Technology & Innovation…System Integration

Controls & Software Systems Mission

Our primary goal is to develop cost effective, reliable
and differentiated control products that provide energy
savings to our customers while positioning HIAS as the
leader in compressed air system solutions through
service connectivity.
 Strategy
• Continuously improve our machine control capabilities
• CMC – IMPROVED EFFICIENCY & TURNDOWN
• Ambient Control plus Parallel Valve Control
• Enhancements to CMC Hardware & Internal Software
• Develop control logic for all positive displacement,
dynamic system and mixed compressor systems
• Positive Displacement System Control
• Dynamic System Control
• Mixed Technology System Control
• Develop integrated software products which will control &
optimize the ENTIRE compressed air system
• Air System Controller (ASC)
• Air System Manager (ASM)
CMC Controller
Inside CMC Controller
 CMC Control Solution

Ingersoll-Rand’s CMC Control Solution

• Individual Compressor & System Control
– Precise Pressure Control
– Health Monitoring
• Networking & Connectivity
• Maximum Energy Savings – $$$$’s
• Information Management
• Internet / Intranet Monitoring through ASC
 CMC Control Solution
CMC Control Panel
• Supplied on all Centac Centrifugal Compressors
– Completes or as Retrofit
• Supplied on all PowerWorks™ Microturbines
• Supplied on all Sierra CD-26 Oil Free Rotary Screw Compressors
• Supplied on all IR Heat of Compression Dryers
• Available for Competitive Centrifugal Compressors
• Available for Reciprocating Compressors
– Ingersoll-Rand or Competitive Recips
• Utilized as an Input/Output Box to control & monitor accessories
– Dryers, cooling tower fans, pumps, flow meters, dew point monitors
CMC Panel
Operator User Interface (OUI)
• 240 x 128 pixel LCD graphic Display
• Tabbed Folders for ease of Navigation
– Status Bar with Compressor State
– Access to operating parameters
– Event log - 224 events on CMC
» 1004 with CMC Service Tool
– Commands
– Edit changes
– Alarms and trips
– Compressor status
• Left/Right/Up/Down/Return push
buttons
• Acknowledge/Reset push buttons
• Password Protected
• Multiple language support
CMC Panel
Base Control Module (BCM)
– PLC design (3 boards max per
panel)
– Inputs and Outputs per board
» 23 (4-20 mA) analog inputs
» 1 (0-5 amp) current
transformer
» 1 (0-5kHz) speed input
» 4 (4-20 mA) analog outputs
» 16 (24 vDC) discrete inputs
» 16 (120 VAC) discrete
outputs
– Ladder logic programming
» Portability to and from other
hardware devices
» Customizable functions
– Ultimate Flexibility
CMC Panel
Communications
• Universal Communication Module
(UCM)
– Connect as many as three cards
– Access to most OUI parameters (start,
stop, load, unload, monitor data, setpoint
changes)
• Protocols
– Modbus
– Modbus Plus Converter
– Allen-Bradley DF1 … with AB 1170-KF2
module connect to DH+ networks
– Modbus / TCP Ethernet
 CMC Features
• Continuous Health Monitoring
• Event Log
• Min/Max Load Proportional
Integral Settings
• Valve Characterization
• Check Valve Closed Indicator
• Precise Pressure Control
• Ambient Control™ plus Parallel
Valve Control Logic™
• Gas / Steam Turbine Drive
• Engine Drive Control
• Mass Flow Control
• Motor Failure Trip
• Anti-Surge Control
• Zero & Span of Instruments
• Edit Date, Time & Display
• Manual Valve Control
• Surge Sensitivity
• Surge Indexing™
• Surge Absorber™
• Modbus
• Modbus Plus
• Allen Bradley DF1
• Modbus / TCP Ethernet
• Listing of Consumable Spares
• Operating Instructions on Display
• Maintenance Notification
• Auxiliary Device Control – dryers,
traps, cooling water valves, etc.
• Analog Input Failure
 Typical CMC Scope
• Lube Oil Temperature RTD w/
Transmitter
• Seal Air Interlock with Panel
mounted Seal Air Switch
• Panel Mounted Cooling Fan
• N.O. Contact for Remote
Indication of common alarm &
trip
• N.O. Contact for Remote
Indication of Compressor Unload
• Lube Oil Pressure Transducer
• Motorized Demister Circuit
• Universal Communication
Module (UCM)
• Vibration Transmitter, per stage
• Control Air Pressure
• Pressure Transmitter for last stage
upstream of check valve
• Stage Data Package – Pressure &
Temperature per stage
• Electrical Control Package
– 1.0 KVA Transformer
– Prelube Pump Starter
– Lube Oil Heater Contactor
• “Local-Network” Selector Switch
 CMC Language & Units of Measure
Two Language and two Units of Measure sets are selectable from display

Languages
Arabic Bulgarian Chinese Croatian
Czech Danish Dutch French
Finnish German Greek Hungarian
Italian Korean Norwegian Polish
Portuguese Romanian Russian Slovakian
Slovenian Spanish Swedish Turkish

Units of measure are available upon request

 Local Machine Control
MP-3 Features
• EPROM (upgrade requires a
hardware change)
• 23 analog inputs, 12 digital
inputs
• Five custom inputs with generic
display names
• First out annunciation
• RS-232 communications
• One communication card per
compressor
• Utilizes Surge Switch
CMC Features
• Programmable logic (upgrade
requires a simple software change
• Up to 69 analog & 48 digital inputs
• All inputs can be custom named to
match the function
• Events log details last 224 events
•
Modbus, Modbus Plus & Allen-
Bradley DF-1 protocol
• Multiple communication cards
available per compressor
• Utilizes Analog surge detection
– Surge Absorber
– Surge Indexing™
Typical CMC Text

• Operating Instructions
• Spare Parts List
• Maintenance Notification
• Instruction Book Internet
address
• Service Phone Number
 CMC Screen Format

Folders
• Easy to use Folders
– System
SYSTEM INFO SETTINGS SERVICE
–
105.3 95
System Inlet
Info
Pressure Valve
–
105.0 0
Pressure Bypass
Settings
–
Page
Setpoint Valve

173.4
Motor Service
•
Current
Kilowatts (est.) 1199
Running Hours 11445 18-Feb-2004 12:00:00 Easy to scroll Page format
Status Bar
Loaded Load Selected
Remote 1/2 Page Number
• Status Bar on every page
• Compressor control Location
• User Friendly Design / Format
Compressor Compressor Compressor
Operating Control Status
State Location

Graphics Display Area Definitions

 CMC Analog Input Failure
SYSTEM INFO SETTINGS SERVICE
System
Pressure FAIL Inlet
Valve 95 • Automatic notification of exact input
Pressure
Setpoint 105.0 Bypass
Valve 0 device that fails
Motor
Current 173.4 • Notification if device failed high or
Kilowatts (est.) 1199
Running Hours 11445 18-Feb-2004 12:00:00 low
Loaded Alarm
Local 1/4
• Recorded in Event Log
SYSTEM INFO SETTINGS SERVICE • Allows for easy identification &
Event Name Time Date
1 Low Failure on AIN3 09:18:44 0720
replacement of device
• Enhanced Serviceability
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
6
Low Oil Press Alarm
Load key pressed
08:58:23
08:24:01
0720
0720 • Increased Reliability
7 Start key pressed 08:23:12 0720

Not Ready Alarm

Local 2/3
 SYSTEM INFO SETTINGS SERVICE CMC System Folder
System
Pressure 105.3 Inlet
Valve 95
Pressure
Setpoint 105.0 Bypass
Valve 0
Motor
Current 173.4 • System Folder provides information
Kilowatts (est.) 1199
Running Hours 11445 18-Feb-2004 12:00:00 about the compressor system
Loaded Load Selected
Remote 1/4 • Operating Parameters
SYSTEM INFO SETTINGS SERVICE – System Pressure
–
Press Temp Vib
Stage 1 30.1 95.8 0.25 Pressure Setpoint
Stage 2 106.6 93.5 0.22
Oil 18.8 115.3 – Inlet & Bypass Valve Positions
Water 80.1
– Motor Current, kW or Feet of head
•
Loaded Load Selected
Analog Input Page
– Stage Temperatures, Pressures &
Remote 2/4

SYSTEM INFO SETTINGS SERVICE Vibration Levels

•
Digital Inputs
Starter Feedback Digital Input & Output Pages
E-Stop Pressed
Low Seal Air
– Digital Inputs & Outputs

Loaded Load Selected

Remote 3/4
 CMC Info Folder
SYSTEM INFO SETTINGS SERVICE

•
Event Name Time Date
1 Low Oil Press Trip 09:18:44 0720 The Info Folder Contains
2 Low Oil Press Alarm 09:18:43 0720
3
4
Reset key pressed
Low Oil Press Trip
09:18:34
09:08:43
0720
0720
– Operator User Interface (OUI)
5 Low Oil Press Alarm 08:58:23 0720 Key Map
6 Load key pressed 08:24:01 0720
7 Start key pressed 08:23:12 0720
– Compressor Event Log
Not Ready Trip
Remote 2/3 • Time & Date Stamped
• 224 Events Displayed (1004
available)
SYSTEM INFO SETTINGS SERVICE
• All Alarms & Trips
Power On Hours 12338
Running Hours 11445 • First Out Annunciation
Loaded Hours 11223
Number of Starts 35 – The Hour Meters
• Power On Hours
BCM Ver: 3.10
• Running Hours
Loaded Load Selected
Remote 3/3 • Loaded Hours
• Number of Starts
• Base Control Module Version
Number
 SYSTEM

Password
INFO SETTINGS SERVICE

* * * *
CMC Settings Folder
Setpoint Changes Enabled
Language and Units
English degF mils amps psi
English degC mils amps kg/cm2
• Setting Folder is used for
Date, yyyy/mm/dd 2004/02/18
Time, hh:mm:ss 12:00:00 Compressor Setup
Loaded Load Selected
Remote 1/10 – User Performance Settings
SYSTEM INFO SETTINGS SERVICE
– Control Operating Parameters
MaxLoad (HLL), amps 400.0
– Analog Health Monitoring Settings
MinLoad for alarm & trip settings
User Setpoint (TL), amps 100.0
Control Setpoint, amps
Surge Index Increment, amps
100.0
1.0 – Control Mode Selection
Surge Absorber Enabled
Surge Sensitivity 9.0 – Setpoint changes
– Password Administration
Loaded Load Selected
Remote 2/10
– User Interface language
– kW Calculation Parameters
SYSTEM INFO SETTINGS SERVICE

PB IT D

Inlet Valve
rep/sec sec – Zero & Span Adjustments
Pressure 10.00 0.50 0.00
MinLoad (TL) 25.00 0.50 0.00
MaxLoad (HLL) 99.99 0.50 0.00
Bypass Valve
Pressure 10.00 0.50 0.00

Loaded Load Selected

Remote 3/10
 CMC Settings Folder
SYSTEM INFO SETTINGS SERVICE SYSTEM INFO SETTINGS SERVICE SYSTEM INFO SETTINGS SERVICE
Control Mode Alarm Trip DESCRIPTION ACTUAL MIN(4ma) MAX(20ma)
Manual Stage 1 Temperature 120.0 125.0 System Pres 105.3 0.0 200.0
Modulate Stage 2 Temperature 120.0 125.0 Oil Press 18.8 0.0 50.0
Autodual High Oil Temperature 120.0 125.0 Oil Temp 115.3 0.0 500.0
Reload Pressure, % of Setpoint 98 Low Oil Temperature 95.0 90.0 Water Temp 80.1 0.0 200.0
Unload Point, BV % Open 1 Stage 1 Vibration 0.75 0.95
Unload Delay Time, seconds 1 Stage 1 Temp 95.8 0.0 500.0
Stage 2 Vibration 0.75 0.95 Stage 1 Press 30.1 0.0 200.0
Oil Pressure 18.0 16.0

Loaded Load Selected

Remote 4/10 Loaded Load Selected
Remote 6/10 Not Ready
Loaded Load Selected
Remote 8/9

SYSTEM INFO SETTINGS SERVICE SYSTEM INFO SETTINGS SERVICE SYSTEM INFO SETTINGS SERVICE
DESCRIPTION ACTUAL MIN(4ma) MAX(20ma)
Starting Timer, seconds 20 Motor Power Calculation Settings
Stage 2 Temp 93.5 0.0 500.0
Coasting Timer, seconds 240 Motor Voltage 4000
Stage 2 Press 106.6 0.0 200.0
CT Ratio 60 Power Factor 0.98
Motor Failure Trip Enable
Inlet Valve Unload Position, % 15
Setpoint Ramp Rate, pressure/scan 5.0

Loaded Load Selected

Remote 5/10 Loaded
Loaded Load Selected
Remote 7/10 Not Ready Load Selected
Remote 9/9
 SYSTEM INFO SETTINGS SERVICE
CMC Service Folder
For parts or service contact your
local Ingersoll-Rand representative
at the following number:

39 02 950 56499
• The Service Folder contains

Ready
phone number to call for service
Load Selected
Local 1/7 & parts
SYSTEM INFO SETTINGS SERVICE • List of part numbers for
REPLACEMENT PARTS consumable parts
Part No. Description
67731168
67731158
Inlet Filter Element Primary
Inlet Filter Element Secondary
• Routine Start / Stop Procedures
•
67773499 Oil Filter
43083401 Demister Element Maintenance Instructions
68140490 Lubricant, 55 gallon drum
68140508 Lubricant, 5 gallon drum
•
Ready
Time based configuration tool
Load Selected
Local 2/7 that notifies the user of
SYSTEM INFO SETTINGS SERVICE scheduled maintenance
STARTING
1. Turn on the cooling fluid to all
– Inlet Filter
heat exchanger(s). Ventthe air
if not continuously vented. – Oil Filter
– Oil Change
2. Open the valve in the nstrument
air line to the control panel.
3. Check the seal air pressure gauge.
seal air pressure must be between

Ready Load Selected

Local 3/7
 CMC Service Folder

SYSTEM INFO SETTINGS SERVICE SYSTEM INFO SETTINGS SERVICE

Inlet Filter
Control Mode Service Configuration
System
Pressure 105.3 Inlet Valve 95
105.0 0
Hours Left Before Service
Manual 730
Modulate
Service Schedule, hours 2190 Pressure SERVICE REQUIRED
Bypass
Autodual Inlet
Setpoint Filter Element
Valve

173.4
Reload Pressure, % of Setpoint 98 Due in: 109 Loadded Hours
Reset Notification On Motor
UnloadTime
Point, BV % Open 1 Current
Unload Delay Time, seconds 1 Clear Go To
Kilowatts (est.) 1199
Running Hours 11445 18-Feb-2004 12:00:00

Ready
Loaded
Load Selected
Local
Remote 4/7
4/10 Loaded Load Selected
Remote 1/4
 CMC – Software & Features
• Centac Limit Amp Control – Standard on all machines
• Ambient Control™ plus Parallel Valve Control™ (optional)
• Mass Flow Control (optional)
• Gas or Steam Turbine Control
• Engine Drive Control
• Valve Characterization Capability
• Enhanced Surge Absorber™
• Operating Instructions on Display Capability
• Maintenance Notifications
• ASC/ASM Integration (optional)
 CMC Features
• Designed by I-R development engineers
• I-R owned hardware/software
• Precise control through multiple PID loops
• Monitors up to 69 analog inputs, 12 analog outputs,
48 digital inputs 48 digital outputs
• Analog surge sensing (pressure and current)
• Surge Absorber (partial unload only)
– Energy Savings
– System Reliability (Maintains System Pressure)
 CMC Features

• Surge Indexing
• Time/date stamped event log (224 events)
• Modbus and Allen-Bradley DF1 communications
• Motor overload protection
• Coast down timer to prevent early motor starting
• Adjustable ramp rates minimize system upsets
• Graphical LCD display
 CMC Advanced Features
• Mass flow control (optional)
• Adaptive transition between control loops
– Ambient Control plus Parallel Valve Control Logic
• Surge prevention through kW or head based
methods
• Additional language / units capabilities
• Control of steam turbine or engine drivers
• Expanded math capabilities
• Multiple communications cards capable
• Control of accessory equipment
• Portable to industrial PLC platforms
 Ambient Control™ plus Parallel Valve
Control™ Logic
• More effective transition between control loops
– Both inlet & bypass valve work together
• Increases throttle range by running closer to the surge line
• Reduces throttle horsepower by 4 – 12%
• Utilizes Polytropic head to control surge (MinLoad Variable)
• Saves energy by reducing blowoff
– More useful and effective turndown capability.

The best control for ANY centrifugal compressor

 Natural Curve
Pressure

T1 hot

MinLoad
Control
Point

Reduced turndown 0° F
Due to Temperature 60°F
Variations 95°F

Flow (Motor Current, KW, Mass Flow)

 Amps vary with voltage
Motor Current, amps
Natural
Surge Previous MinLoad
Transition Method (Amps)
Points

MinLoad
Setpoint

Curve "marginally" affected by

changes in T1 at a constant P2!

Capacity, scfm
 Savings over Amps
Natural
Motor Power, kW
Surge
Points Previous MinLoad
Transition Method (KW)

MinLoad
Setpoint

Curve "marginally" affected by

changes in T1 at a constant P2!

Capacity, scfm
 Natural
Surge For a given set of
Point
Head, ft-lb/lb

hardware (impellers
and diffusers) running
MinLoad at a constant speed,
Setpoint this curve is fixed

Curve unaffected by changes in

T1, P1 or P2 !

Capacity, icfm
 Ambient Control Option
Polytropic Head Equation
K-1
P K

Head = ZRT1( ) -1
K
P
2
K-1
1

~
Head = T1P 2

Z = Compressibility of Air = 1
P 1
R = Gas Constant
K = Adiabatic Component
Pressures in Absolute
Temperature in Rankin
 Surge Line

Surge Line is constant regardless of

Changes in inlet temperature or discharge
Pressure. It is strictly dependent on
The work the unit is capable of
Head

Performing.

ICFM
 Controls – Customer Savings Solution
Customer Benefits


Ambient Control™ plus
Surge Line
Parallel Valve Control™

CMC Limit Amp Control

Discharge Pressure (PSIG)

IR MP-3 or
Competitive Reliability
Controls Solution

The closer to surge line you get … Energy

Saving
Solution

Better
precision
Compressor Flow, CFM
Improve
part-load More

Millions $$
efficiency uptime

Reduced
Power, kW

… the less power you consume! energy Efficient

consumption control

Lower
operating
4 – 12% costs
Energy Savings

Capital Energy Lost Production

 CMC Retrofits
• MP-3 NO longer available
– No Boards
– No Faceplates
– No Repairs (typical board repairs last only 90 days)
• CMC Retrofits available for IR and competitive units
• Super Stock Pricing through Aftermarket
• Installation time approx. 2 - 4 days
• Allows for system integration communications

Need to proactively promote Retrofits to avoid downtime

 CMC Review
• Ambient Control™ plus Parallel Valve™ Control Logic – software only
– Available on all installed CMC’s (software upgrade only)
– Available on all new machines (optional pricing)
• CMC must have Stage Data Package
• Service Certification – Advanced Course 451 Required
• CMC 2004
– More expanded capability allowing additional features
• Instructions on CMC
• Maintenance Notifications on CMC (Change oil, filters, etc.)
• Service Phone Number
• Spare Parts List
• CMC Retrofits for Centac and Competitive Units
– Required for Air System Controller and Air System Manager
– BEST Control Logic and Reliability in the industry
CMC NEMA 4X – Stainless Steel
Allen Bradley Compactlogix with CMC
Valve Logic
CMC Installed on Joy - MSG
CMC Installed on Demag
CMC Installed on Joy
THANK YOU