.20

 

460

 
  • 189.70 189.90

190.10

 
  • 190.30 190.50

 
  • 190.70 190.90

 
  • 191.10 191.50

191.30

 

470

 
  • 191.70 191.90

192.10

 
  • 192.30 192.50

 
  • 192.70 192.90

 
  • 193.10 193.50

193.30

 

480

 
  • 193.70 193.90

194.10

 
  • 194.30 194.50

 
  • 194.70 194.90

 
  • 195.10 195.50

195.30

 

490

 
  • 195.70 195.90

196.10

 
  • 196.30 196.50

 
  • 196.70 196.90

 
  • 197.10 197.50

197.30

 

500

 
  • 197.70 197.90

198.10

 
  • 198.30 198.50

 
  • 198.70 198.90

 
  • 199.10 199.50

199.30

 

CMC TECHNICAL REFERENCE MANUAL

13

Degrees Celsius versus Ohms value chart for 100 OHM Platinum RTD

 

°C

0.00

0.62

1.23

1.85

2.47

3.09

3.70

4.32

4.94

5.56

-17.78

93.01

93.22

93.44

93.66

93.88

 
  • 94.10 94.32

94.54

 
  • 94.76 94.98

-12.22

95.20

95.42

95.63

95.85

96.07

 
  • 96.29 96.51

96.73

 
  • 96.95 97.17

-6.67

97.38

97.60

97.82

98.04

98.26

 
  • 98.47 98.69

98.91

 
  • 99.13 99.35

-1.11

99.56

99.78

 
  • 100.00 100.22

 
  • 100.43 100.87

100.65

   

101.30

  • 101.08 101.52

4.44

101.74

101.95

 
  • 102.17 102.39

 
  • 102.60 103.04

102.82

   

103.47

  • 103.25 103.69

10.00

103.90

104.12

 
  • 104.34 104.55

 
  • 104.77 105.20

104.98

   

105.63

  • 105.42 105.85

15.56

106.07

106.28

 
  • 106.50 106.71

 
  • 106.93 107.36

107.14

   

107.79

  • 107.58 108.01

21.11

108.22

108.44

 
  • 108.66 108.87

 
  • 109.09 109.52

109.30

   

109.95

  • 109.73 110.16

26.67

110.38

110.60

 
  • 110.81 111.03

 
  • 111.24 111.67

111.46

   

112.10

  • 111.89 112.32

32.22

112.53

112.75

 
  • 112.96 113.18

 
  • 113.39 113.82

113.61

   

114.25

  • 114.04 114.47

37.78

114.68

114.89

 
  • 115.11 115.32

 
  • 115.54 115.97

115.75

   

116.40

  • 116.18 116.61

43.33

116.83

117.04

 
  • 117.25 117.47

 
  • 117.68 118.11

117.90

   

118.54

  • 118.32 118.75

48.89

118.97

119.18

 
  • 119.39 119.61

 
  • 119.82 120.25

120.04

   

120.68

  • 120.46 120.89

54.44

121.11

121.32

 
  • 121.53 121.75

 
  • 121.96 122.39

122.17

   

122.81

  • 122.60 123.03

60.00

123.22

123.43

 
  • 123.65 123.87

 
  • 124.08 124.51

124.30

   

124.94

  • 124.73 125.16

65.56

125.37

125.58

 
  • 125.79 126.01

 
  • 126.22 126.65

126.43

   

127.07

  • 126.86 127.28

71.11

127.50

127.71

 
  • 127.92 128.13

 
  • 128.35 128.77

128.56

   

129.20

  • 128.98 129.41

76.67

129.62

129.83

 
  • 130.04 130.26

 
  • 130.47 130.89

130.68

   

131.32

  • 131.10 131.53

82.22

131.74

131.95

 
  • 132.16 132.38

 
  • 132.59 133.01

132.80

   

133.43

  • 133.22 133.65

87.78

133.86

134.07

 
  • 134.28 134.49

 
  • 134.70 135.12

134.91

   

135.55

  • 135.34 135.76

93.33

135.97

136.18

 
  • 136.39 136.60

 
  • 136.81 137.24

137.02

   

137.66

  • 137.45 137.87

98.89

138.08

138.29

 
  • 138.50 138.71

 
  • 138.92 139.34

139.13

   

139.76

  • 139.55 139.97

104.44

140.18

140.39

 
  • 140.60 140.81

 
  • 141.02 141.45

141.24

   

141.87

  • 141.66 142.08

110.00

142.29

142.50

 
  • 142.71 142.92

 
  • 143.13 143.55

143.34

   

143.97

  • 143.76 144.18

115.56

144.39

144.59

 
  • 144.80 145.01

 
  • 145.22 145.64

145.43

   

146.06

  • 145.85 146.27

121.11

146.48

146.69

 
  • 146.90 147.11

 
  • 147.32 147.73

147.53

   

148.15

  • 147.94 148.36

126.67

148.57

148.78

 
  • 148.99 149.20

 
  • 149.41 149.82

149.61

   

150.24

  • 150.03 150.45

132.22

150.66

150.87

 
  • 151.08 151.28

 
  • 151.49 151.91

151.70

   

152.33

  • 152.12 152.54

137.78

152.74

152.95

 
  • 153.16 153.37

 
  • 153.58 153.99

153.78

   

154.41

  • 154.20 154.62

143.33

154.82

155.03

 
  • 155.24 155.45

 
  • 155.66 156.07

155.86

   

156.49

  • 156.28 156.69

148.89

156.90

157.11

 
  • 157.32 157.52

 
  • 157.73 158.15

157.94

   

158.56

  • 158.35 158.77

154.44

158.98

159.18

 
  • 159.39 159.60

 
  • 159.80 160.22

160.01

   

160.63

  • 160.42 160.84

160.00

161.05

161.25

 
  • 161.46 161.67

 
  • 161.87 162.29

162.08

   

162.70

  • 162.49 162.91

165.56

163.11

163.32

 
  • 163.52 163.73

 
  • 163.94 164.35

164.14

   

164.76

  • 164.56 164.97

171.11

165.17

165.38

 
  • 165.59 165.79

 
  • 166.00 166.41

166.20

   

166.82

  • 166.62 167.03

176.67

167.23

167.44

 
  • 167.64 167.85

 
  • 168.06 168.47

168.26

   

168.88

  • 168.67 169.08

182.22

169.29

169.49

 
  • 169.70 169.90

 
  • 170.11 170.52

170.32

   

170.93

  • 170.73 171.14

187.78

171.34

171.55

 
  • 171.75 171.96

 
  • 172.16 172.57

172.37

   

172.98

  • 172.78 173.19

193.33

173.39

173.59

 
  • 173.80 174.00

 
  • 174.21 174.62

174.41

   

175.03

  • 174.82 175.23

198.89

175.44

175.64

 
  • 175.84 176.05

 
  • 176.25 176.66

176.46

   

177.07

  • 176.86 177.27

204.44

177.48

177.68

 
  • 177.88 178.09

 
  • 178.29 178.70

178.49

   

179.11

  • 178.90 179.31

210.00

179.51

179.72

 
  • 179.92 180.12

 
  • 180.33 180.73

180.53

   

181.14

  • 180.94 181.35

215.56

181.55

181.75

 
  • 181.95 182.16

 
  • 182.36 182.77

182.56

   

183.17

  • 182.97 183.38

221.11

183.58

183.78

 
  • 183.98 184.19

 
  • 184.39 184.80

184.59

   

185.20

  • 185.00 185.40

226.67

185.60

185.81

 
  • 186.01 186.21

 
  • 186.41 186.82

186.62

   

187.22

  • 187.02 187.43

232.22

187.63

187.83

 
  • 188.03 188.24

 
  • 188.44 188.84

188.64

   

189.25

  • 189.04 189.45

237.78

189.65

189.85

 
  • 190.05 190.25

 
  • 190.46 190.86

190.66

   

191.26

  • 191.06 191.46

243.33

191.67

191.87

 
  • 192.07 192.27

 
  • 192.47 192.87

192.67

   

193.28

  • 193.08 193.48

248.89

193.68

193.88

 
  • 194.08 194.28

 
  • 194.48 194.88

194.68

   

195.29

  • 195.09 195.49

254.44

195.69

195.89

 
  • 196.09 196.29

 
  • 196.49 196.89

196.69

   

197.29

  • 197.09 197.49

260.00

197.69

197.89

 
  • 198.09 198.29

 
  • 198.49 198.90

198.70

   

199.30

  • 199.10 199.50

 

NOTE: This chart converted from Fahrenheit chart using formula °C= ((°F-32)/1.8)

 

14

CMC TECHNICAL REFERENCE MANUAL

Checking the RTD Transmitter TMS #3 1. With control power off, connect a 100-ohm resistor to
Checking the RTD Transmitter
TMS #3
1.
With control power off, connect a 100-ohm resistor to terminals #3 and #4 of the
transmitter.
2.
Turn control power on, the OUI reading should be 32°F (0°C) ±5%.
3.
If the reading is not within specification, the transmitter may be faulty.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs,
(4-20mA) Channels 3-23
Pin 25
Pin 1
100
1 234
OHM
5%
Temperature transmitter

CMC TECHNICAL REFERENCE MANUAL

15

Checking proper operation of the BCM and wiring TMS #4 1. Ensure control power is off.
Checking proper operation of the BCM and wiring
TMS #4
1.
Ensure control power is off. At the affected RTD transmitter, disconnect the wires at
transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals (Observe
correct polarity). Power up the control panel and then vary the simulator output.
2.
At 12 mA (50%) the OUI should read 1/2 the RTD transmitter range; 250°F (121.1°C).
The readout should change as the simulator output is varied.
3.
If the reading on the OUI is incorrect or does not change, turn control power off and
reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4
to 20 mA simulator to the respective terminals at connector J1, (see electrical schematic
for connection points).
4.
Turn control power on and observe the OUI readout while varying the 4-20mA. If the
reading is correct there is an open or short in the wire or terminals connecting the CMC
to the RTD transmitter. If reading is not correct the BCM may be faulty.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs,
(4-20mA) Channels 3-23
Pin 25
4-20 mA SURCE OR
2 WIRE SIMULATOR
Pin 1
BATTERY
LOOP
CHECK
ON
mA OUT
100%
OFF
DIAL
2 WIRE
00.0%
XXXXXX
MODEL CL-XXX
00.0% - 100%
5 5 5

Input/Output (I/O) System

Temperature Monitoring System (TMS)

Description:

16

CMC TECHNICAL REFERENCE MANUAL

A thermistor with external transmitter is used by the CMC for temperature monitoring. A thermistor resistance (ohmic value) varies with temperature. A transmitter for monitoring by the CMC analog input channel converts the resistance to a 4-20 mA signal.

Component specification:

Probe:

10000 ohm resistance at 77 °F (25°C) Transmitter:

The transmitter is mounted in the control panel enclosure. The transmitter is supplied 24 VDC and outputs 4-20mA over a fixed range of –30 to 250°F (-34.4 to +121°C).

Troubleshooting:

The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:

Typical Problem

Probable Cause

Troubleshooting

   

Procedure

High OUI readout

 

TMS #4a

High resistance connection Transmitter not calibrated

TMS #3a

Thermistor failure

TMS #2a

Transmitter failure

TMS #3a

Low OUI readout

Transmitter failure

TMS #3a

Thermistor failure

TMS #2a

Transmitter not calibrated

TMS #3a

Erratic OUI readout

Loose terminal connection

TMS #4a

Thermistor internal wire fault

TMS #2a

Transmitter failure

TMS #3a

Incorrect OUI readout

Transmitter not calibrated

TMS #3a

Thermistor or transmitter failure

TMS #2a, 3a

Any

TMS #1a, 2a, 3a, 4a

CMC TECHNICAL REFERENCE MANUAL

17

Checking for Power to the Temperature Transmitter TMS #1a 1. Disconnect the wires at terminals #1
Checking for Power to the Temperature Transmitter
TMS #1a
1.
Disconnect the wires at terminals #1 and #2 on the transmitter and connect a
voltmeter to these wires.
2.
With control power on, there should be approximately 24 VDC present at the
terminals.
3.
If approximately 24 VDC is not present, see the section titled “Control Power
System”.

18

CMC TECHNICAL REFERENCE MANUAL

Checking for a Faulty Thermistor TMS #2a 1. Turn control power off. 2. Check ohms versus
Checking for a Faulty Thermistor
TMS #2a
1.
Turn control power off.
2.
Check ohms versus temperature.
Use an Ohmmeter and table below to
determine if the thermistor is faulty.
Vary the temperature to the
thermistor and check the ohms
around the normal operating range.

Temperature, o F

Resistance, ohms

  • 50 ±1.92 o

  • 20250 ±5.24%

  • 75 ±1.88 o

  • 10520 ±4.73%

  • 77 ±1.88 o

  • 10000 ±4.73%

  • 90 ±1.84 o

  • 7572 ±4.41%

  • 150 ±1.69 o

  • 1962 ±3.75%

  • 212 ±1.41 o

  • 637.0 ±2.35%

  • 228 ±1.33 o

  • 491.4 ±2.11%

  • 239 ±1.30 o

  • 413.9 ±2.00%

Temperature vs. Resistance Chart for 10000 ohm at 77 o F Thermistor

CMC TECHNICAL REFERENCE MANUAL

19

Checking the Thermistor Transmitter TMS #3a 4. With control power off, connect a 10000-ohm resistor to
Checking the Thermistor Transmitter
TMS #3a
4.
With control power off, connect a 10000-ohm resistor to terminals #3 and #4 of the
transmitter.
5.
Turn control power on, the OUI reading should be 77°F (25°C) ±5%.
6.
If the reading is not within specification, the transmitter may be faulty.

20

CMC TECHNICAL REFERENCE MANUAL

Checking proper operation of the BCM and wiring TMS #4a 1. Ensure control power is off.
Checking proper operation of the BCM and wiring
TMS #4a
1.
Ensure control power is off. At the affected thermistor transmitter, disconnect the
wires at transmitter terminal #1 and #2. Connect a 4-20mA source to these terminals
(Observe correct polarity). Power up the control panel and then vary the simulator
output.
2.
At 12 mA (50%) the OUI should read 1/2 the thermistor transmitter range; 110°F
(43.3°C). The readout should change as the simulator output is varied.
3.
If the reading on the OUI is incorrect or does not change, turn control power off and
reconnect the transmitter, remove the wires for this transmitter from J1 and move the
4 to 20 mA simulator to the respective terminals at connector J1, (see electrical
schematic for connection points).
4.
Turn control power on and observe the OUI readout while varying the 4-20mA. If the
reading is correct there is an open or short in the wire or terminals connecting the
CMC to the thermistor transmitter. If reading is not correct the BCM may be faulty.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs,
(4-20mA) Channels 3-23
Pin 25
4-20 mA SURCE OR
2 WIRE SIMULATOR
Pin 1
BATTERY
LOOP
CHECK
ON
mA OUT
100%
OFF
DIAL
2 WIRE
00.0%
XXXXXX
MODEL CL-XXX
00.0% - 100%
5 5 5

CMC TECHNICAL REFERENCE MANUAL

21

Pressure Monitoring System (PMS)

Description:

A Pressure Transducer (PT) is used to convert pressure (psi) to a 4-20 mA signal for monitoring by the CMC.

Component specification:

0 to –14.7 PSIG (101.35 kpa) range

0-100 PSIG (689.5 kPa) range

0-200 PSIG (1379 kPa) range

Power = 24 VDC

Troubleshooting:

The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:

Typical Problem

Probable Cause

Troubleshooting Procedure

Zero OUI readout

Open circuit/cable disconnected

PMS #1, 2

Loss of power to transmitter

PMS #1

 

PMS #3, 4

Erratic OUI readout

Malfunctioning transmitter Loose wire/terminal/connector

PMS #1,2

Incorrect OUI readout

Any

PMS #1, 2, 3, 4

22

CMC TECHNICAL REFERENCE MANUAL

Checking for Power to the Pressure Transmitter PMS #1 1. Ensure control power is off. Disconnect
Checking for Power to the Pressure Transmitter
PMS #1
1.
Ensure control power is off. Disconnect the wires at the suspect PT and connect a
voltmeter to these wires.
2.
With control power on, there should be approximately 24 VDC present at the terminals.
3.
If approximately 24 VDC is not present, see the section titled “Control Power System”.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs,
(4-20mA) Channels 3-23
Pin 25
Pin 1
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
VAC
INGERSOLL RAND
mA COM
V

CMC TECHNICAL REFERENCE MANUAL

23

Checking proper operation of the BCM and wiring PMS #2 1. Ensure control power is off.
Checking proper operation of the BCM and wiring
PMS #2
1.
Ensure control power is off. Disconnect the wires at the suspect PT and connect a 4-20
mA source to the lifted wires (Observe correct polarity).
2.
Restore control power and then vary the simulator output.
3.
At 12 mA (50%) the OUI should read 1/2 the PT range. The readout should change as
the simulator output is varied.
4.
If the reading on the OUI is incorrect or does not change, turn control power off and
reconnect the transmitter, remove the wires for this transmitter from J1 and move the 4-
20 mA simulator to the respective terminals at connector J1, (see electrical schematic for
connection points).
5.
Turn control power on and observe the OUI readout while varying the 4-20 mA. If the
reading is correct there is an open or short in the wire or terminals connecting the CMC
to the PT. If the reading is not correct the BCM may be faulty.
BCM
J2-Floating Analog Inputs, (4-20mA) Channels 1-2
J1-Grounded Analog Inputs,
(4-20mA) Channels 3-23
Pin 25
4-20 mA SURCE OR
2 WIRE SIMULATOR
Pin 1
BATTERY
LOOP
CHECK
ON
mA OUT
100%
OFF
DIAL
2 WIRE
00.0%
XXXXXX
MODEL CL-XXX
00.0% - 100%
5 5 5

24

CMC TECHNICAL REFERENCE MANUAL

Quick check of the PT PMS #3 1. Connect an ohmmeter to the disconnected wires coming
Quick check of the PT
PMS #3
1.
Connect an ohmmeter to the disconnected wires coming from the PT.
2.
If there is no continuity either the wiring or the PT is faulty.
M
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
VDC
mA
VAC
mA COM
V
INGERSOLL RAND
Functional PT test
PMS #4
1.
Remove control power.
2.
Remove the PT and connect a regulated air supply to the pressure connection. Power
up the CMC and vary the regulated air supply. The OUI should read the pressure being
applied.

CMC TECHNICAL REFERENCE MANUAL

25

Digital Input System (DIS)

Description:

The digital input devices associated with the CMC are on/off devices that turn on or off the associated CMC digital input.

Typical digital device name and type:

  • 1. Starter Feedback

  • 2. Main motor overload

  • 3. Fan motor overload

  • 4. Remote start/stop

  • 5. Condensate level switch (option)

  • 6. Auxillary inputs

Troubleshooting:

The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:

Typical Problem

Probable Cause

Troubleshooting Procedure

False alarm or trip

Faulty device

DIS #1

Faulty wiring

DIS #1

26

CMC TECHNICAL REFERENCE MANUAL

Checking proper operation of the digital devices DIS #1 1. Verify approximately 24 VDC is present
Checking proper operation of the digital devices
DIS #1
1.
Verify approximately 24 VDC is present as described in the section titled
“Troubleshooting the Power System”.
2.
If approximately 24 VDC is present, install a multimeter with VDC selected between J4
or J5 pin1 and the input pin (the input pin can be determined from the electrical
schematic, or wire number).
3.
Ensure the digital device is not in the trip condition, the meter should read 0 VDC.
4.
Actuate the switch, the meter should read approximately 24 VDC.

CMC TECHNICAL REFERENCE MANUAL

27

Control Power System (CPS)

Description:

The control power system provides 24 VDC to the CMC system for processing logic, displaying data, and monitoring instrumentation. The 24 VDC power supply feeds the Base Control Module (BCM) at connector J10. Over current protection and power distribution are performed as shown below:

J2 J1 AC2 pin 3 Power Supply +24 VDC pins 11 thru 14 BCM shown cover
J2
J1
AC2 pin 3
Power Supply
+24 VDC pins 11 thru 14
BCM shown
cover removed
F1
AC1 pin 1
Return pins 7 thru 10
Fuse 5A/250VAC, normal blo.
J12-Digital Output Power 120 VAC (Pin 1)
To OUI J2 pin 2
To OUI J2 pin 1
OUI Power
To Ground Bar
J10-Power Input (24 VDC)
F100
J9-Current Transformer
(0-5 amp)
F101
F102
F103
CPU Power
BCM
All BCM Fuses are 5x20mm,
GMA 1.5 amp, Fast Blow
Digital Input Power
J4 & J5 - Digital Input Power 24 VDC (pin 1)
Analog Input/Output Power
LEGEND:
Trace
Wire
J1- Analog Input Power 24 VDC (pin 26)
J3- Analog Output Power 24 VDC (pins 2 & 8)

28

CMC TECHNICAL REFERENCE MANUAL

Power Supply:

Input power:

85-132 VAC, or 180-264 VAC (auto-selecting input), 2.5A RMS max, 47-63

Hz.

Output power: 24 VDC, 4.3 A maximum at 50 °C.

Troubleshooting:

The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:

Typical Problem

Probable Cause

Troubleshooting

Procedure

All analog inputs are zero or negative on System Page

No AC power

CPS #1

 

CPS #2

No DC power No analog input

CPS #5

OUI displays: “OUI Port: RS232 Address: 0x0141

OUI

power Cable

 

Display Table CRC: D672

BCM Not Responding”

disconnected

 

No CPU power

CPS #8

BCM problems

CMCS #3

OUI is black

No AC power

CPS #1

No DC power

CPS #2

No OUI power

CPS #7

Event Log indicates all digital alarms and trips active

 

No AC power

CPS #1

   

CPS #2

No DC power No digital input

CPS #3

power

All digital outputs not working

No AC power

CPS #1

 

CPS #2

No DC power No digital output power

CPS #4

No AC power

CPS #1

  • 1. Ensure control power is off.

  • 2. Install a multimeter set for VAC between pins 1 and 3 at connector J1 on the power supply.

  • 3. Restore control power, the meter should read 120 VAC or 220 VAC depending upon the rated supply power. The rated supply power can be verified from the electrical schematic.

CMC TECHNICAL REFERENCE MANUAL

29

No DC power

CPS #2

  • 1. Ensure control power is off.

  • 2. Install a multimeter set for VDC between pins 11-14 and 7-10 at connector J2 on the power supply.

  • 3. Restore control power, the meter should read approximately 24 VDC. If approximately

  • 24 VDC is not present, check F1 on the power supply, if fuse is good, the power supply

may be faulty.

  • 4. Ensure control power is off.

  • 5. Install a multimeter set for VDC between pins 1 and 2 at connector J10 on the BCM.

  • 6. Restore control power, the meter should read approximately 24 VDC. If approximately

  • 24 VDC is not present, check the wiring between the power supply and the BCM.

No digital input power

CPS #3

  • 1. Ensure control power is off.

  • 2. Install a multimeter set for VDC between pin 1 at connector J4 on the BCM and the ground bar.

  • 3. Restore control power, the meter should read approximately 24 VDC. If approximately

  • 24 VDC is not present, check F103 on the BCM, if F103 is good, check for DC power.

No digital output power

CPS #4

  • 1. Ensure control power is off.

  • 2. Install a multimeter set for VAC between pin 1 at connector J12 on the BCM and the ground bar.

  • 3. Restore control power, the meter should read 120 VAC.

No analog input power

CPS #5

  • 1. Ensure control power is off.

  • 2. Install a multimeter set for VDC between pin 26 at connector J1 on the BCM and the ground bar.

  • 3. Restore control power, the meter should read approximately 24 VDC. If approximately

  • 24 VDC is not present, check F102 on the BCM, if F102 is good, check for DC power.

No OUI power

CPS #7

  • 1. Ensure control power is off.

  • 2. Install a multimeter set for VDC between pins 1 and 2 at connector J2 on the OUI.

  • 3. Restore control power, the meter should read approximately 24 VCD. If approximately 24VDC is present, check F2 on the OUI. If F2 is good, go to next step.

  • 4. Restore control power, the meter should read approximately 24 VDC. If approximately

  • 24 VDC is not present, check F101 on the BCM, if F101 is good, check for DC power.

No CPU power

CPS #8

  • 1. Ensure control power is off.

  • 2. Verify approximately 24 VDC is present at J10.

  • 3. Check F100, if F100 is blown the BCM must be replaced, not the fuse.

  • 4. If F100 is not blown, and the BCM is not functioning, the BCM must be replaced.

30

CMC TECHNICAL REFERENCE MANUAL

Controller Problems

Description:

The CMC System is generally comprised of a Base Control Module (BCM), Operator User Interface (OUI), and Power Supply (PS). There are few user serviceable components within the system; however, a brief understanding of the system will help in overall troubleshooting. All components require 24 VDC and rely on hardware and software to perform correctly, if the problem cannot be isolated to a power problem it is most likely a hardware or software problem, which will require Ingersoll-Rand support to correct.

Component Specification:

24 VDC power required

Software required for BCM and OUI

Troubleshooting:

The following table identifies typical problems, probable causes, and appropriate procedures for verifying the probable cause:

Typical Problem

Probable Cause

Troubleshooting

Procedure

 

No power

CMCS #4

BCM fault suspected OUI is dim

Wrong contrast selected

CMCS #1

Backlight failing

CMCS #1

OUI is black

 

CMCS #2

OUI displays: “OUI Port: RS232

No power Cable disconnected

CMCS #3

Address: 0x0141

OUI Display

Table CRC: D672 Responding”

BCM Not

OUI displays: “OUI Port: RS232

   

Address: 0x0141 Table CRC: D672 Table CRC: 6C24

OUI Display BCM Display OUI / BCM

Wrong program in either the BCM or the OUI

Program appropriate module with correct file.

Waiting for Tables (*.ABS) OUI displays “Status XXH” Where XX is a specific number

Many

Refer to Status Codes under System Information Section.

MODBUS communications problem

No power

CMCS #5

Many

Refer to the UCM Section.

CMC TECHNICAL REFERENCE MANUAL

31

BCM Problems

BCM is not controlling

CMCS #4

  • 1. Check the CPU power as described in the section titled “Control Power System”.

OUI Problems

OUI is dim

CMCS #1

  • 1. Depress the contrast key to step to the desired brightness.

  • 2. Replace the OUI backlight as described in the section titled “Backlight Replacement Procedure”. If the backlight does not fix the problem the OUI may be faulty.

OUI is black

CMCS #2

  • 1. Check for OUI power as described in the section titled “Control Power System”. If approximately 24 VDC is present, check F2. If F2 is O.K. the OUI may be faulty.

 

OUI displays “OUI Port: RS232 Address: 0x0141

OUI Display Table CRC:

CMCS #3

D672

BCM Not Responding”

  • 1. Check the cabling between OUI J1 and BCM J6.

 
  • 2. Check the BCM CPU power.

  • 3. The BCM may be faulty.

UCM Problems

All UCM LED’s are not lit

 

CMCS #5

  • 1. Check for approximately 24 VDC at pins 1 and 2 at J3 on the UCM.

 
  • 2. If power is present at J3 the UCM may be faulty.

 

32

CMC TECHNICAL REFERENCE MANUAL

Communication

Customers may want to communicate to the CMC control systems for remote compressor control and monitoring. This communication capability provides for flexibility in the customer's compressed air operation through remote start and stop, data gathering for preventative maintenance, and incorporation into plant-wide control system.

The major avenue for communicating with the CMC is via MODBUS protocol over an RS422/485 hardware link. This requires hardware for the control panel, and a communications device with the appropriate driver software to perform the desired panel functions. The RS422/485 interface can communicate with any serial device that has an RS422 or RS485 port. The customer or his representative must write system software to suit his individual needs for remote control and monitoring. Since the customer writes this interface, the system can be as flexible as the customer desires.

Remote communications will be disabled through the UCM until the Remote Communications are enabled. Remote communications are enabled through the OUI. When this setting is set to “YES”, remote communications through the UCM will be possible.

Human Machine Interface (HMI) Systems

Air System Controller (ASC) and Air System Manager (ASM) are software packages available for compressors with CMC panels.

ASC and ASM are graphical integration software specifically developed for air compressor systems. Both provide energy management through load sharing and reduction of air bypass by using a minimum amount of energy to meet the system demand. The primary goal of both systems is to maintain stable system pressure, to integrate, monitor and control the compressed air system.

ASM is the integration of compressor control software in an off-the-shelf Supervisor Control and Data Acquisition (SCADA) package that is available from various manufacturers. The ASM provides more custom features than does ASC.

Both ASC and ASM provide a window into the compressor room by making the raw data from compressors and other equipment available to plant operators and managers in formats that are easy to understand.

Implementing the CMC in any HMI system may require additional hardware and/or software upgrade.

Direct CMC Communications with RS422/485

For the descriptions that follow, a serial device can be a Personal Computer (PC), Programmable Logic Controller (PLC), Distributed Control System (DCS) or any other device that can transmit, receive and interpret an RS422/485 formatted signal over a hardware link. In the descriptions that follow, the PC and PLC serial devices are not specific to manufacturers or operating systems.

There are many ways of interfacing to CMC control systems through an RS422/485 port. Most of the following methodologies are currently available; but please be aware, other possible configurations can exist.

All RS422/485 interfaces require custom interface software and custom application software. The interface software allows a specific serial device and operating system to transmit, receive and interpret data from a CMC control system. The application software

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tells the CMC control system what to do; for example, start compressor when ready, stop compressor after midnight and retrieve the current data and save to a disk file.

Currently there are hundreds of different serial devices using different operating systems and languages in the industrial equipment world. Therefore, the practicality of having an interface for many systems is limited. Custom interfaces must be written as required by the hardware and operating system used.

The capabilities of the hardware and the imagination of the developer only limit the application software. For example, one developer may have two compressors. In this application the developer wants a screen to display the compressor interstage pressure and temperatures for both machines with various other compressor data. A second developer has five compressors. He also wants to display the same data, but this time for all five machines. The only way this is done is through changing the application software (custom modification).

The developer may write functions to read and display data, log that data to some magnetic media for storage, change compressor set points, sequence the compressors for efficient operation and network additional devices, such as pumps, dryers, etc., into the system. All of these functions require specially written application software for the intended use.

The CMC-MODBUS Interface

Introduction

The CMC can communicate with other devices over a variety of communications standards. Supported standards, or protocols, include RS-232, IRBUS (Ingersoll-Rand Proprietary), and Modicon’s MODBUS. The built-in ports on the CMC’s optional Universal Communication Adapters access communications. The CMC-MODBUS Interface defines the message structure that a CMC uses to exist on a MODBUS network. This interface will allow the MODBUS network to gather information and control the compressor.

NOTE

Unless specified otherwise, numerical values (such as addresses, codes, or data) are expressed as decimal values in the text of this section. They are expressed as hexadecimal values in the message fields of the examples.

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CMC TECHNICAL REFERENCE MANUAL

In order to communicate over other types of networks, a network adapter must be used. The information presented in the following sections does not include MODBUS protocol details like framing messages and calculating checksums. This detailed information can be obtained from Schneider Automation’s MODBUS PROTOCOL Manual, Chapters 1 through 6. This can be obtained through the Internet at “www.modicon.com”.

Serial Modes

MODBUS Controllers can be setup to communicate on MODBUS networks using either of two transmission modes: ASCII or RTU. The CMC supports only the RTU mode. The user must specify the serial port communication parameters (baud rate, parity mode, etc.) during configuration of each CMC. The mode and serial parameters must be the same for all devices on a MODBUS network.

Slave Master Query
Slave
Master
Query

Device

Device

Address

Address

Function

Function

Code

Code

Data

Byte

Address

Count

Data

Data

CRC

CRC

Slave Master Query Device Device Address Address Function Function Code Code Data Byte Address Count Data

Response

Figure 3: MODBUS Messages

MODBUS Messages

A MODBUS network uses a master-slave relationship (Figure 3). The CMC always acts as a slave device. The slave cannot initiate a message, and returns a message (response) only to queries (reads) that are addressed to them individually. For example, a force coil command (write to module) that is broadcast to all MODBUS devices would not get a response. Responses are not returned to broadcast writes from the master.

Device Address

This address is the physical address of the Universal Communication Module (UCM) for the compressor. This address must be unique in the MODBUS network. The valid range for this address is 01-FF (hexadecimal). NOTE: 00 (hexadecimal) is reserved for broadcast. Configuration of the slave address is available through the Ingersoll-Rand Service Tool and will be provided by a certified Ingersoll-Rand Service Representative.

Function Code

The listing below shows the function codes that are supported by the CMC. Additional detail about each function is provided in sections that follow.

Function Code

Function Code

Function Name

(decimal)

(hex)

 
  • 1 Read Coil Status

01

 
 
  • 2 Read Input Status

02

 
 

03

  • 3 Read Holding Registers

 

04

  • 4 Read Input Registers

 
  • 5 Force Single Coil

05

 
 

06

  • 6 Preset Single Register

 
  • 15 Force Multiple Coils