SmartAir Master

Intelligent interconnected control

GB USA Id. Nr. 100016248 / 06
Basis: German operating instructions 100016247/06

Valid for software versions 2.0x

Subject to technical change without notice.

 1. Foreword

1. F oreword

1.1 Intended use 1.2 Maintenance

The control has been designed in accordance with good Servicing

engineering practice and accepted safety standards.
Nevertheless, its use may constitute a risk to the health Please contact your authorized CompAir dealer in the
and safety of users or to third parties or cause damage event of a fault or for spare parts. In case of damage,
to the machine or to other items, if our fully trained personnel will ensure that a quick and
proper repair is carried out using original CompAir
it is not used for the purpose for which it was spare parts. Original CompAir spare parts are
intended manufactured using state-of-the-art technology, thereby
it is operated by untrained personnel guaranteeing the continued reliable operation of the
it is improperly modified or changed unit.
the safety instructions are not observed.
In case of queries
Therefore, any person entrusted with the operation,
maintenance or repair of the machine must read and Please note the data on the typeplate of your control.
observe the safety instructions. This must be confirmed For queries or spare parts orders, please state the
by signature if required. compressor type indicated on the nameplate, the
identification no. and the year of construction. This
In addition: information will ensure that you receive the right
information or required spare part.
applicable accident prevention regulations,
generally accepted safety rules and
national regulations

must be observed.

The control must only be used in full working order and

in accordance with its intended use and the instructions
set out in the operating manual. All operators must be
fully aware of the risks involved in operating the control
and must observe all safety instructions. Any functional
defects, especially those with safety implications, must
be rectified immediately.

The control is designed exclusively for regulating

systems which generate compressed air. Using the
control for any other purpose is contrary to its intended
use. The manufacturer/supplier cannot be held
responsible for damage resulting from such use. The
risk of such misuse lies solely with the user.

Operation of the control within the limits of its intended

use also includes observation of the operating
instructions and compliance with the inspection and
maintenance instructions.

3
1. Foreword

1.3 Notes Guarantee

Operate the control only if you have familiarized
General yourself with the control and these operating
instructions.
These operating instructions are intended to familiarize
the user with the control and its intended use. The CompAir Drucklufttechnik cannot be held responsible
instructions contain important notes on how to operate for the safe operation of the control if it is used in a
the control safely, properly and cost effectively. manner which does not correspond to the intended use,
Observing these instructions helps to avoid risks, to or for applications other than those mentioned in these
reduce repair costs and downtimes and to increase the instructions.
reliability and service life of the control.
Warranty claims will not be accepted in the case of:
The operating instructions apply in addition to
applicable national rules and regulations regarding the Operating errors
prevention of accidents and environmental protection. Use of spare parts other than CompAir original spare
They must be kept available at all times at the place of parts
use of the control. The operating instructions must be Modifications and changes to the installation.
read and observed by any person carrying out work in
connection with the control, e.g. operation, including The above exclusions do not extend the scope of the
setting up, fault-finding during operating cycles, warranty and liability conditions of the general terms
disposal of production waste, care, service, and and conditions of CompAir Drucklufttechnik.
disposal of waste fuels and consumables, upkeep
(maintenance, inspection, repair), transport. Any unauthorized changes to the control or the
installation of components not approved by the
In addition to the operating instructions and the binding manufacturer will result in the withdrawal of the CE
regulations for the prevention of accidents which apply mark. As a consequence, any liability and warranty
in the country and place of operation of the control, the claims will not be accepted by the manufacturer.
generally accepted technical rules for safe and proper
working must also be observed.
Safety instructions

Danger
The safety instructions in chapter 3 of the operating
instructions must be strictly observed.

4
 2. Table of contents

2. T able of contents

1. Foreword ...................................................................................................................................................... 3

1.1 Intended use ........................................................................................................................................... 3

1.2 Maintenance............................................................................................................................................ 3
1.3 Notes ....................................................................................................................................................... 4

2. Table of contents ......................................................................................................................................... 5

3. Safety regulations........................................................................................................................................ 7

3.1 Identification of safety instructions .......................................................................................................... 7

3.2 General safety instructions ..................................................................................................................... 7
3.3 Changes and modifications..................................................................................................................... 8
3.4 Installation and normal operation............................................................................................................ 8
3.5 Special work/maintenance ...................................................................................................................... 9
3.6 Warning of special risks ........................................................................................................................ 10

4. Features of the system.............................................................................................................................. 11

4.1 Functions............................................................................................................................................... 11
4.2 Overview ............................................................................................................................................... 12
4.3 Example of a compressed air station with SmartAir Master ................................................................. 13
4.4 Technical data for the SmartAir Master ................................................................................................ 15
4.5 Scope of delivery................................................................................................................................... 16
4.6 System components.............................................................................................................................. 16

5. Operation.................................................................................................................................................... 18

5.1 First commissioning .............................................................................................................................. 18

5.2 Main display .......................................................................................................................................... 19
5.3 Compressor information........................................................................................................................ 20
5.4 SD card ................................................................................................................................................. 20
5.5 Air station information ........................................................................................................................... 21
5.6 Controlling the air station ...................................................................................................................... 22
5.7 Settings ................................................................................................................................................. 24
5.8 Messages .............................................................................................................................................. 27
5.9 Codes .................................................................................................................................................... 28

6. Compressor module (STD) ....................................................................................................................... 29

6.1 Functions............................................................................................................................................... 29
6.2 Technical data....................................................................................................................................... 29
6.3 Scope of delivery................................................................................................................................... 29
6.4 Connection to the SmartAir Master....................................................................................................... 30
6.5 Connection to the compressor .............................................................................................................. 30
6.6 Parameters............................................................................................................................................ 32

5
2. Table of contents

7. Compressor module (VSD) ....................................................................................................................... 33

7.1 Functions............................................................................................................................................... 33
7.2 Technical data....................................................................................................................................... 33
7.3 Scope of delivery................................................................................................................................... 34
7.4 Connection to the SmartAir Master....................................................................................................... 34
7.5 Connection to the compressor .............................................................................................................. 34
7.6 Parameters............................................................................................................................................ 37

8. Extension module...................................................................................................................................... 38

8.1 Function ................................................................................................................................................ 38

8.2 Technical data....................................................................................................................................... 38
8.3 Scope of delivery................................................................................................................................... 38
8.4 Connection to the SmartAir Master....................................................................................................... 39
8.5 Connection of external signals.............................................................................................................. 39

9. Webserver module..................................................................................................................................... 41

9.1 Function ................................................................................................................................................ 41

9.2 Technical data....................................................................................................................................... 41
9.3 Scope of delivery................................................................................................................................... 41
9.4 Connection to the SmartAir Master....................................................................................................... 42
9.5 Connection to the net work ................................................................................................................... 42
9.6 Access via browser ............................................................................................................................... 42
9.7 Configuration......................................................................................................................................... 42

Annex .............................................................................................................................................................. 43

Annex A: Wiring diagrams............................................................................................................................ 43

Annex B: Module settings ............................................................................................................................ 48
Annex C: Technical data of the line pressure sensor .................................................................................. 54
Annex D: Drill templates for mounting ......................................................................................................... 55
Annex E: Spare parts and accessories........................................................................................................ 57

6
 3. Safety instructions

3. Safety r egulations

3.1 Identification of safety instructions 3.2 General safety instructions

CompAir cannot be held liable for any damage or injury Organizational measures
resulting from of the failure to observe these safety
instructions or negligence of the usual care and The operating instructions must be kept available at all
attention required during handling, operation, times at the place of use of the control (in the tool
maintenance or repair, even if this is not explicitly compartment or box provided for such a purpose). In
mentioned in these operating instructions. addition to the operating instructions, other generally
applicable legal and other mandatory regulations
If any of the regulations contained in these instructions - relating to accident prevention and environmental
especially with regard to safety – does not correspond protection must be observed. Such compulsory
to the local legal provisions, the stricter of the two shall regulations may also cover the handling of hazardous
prevail. materials or the issuing/ wearing of personal protective
equipment, or traffic regulations.
These safety instructions are general in nature and
apply to various types of machines and equipment. Instructions regarding supervisory responsibility and
Therefore some references may not apply to the unit(s) duty of notification in relation to internal factors, for
described in these instructions. example regarding work organization, sequences of
operations, duties and responsibilities, shall be
maintained in addition to the operating instructions.
Danger
Passages marked with this sign indicate a risk of Personnel asked to work on the machine must have
injury to personnel. read the operating instructions and in particular the
chapter on safety instructions before starting work.
Important Reading the instructions after work has begun is too
late. This applies in particular to persons working only
Passages marked with this sign indicate a risk of occasionally on the machine, e.g. for setting up or
damage to machinery or parts of machinery. maintenance.

Note Regular checks must be made to ensure that personnel

are observing the operating instructions and in
Passages marked with this sign provide technical particular the safety requirements
information on an optimal cost-effective use of the
machine. For safety reasons, long hair must be tied back or
otherwise secured, garments must be close-fitting and
no jewellery must be worn. Injury may result from being
caught up in the machinery or from rings catching on
moving parts. As necessary or as required by
regulations, personal protective equipment should be
used.
Observe all safety and warning notices attached to the
control.
Ensure that safety instructions and warnings attached
to the control are always complete and perfectly legible.

If changes to the machine/unit or its operating

behaviour which could have safety implications are
observed, stop the control immediately and report the
fault to the appropriate department/person.

Spare parts must comply with the technical

requirements specified by the manufacturer. This is
ensured by the use of original spare parts.

Follow the prescribed intervals or those specified in the

operating instructions for routine checks and
inspections. For maintenance work, tools and
equipment appropriate to the task must be used.
Personnel must be made familiar with the location and
operation of fire extinguishers. Observe all fire-warning
and fire-fighting procedures. Limit values (pressures,
time settings, etc.) must be permanently displayed.

7
3. Safety instructions

Selection and training of personnel; 3.4 Installation and normal operation

basic responsibilities
Installation
Work on/with the control must be carried out by reliable
personnel only. Statutory minimum age limits must be In addition to general operating requirements laid down
observed. by local authorities, the following specific instructions
Employ only trained or instructed personnel and clearly must be observed.
set out individual responsibilities for operation, setup,
maintenance and repair. For the lifting of a control cabinet, suitable lifting gear
Ensure that only authorized personnel work on or with must be used which meets local safety regulations. All
the machine. loose or slewable parts must be safely fixed before the
Define the machine operator's responsibilities, giving unit can be lifted. It is strictly prohibited for personnel to
the operator the authority to refuse instructions by third remain within the danger zone of a lifted load.
persons that are contrary to safety regulations.
The correct method of lifting (according to the operating
Do not allow persons to be trained or instructed or instructions of the load suspension device) must be
persons taking part in a general training course to work ensured.
on or with the control without being continuously
supervised by an experienced person. If a remote control is used, the system must carry a
clearly visible notice as follows: Attention: This system
Work on the electrical equipment of the control must be is operated by remote control and can start up without
carried out only by a skilled electrician in accordance prior warning!
with electrical engineering rules and regulations.
As an additional safety measure, persons who start
remotely controlled systems must take adequate safety
precautions to ensure that nobody is checking or
3.3 Changes and modifications working on the system. A label with a corresponding
warning notice must be attached to the remote control
equipment.
Do not make any changes, modifications or
attachments to the control which could affect safety
If a system comprises several compressors, hand-
without the supplier's prior permission.
operated isolator valves must be installed in order to be
able to shut off each machine individually. When
Unauthorized changes to the unit are not permitted for
working with pressure systems, do not rely on the
safety reasons.
effectiveness of check valves alone to isolate these
systems.
Original parts were designed specifically for this unit.
We wish to point out that we have not approved and will
Safety equipment, protective covers or insulation must
not approve parts and special accessories which have
not be removed or modified. Any pressure vessel which
not been supplied by us. The installation and/or use of
is located outside the system, the permissible operating
such products can therefore affect active and/or passive
pressure of which is higher than atmospheric pressure
safety.
and which is fitted with two or more pressure supply
lines, must be provided with additional safety equipment
The manufacturer cannot be held liable for damage
that will automatically prevent the pressure from
resulting from the use of non-original parts or special
exceeding the permissible operating pressure by more
accessories.
than 10%.

Electrical connections must comply with local

regulations. Power units must be connected to earth
and protected from short-circuits by means of fuses.

Normal operation
Take all necessary precautions to ensure that the
system is used only when in a safe and reliable state.

Operate the system only when all protective equipment,

emergency shut-off equipment, soundproofing elements
and extraction devices are in place and in full working
order.

8
3. Safety instructions

Make regular checks to ensure that: Maintenance/rectification of faults

all means of protection are correctly fitted The employer must inform personnel of the dangers
and fixed, possibly arising during the repair and maintenance of
all fittings are firmly tightened, the system and of measures to avoid them; personnel
all electrical cables are connected correctly and are must observe all measures for safety at work. Safety
in good condition, equipment for the prevention or elimination of danger
the safety mechanisms are in full working order. must be maintained regularly and its function checked
at least once a year. Faults observed must be rectified
Avoid any working practices which may compromise immediately and/or reported to the responsible person.
safety. Access panels, etc. must be kept closed during
operation. If a fault occurs, stop the machine/unit Only use original spare parts.
immediately and lock it. Have any defects rectified Only carry out maintenance and repair work when the
immediately. system is not in operation and the power supply
disconnected. Ensure that the power unit cannot be
Observe the start-up and stopping procedures and the switched on inadvertently.
control displays according to the operating instructions.
Before removing or opening pressurized components,
Before starting up or setting the machine in motion, positively isolate any source of pressure and
ensure that nobody is at risk. depressurize the entire system.
If work which produces heat, flames or sparks has to be
carried out on a machine, the adjacent components
3.5 Special work/maintenance must be protected by means of non-inflammable
material.
Precautions Before releasing the system for operation after
maintenance or overhaul, check that the operating
Observe the adjusting, maintenance and inspection pressures, temperatures and time settings are correct
activities and intervals set out in the operating and that the regulating and shutdown equipment is
instructions, including information on the replacement of working properly.
parts and equipment. These activities may be carried
out by skilled personnel only. Motor, air filter, electrical components and regulating
equipment must be protected from the ingress of
Brief the operating personnel prior to starting special humidity, e.g. when cleaning the system by means of a
operations or maintenance work. Appoint a person to steam jet.
supervise the activities. Never use etching solvents which could attack the
materials used.
Maintenance and repair work may only be carried out
under the supervision of a person who is qualified for Check the accuracy of the pressure indicator at regular
this work. intervals. When the permissible tolerance limits are
exceeded, these devices must be replaced.
If the machine/unit is completely shut down for
maintenance and repair work, it must be secured to The fastening of loads and the instructing of crane
prevent inadvertent restart: operators should be entrusted to experienced persons
only. The person giving the instructions must be within
• Lock the main command elements and remove the sight or voice contact with the operator. For carrying out
key and/or overhead assembly work always use specially designed
• Attach a warning sign to the main switch. safety ladders and working platforms. Never use
machine parts as a climbing aid. Wear a safety harness
Always use the correct tools for maintenance and repair when carrying out maintenance work at elevated
work. heights.

Never use inflammable solvents or carbon tetrachloride Keep all steps, handles, handrails, platforms, landings
to clean parts. Take precautions against toxic vapours and ladders free from dirt, snow and ice. Always re-
from cleaning agents. tighten screwed connections which have been loosened
for maintenance and repair work. If the setup,
In any work concerning the operation, conversion or maintenance or repair requires the removal of safety
adjustment of the control and its safety devices or any equipment, this equipment must be remounted and
work related to maintenance, inspection and repair, checked immediately after completion of these
always observe the start-up and shutdown procedures activities.
set out in the operating instructions and the information Ensure that consumables and replacement parts are
on maintenance work. disposed of in a safe and environmentally friendly
manner.
Ensure that the maintenance area is adequately
secured.

9
3. Safety instructions

3.6 Warning of special risks Gas, dust, steam, smoke

Carry out welding, flame-cutting and grinding work on
Electrical power the control only if this has been expressly authorized,
as there may be a risk of explosion and fire.
Attention: external voltage:
Before carrying out welding, flame-cutting and grinding
If external electrical circuits which cannot be cut out by operations, clean the control and its surroundings to
the main switch are connected to the control, these remove dust and inflammable substances and make
external electrical circuits must be identified in sure that the premises are adequately ventilated (risk of
accordance with EN 60204. Warning signs must be explosion).
fixed near the main switch and near these electrical
circuits. In addition, these conductors must be laid Adhere to the regulations in force for the place of
separately and/or colour-coded. operation.

Use only original fuses with the specified current rating. Observe any existing national regulations if work is to
Switch off the control immediately if a fault occurs in the be carried out in confined spaces.
electrical system.

Work on the electrical system or equipment may only

be carried out by a skilled electrician or by specially
instructed personnel under the control and supervision
of such an electrician and in line with the relevant
electrical engineering rules.

If regulations require, the power supply to parts of

machines and plants on which inspection, maintenance
and repair work is to be carried out must be cut off.
Before starting any work, check the de-energized parts
for the presence of power and earth or short-circuit
them in addition to insulating adjacent live parts and
elements.

The electrical equipment of the control must be

inspected and checked at regular intervals. Defects
such as loose connections or scorched cables must be
rectified immediately.

Necessary work on live parts and elements must be

carried out in the presence of a second person who can
cut off the power supply in case of danger by operating
the emergency shutdown or main power switch. Secure
the working area with a red-and-white safety chain and
a warning sign. Use insulated tools only.

Before starting work on high-voltage assemblies and

after having cut off the power supply, the feeder cable
must be earthed, and components such as capacitors
short-circuited with an earthing rod.

10
 4. Features of the system

4. F eatures of the s ystem

SD card drive
4.1 Functions
to log data from the compressed air station.

The SmartAir Master is an intelligent interconnected Battery buffered real time clock
control for up to 12 compressors, which is responsible
for keeping a pressurized air network within a relatively Code-protected menus
small pressure band in the interests of energy to adjust all necessary parameters.
efficiency.
RS485 interface
An optimal use and display of the compressor station The customer can use a separate RS485 interface
and states is provided by the colour graphic display with to communicate with the SmartAir Master.
touch function. The ModBus-RTU protocol is implemented as
standard; an optional PROFIBUS module can be
The main functions and features of the SmartAir Master installed if required.
are as follows:
Extension modules
Choice of language settings Extension modules can increase the number of
programmable inputs and outputs. Up to 4
Guided commissioning extension modules can be added to the SmartAir
The user is guided through the necessary steps for Master.
commissioning a station, compressor or extension
module. Help functions
to show wiring diagrams and necessary
Connection of compressors adjustments to the compressor controls for
CompAir compressors are directly connectable via operation via the SmartAir Master.
a data line (see chapter 4.2).

For all other compressors, an appropriate Abbreviations

compressor module has to be used: In this document and in the display of the SmartAir
Master, the following abbreviations are used:
Compressor module (STD)
For connecting a compressor with fixed speed or AI-x = Analog input no. x
half/full load control. DI-x = Digital input no. x
DO-x = Digital output no. x
Compressor module (VSD)
For connecting a compressor with speed AC = Alternating current
regulation. DC = Direct current
UC = Universal current (AC or DC)
Control of compressors COM = Common connection e.g. at a
Switching of the compressor based on the change-over contact.
calculated air need to maximize the energy-efficient
operation of the compressors. STD = Standard
VSD = Variable Speed Drive
User-defined profiles
A profile is a set of parameters (i.e. pressure band
and compressor priorities) corresponding to Overviews
different operating requirements of the station. Section 4.2 "Overview" shows all system components
Up to 12 profiles are definable and can be with the appropriate order numbers.
activated by the timer control or a programmable
digital input. Section 4.3 "Example of a compressed air station with
SmartAir Master" shows an example of an installation.
Current station status display
Touch controls can display further information
about the station (i.e. statistics, events, etc.)

Current compressor status display

Touch controls can display further information
about each compressor (i.e. operating hours,
events, etc.)

Programmable inputs and outputs

Programmable inputs and outputs can be used to
control the stations and/or output status messages
to the customer.

11
4. Features of the system

4.2 Overview

SmartAir Master (100016136)

Compressor
Analog input AI-1 module (VSD)
Line pressure sensor (100003136) (100016222SIM)
+
Analog input AI-2
Compressor Connection plug
Programmable (Line pressure / Volume flow / Temperature / Dew point)
module (STD) SureScan
RS485-1 (100016166) (ZS1055047)

RS485-2

DELCOS 1000 DELCOS Pro

DELCOS 3100 DELCOS XL

RS485-3 SureScan-L SureScan-LSR

(Customer)

Digital input
DI-1..3 SD card
Digital outputs (100016138)
DO-1..2
2x2x0,5..1,5mm²
For spare parts and twisted pair and
Accessories screened
see "Annex E" (100003989)

Compressor Compressor
module (STD) module (VSD)
(100016166) (100016222SIM)

PROFIBUS- Webserver ModBus-RTU Extension

module module module
(100016156) 230V/50-60Hz 230V/50-60Hz
(ZS1055779) (100016226)
110V/50-60Hz 110V/50-60Hz Standard or Speed regulated
(ZS1055780) (100016230) half/full compressor
compressor (Three-phase asynchronous
Digital inputs DI-1..8
Digital outputs DO-1..2 motor with max. 500A rating
Analog inputs AI-1..2 current)
Fig. 1

12
4. Features of the system

4.3 Example of a compressed air station with SmartAir Master

ModBus-RTU
PROFIBUS (optional)
RS485-3 Customer PLC
SmartAir Master or digital I/O to read datas Extension module
Dig.input
RS485-2 RS485

Dig. input DI-1

Selection switch
to activate a profile
Dig. Eingang DI-2

Dig. Input

Dig. input
Analog input AI-1 Selection switch
to activate a profile
RS485-1

Line pressure
sensor

L30 L30 L45SR

Compressor 1 Compressor 2 Compressor 3 Recevier Dryer Filter

Fig. 2

13
4. Features of the system

Fig. 2 shows an example of a compressed air station

with a SmartAir Master:

The connection of the compressors with DELCOS

3100 is directly via the RS485 interfaces.

The size of the compressed air receiver equals the

parameter "Receiver volume" that has to be set on
the SmartAir Master.

A programmable digital input at the SmartAir

Master can monitor a warning or error message
from a dryer.

A further programmable digital input at the

SmartAir Master can be used to set a selection
switch, for example, for switching to a different
profile (e.g. for pressure reduction).

The RS485-3 interface allows the customer to read

data from the SmartAir Master, e.g. the status of
the compressors, and to activate a profile or reset a
statistics counter, for example.
The data is transmitted via the ModBus protocol.
An optional PROFIBUS interface can be retrofitted
if required.

Communication to the customer is also provided by

digital inputs or outputs.

If the distance to further filters, dryers or selection

switches is too great or if the number of inputs and
outputs on the SmartAir Master is too small, an
extension module can be added.

14
4. Features of the system

4.4 Technical data for the SmartAir Master Connection of extension modules
Interface: RS485-2
Cable type: 2x2x0.5..1.5mm²
Electrical connection twisted pair and screened
Wiring length: max. 1200m
System: 1~/N/PE Devices: max. 4 extension modules
Voltage: 110/230V +/-10% 50/60Hz
Adjust control transformer accordingly
Power: 16VA Customer interface
Cable: 1.0 .. 2.5 mm² / AWG 17..13
Fuse: max. 10A Interface: RS485-3
Cable type: 2x2x5..1.5mm²
twisted pair and screened
Display Wiring length: max. 1200m
Protocol: ModBus-RTU
Type: Colour graphical display PROFIBUS (optional)
Resistive touch panel Baudrate: 2400..38400 (adjustable)
above the display
Screen size: 5.7" (diagonal)
Resolution: QVGA (320x240)
Memory card
Type: SD card
Analog inputs AI-1..2 Class: max. Class 2
Size: max. 2GB
Type: 4..20mA
Input voltage: 24VDC
Ambient temperature
AI-1: Passive / Active dep. on connection
AI-2: Passive / Active dep. on connection Operation: 0..55°C
Storage: -25..75°C

Wiring length: max. 500m

>500m: use amplifier EMC conformity
Immission: DIN EN 61000-6-3
Digital inputs DI-1..3 Immunity: DIN EN 61000-6-2

Wiring length: max. 20m

>20m: use coupling relay Dimensions (W x H x D)
380 x 300 x 155 mm
Digital outputs DO-1..2
Type: Potential-free relay outputs Type of construction / Protection
(change-over contacts)
Load: max. 240V / 1A Steel plate housing / IP54

Connection of compressors Mounting

Interface: RS485-1 Wall mounting

Cable type: 2x2x0.5..1.5mm²
twisted pair and screened Weight: 11 kg / 24 lbs
Wiring length: max. 1200m
Devices: max. 12 compressors

15
4. Features of the system

4.5 Scope of delivery SmartAir

Master
C1 C2 C3 Correct
After receipt, check the scope of delivery: C1 . .C3
SmartAir Master control cabinet
incl. cable glands
SmartAir
2 coded plugs (4-pin) Master
for the RS485-1 and RS485-3 interfaces
Correct
Line pressure sensor C1 C2 C3

Plug kit to connect the compressor controllers

SD card
SmartAir Incorrect
Wiring diagram Master
C1 C2 C3

CD-ROM with manuals

Quick Start Guide incl. drill template for mounting

The drill template can also be found in the annex. SmartAir
Master

4.6 System components Incorrect

C1 C2 C3

Analog inputs
Fig. 3 – Wiring of the compressor station
There are two analog inputs (4..20mA) on the SmartAir
Master:

Analog input AI-1 Connecting CompAir compressors

This is fixed assigned to the "Line pressure 1" function.
The scaling is adjustable in the menu "Adjustments CompAir compressors can be connected directly to the
SmartAir Master " menu, "Inputs/Outputs" sub-menu. SmartAir Master via their RS485 interfaces.
Either a passive or active 4..20mA sensor can be used.
Note
Analog input AI-2 In order to operate correctly, the appropriate minimum
This input can be set to different functions and scalings software version must be installed on the controllers.
in the menu "Adjustments SmartAir Master" , The minimum software versions are listed in the
"Inputs/Outputs" sub-menu. overview in section 4.2.
Either a passive or active 4..20mA sensor can be used.
Note that the RS485 interfaces of the compressor
Information on how to connect the analog inputs can be controls have been set to the correct values for
found in the annex.
Protocol
Baudrate
General information on connecting compressors Address
Compressors are connected to the SmartAir Master via Further information on the connections (wiring diagrams
the RS485-1 interface only. and compressor control settings) can be found in the
annex.
The RS485 interfaces of the SmartAir Master and the
compressor controls should form a bus structure, i.e. all
compressors are connected in series, starting from the
SmartAir Master.

Fig. 3 shows examples of correct and incorrect wiring of

the compressor station.

16
4. Features of the system

Connecting other compressors Extension modules

Compressors from other manufacturers can be An extension module is used to expand the number of
connected to the SmartAir Master via compressor programmable inputs and outputs of the SmartAir
modules: Master.

Compressor module (STD) The RS485-2 interface of the SmartAir Master can
Compressors with fixed speed or half/full load connect a maximum of 4 extension modules.
control can be connected with this module.
The extension modules are available in two versions
Compressor module (VSD) which differ only in terms of their power supply:
Compressors with speed regulation can be
connected with this module. Version 1: 230V AC / 50-60Hz
Version 2: 110V AC / 50-60Hz
Further information on the modules can be found in
chapter 6 "Compressor module (STD)" and chapter 7 An extension module adds
"Compressor module (VSD)" respectively.
8 digital inputs (DI-1..8)
2 digital outputs (DO-1..2)
Programmable inputs and outputs 2 analog inputs (AI-1..2)

The SmartAir Master has to the SmartAir Master.

3 digital inputs (DI-1..3) Further information can be found in chapter 8

2 digital outputs (DO-1..2) "Extension modules".

These are routed to the terminal strip and can be

assigned to various functions.
Further information on programming can be found in the
description of the "Settings" menu in section 5.7.

ModBus-RTU / PROFIBUS interface

A separate RS485 interface is provided for customer

use to read the current operating status of the SmartAir
Master (RS485-3).

The ModBus-RTU protocol is implemented as standard.

Details of the protocol and the addresses can be found
in a separate document ("SmartAir Master Programmer
guide ModBus-RTU").

To enable the SmartAir Master to be connected to a

PROFIBUS network, an optional PROFIBUS module
can be installed in the SmartAir Master control cabinet.

For the PROFIBUS module too, details of the protocol

and the addresses can be found in a separate
document ("SmartAir Master Programmer guide
PROFIBUS").

17
 5. Operation

5. Operation

5.1 First commissioning

Note

Note In order to operate correctly, the appropriate minimum

software version must be installed on the DELCOS Pro
This section describes the behaviour of the control and DELCOS 3100. The minimum software versions
when it is booted up for the first time after delivery. are listed in the overview in section 4.2.

After the first commissioning, this behaviour can be

initialized every time by entering a code (see section
5.9 "Codes”).

Note
Do not touch the display when switching on the power
supply, otherwise the SmartAir Master will not start up
correctly.

After booting up, the language selection screen appears

(see Fig. 4).

Fig. 4 – Language selection

You can select the language by touching the

appropriate flag symbol.

After that you can decide whether to use the wizard to

help with commissioning. The wizard automatically
prompts you to set the necessary parameters.

Before starting this wizard, the SmartAir Master can

show you the list of parameter settings required:

Once commissioning has been completed, the main

screen comes up and the SmartAir Master switches off,
i.e. it shows the status of the compressors but does not
control them.

This is also indicated by the message "SMART

MASTER IS SWITCHED OFF"

To switch on the SmartAir Master, open the menu

"Adjustments SmartAir Master" menu. In the
"Regulation" sub-menu you can switch on the control.
(See also section 5.7 "Settings").

18
5. Operation

5.2 Main display The status of a compressor is indicated on the

compressor key as shown in the following table:

The main display contains essential information about

the condition of the air station. On load
Indication for compressors with fixed
The individual elements of the main display are shown speed.
in Fig. 5.

On load + delivery rate

(1) (2) (3) Indication for compressors with speed
regulation or half/full load control.

Off load
(4)
The compressor motor is running, but
the compressor does not produce
compressed air.

Blow down
(Symbol flashing)
The value of the final pressure as the
(5)
value of the start protection.

Standby
The compressor is at standstill, is ready
and can be started by the SmartAir
(6) (7) (8) (9) (10) Master when pressure is required.

Switched off
Fig. 5 – Main display The compressor is at standstill and no
fault is signalled, but it cannot be started
by the SmartAir Master.
(1) Current line pressure

(2) Current pressure band

Fault
The compressor is signalling a fault.
(3) Current volume flow

(4) Compressor switches showing the compressor

status (see Fig. 6). Service
The compressor is being serviced and is
(5) Status lines showing status, warnings and fault therefore not available. Warnings and
fault messages will be ignored.
indications.

(6) "Info" key to show information about the air Fault communication
station. Serial communication to the compressor
control or to the compressor module has
(7) "Settings" key to change parameters. failed.

(8) Current date and time

Software update necessary
The software of the compressor
(9) "SD card" key
controller needs an update.
(10) "Reset" key to reset warnings and fault
messages.
Warning / Service
The compressor indicates a warning or
requires servicing.

Fig. 6 – Compressor status

19
5. Operation

5.3 Compressor information Warnings and fault messages that are received are
not displayed and are not listed in the event list for
the compressor.
Further information about a compressor can be
displayed by touching the appropriate compressor key. "Service on" is displayed in the list of events for this
compressor.
Here the information can be read but cannot be
changed. Once servicing has been completed the compressor
can be brought back into the sequence by touching this
key again, which is now labelled "Service off", and
entering the appropriate code (see section 5.9
"Codes").

5.4 SD card

The following compressor station data can be logged on

the SD card during normal operation:

Line pressure
Unit: 1/10 bar

Volume flow
Unit: 1/10 m³/min
Fig. 7 – Compressor information
Compressor status
1 = On load
The compressor parameter settings and other keys are 2 = Off load
displayed first. 3 = Blow down
4 = Standby
5 = Off
"Events" key 6 = Fault
7 = Service
Pressing this key displays a list of the last 50 events for 8 = Fault communication
this compressor.
Compressor load
Events are Unit: %

Warnings
Faults The SmartAir Master writes this data to a CSV file and
Maintenance work automatically creates a file for each day with a file name
based on the corresponding date.
For each compressor the list of events can be deleted
in the menu "Adjustments SmartAir Master" after Example: SM100217.csv
entering the appropriate code (see section 5.9 Log file from 17 Feb. 2010
"Codes").
CSV format separates the data with a comma and is
Touching this key again, which is now labelled compatible with MS Excel.
"Parameters", returns you to the list of parameters.

"Service on" key

When the compressor is being serviced, the power

supply to the compressor has to be switched off.

To suppress the resulting fault signal, the compressor

can be set to "Service" status.

If this status is active

The appropriate symbol is shown on the

compressor key (see Fig. 6), the compressor is not
loaded and is taken out of the sequence by the
SmartAir Master.

20
5. Operation

5.5 Air station information Measured values

The line pressure and volume flow values can be

Further information about the air station can be shown here as diagrams.
displayed by touching the "Info" key (see Fig. 5).

Here the information can be read but cannot be Operating hours

changed.
The distribution of the compressor operating hours is
shown here rather than in the compressor information.

There are two types of operating hours:

Absolute operating hours

These are the total and loaded hours as listed in
the compressor controls.

Relative operating hours

These are the total and loaded hours since
a user-defined time.

This can be the time since the distribution of newly

added operating hours to individual compressors
the SmartAir Master, for example.

The relative operating hours can be reset in the

Fig. 8 – Air station information
"Adjustments SmartAir Master" menu.

Overview timer control

Statistics
The timer control programming is displayed here.
Various statistical values since a user-defined time are
displayed here, e.g. the minimum and maximum line
Each day of the week is represented by a horizontal bar
pressures ever measured.
which is the same colour as the current profile displays.
The statistical values can be reset in the “Adjustments
Current profile SmartAir Master” menu.

All parameters of the current profile can be displayed

Software
here.
The SmartAir Master software versions are displayed
A profile is a set of parameters (i.e. pressure band and
here.
compressor priorities) corresponding to different
operating requirements of the station.
Help
Up to 12 profiles are definable and can be activated by
the timer control or a programmable digital input.
This gives the user access to various help topics, such
as wiring diagrams for compressor controls or how to
Events operate the SmartAir Master.

Pressing this key displays a list of the last 50 events for

the air station.

This list includes all compressor events and any relating

to the air station, e.g. a fault in the SmartAir Master line
pressure sensor.

The event list can be deleted in the "Adjustments

SmartAir Master" menu.

21
5. Operation

5.6 Controlling the air station The timer control is programmed using channels.

For the example in Fig. 9, the programming is as

The SmartAir Master offers various options for adapting follows:
the air station to different requirements.
Channel 1: Mon-Fri / 0..24h Profile 1 active
Channel 2: Wed / 10..14h Profile 3 active
Profiles Channel 3: Sat / 0..24h Profile 2 active

A profile is a set of parameters corresponding to Sun / 0..24h Station off

different operating requirements of the station.
If no profile is active for a particular time range (on
A profile contains the following parameters: Sunday in this example), the station stays off, i.e. the
compressors remain on standby, but are not loaded.
Max. pressure warning
Max. pressure
Min. pressure b) Activation by digital inputs or interface
Min. pressure warning
Receiver volume A profile can also be activated by programmable inputs
Compressor priorities or the serial customer interface.
The digital inputs can be located on the SmartAir
Different set points can therefore be defined with Master itself or on extension modules.
different profiles.
This allows the customer to either install a selection
switch in the plant or to activate a profile using a
Activating a profile separate PLC (as also shown in Fig. 2).

If several profiles have been defined by the customer, If no channel of the timer control is active, the station
they can be activated in various ways: can only be controlled by the digital input.
The customer can therefore "relocate" the programming
of the timer control to a separate PLC.
a) Activation by timer control

The timer control allows profiles to be activated at a c) Activation by timer control and digital inputs or
predefined time. Fig. 9 shows an example of a weekly interface
program with different conditions of the customer's
plant. The combination of timer control and activation by
digital inputs or customer interface allows the customer
Profile 1 = Normal production to activate profiles intermittently and outside the
Profile 2 = Weekend programmed times without having to reprogram the
Profile 3 = Retrofitting timer (e.g. unscheduled production or at the weekend or
for unplanned conversions).

This "overrides" the activation of a profile with the help

of a digital input or the serial interface of the currently
loaded profile timer.

Fig. 9 – Weekly program of the timer control

22
5. Operation

Line pressure regulation In addition to the listed criteria, the following parameters
are relevant for the switching of compressors:
To regulate the line pressure within the pressure band,
the SmartAir Master loads the compressor with the
following criteria: Switch on and switch off delay

If a compressor is to be loaded or unloaded, a timer is

Criterion 1: Priority started with the appropriate adjusted time.

Compressors with the highest priority will be loaded If the timer runs out and conditions for switching the
first, followed by compressors with lower priorities. compressor are still valid, the compressors are
switched.
There are four priorities available:

High Pressure above "Max. pressure warning"

These compressors will be loaded first.
If the pressure exceeds the adjusted value of “Warning
Normal line pressure max.”, all compressors are unloaded at
These compressors will be loaded once all high- the same time and an appropriate message is
priority compressors have been loaded. displayed.

Low
These compressors will be loaded once all high- Pressure below "Min. pressure warning"
priority and normal-priority compressors have been
loaded. If the pressure falls below the adjusted value of
"Warning line pressure min.“, all available compressors
Off are loaded and an appropriate message is displayed.
These compressors will never be loaded.

Failure of the SmartAir Master

Criterion 2: Demand
If communication between the SmartAir Master and the
If several compressor with the same priority could be compressors fails due to a broken cable or power loss,
switched, the compressor will be switched which the compressors are switched over automatically to
corresponds to the delivery of the identified additional their internal pressure regulation after 10s.
need of compressed air.

Criterion 3: Total hours

If several compressors with the same FAD could be

switch, the compressor with the lowest number of total
hours will be loaded first.

23
5. Operation

5.7 Settings
Compens. total hours
In this parameter the customer can set how the
Touching the "Settings“ key opens the main menu. SmartAir Master compensates the total hours of
From here the user can access the sub-menus and the the compressors.
language and code input settings.
"Relative"setting
The operating hours are compensated with the
relative operating hours.

"Absolute" setting
The operating hours are compensated with the
absolute operating hours.

The meaning of absolute and relative operating

hours is explained in section 5.5 "Air station
information”.

Regulate pressure to
This parameter defines, on which line pressure
sensor the SmartAir Master is regulating.

If both analog inputs are defined as line pressure

Fig. 10 – Adjustments sensors, the second line pressure value will be also
shown in the header. The value, on which the
SmartAir Master regulates, will be displayed in
Adjustments SmartAir Master large print, the value on which the SmartAir Master
Parameters relating to the SmartAir Master and to the is not regulating will be shown at the right of it in
control of the air station can be set here. small print.

The menu is divided into the following sub-menus: "Line pressure 1" setting
The SmartAir Master regulates the pressure to the
line pressure sensor, which is connected to the
Regulation analog input AI-1.

The parameters for controlling the air station can be set "Line pressure 2" setting
here: The SmartAir Master regulates the pressure to the
line pressure sensor, which is connected to the
SmartAir Master anlaog input AI-2.
This menu item switches the SmartAir Master on
and off. "Highest pressure" setting
The SmartAir Master regulates the pressure to the
If the SmartAir Master is switched off, the status of highest line pressure of "Line pressure 1" and "Line
the compressors is shown, but the air station is not pressure 2".
controlled, i.e. the compressors run on their internal
pressure regulation. "Lowest pressure" setting
The SmartAir Master regulates the pressure to the
Suppress warning Pmin lowest line pressure of "Line pressure 1" and "Line
After activation of a profile, the low pressure pressure 2".
warning is suppressed for this time.

Cut-in delay
Before a compressor is loaded, the SmartAir
Master waits for the time set with this parameter.

If this time elapses and the condition for loading the

compressor is still valid, the compressor is loaded.

Cut-out delay
Before a compressor is unloaded, the SmartAir
Master waits for the time set with this parameter.

If this time elapses and the condition for unloading

the compressor is still valid, the compressor is
unloaded.

24
5. Operation

Determine volume flow Inputs/Outputs

With this parameter the user can set how the
volume flow displayed is determined. Here the inputs and outputs can be assigned to various
functions.
"Line pressure" setting
The volume flow will be calculated with the gradient Programmable functions of digital inputs DI-1..3:
of the line pressure, on which the SmartAir Master
is regulating. No use
Activate profile 1 / 2 / .. / 12
"Volume flow x" setting Warning Dryer 1..4
The volume flow will be measured with a volume Warning Filter 1..4
flow meter, which is connected either to the analog Warning Bekomat 1..4
input AI-2 of the SmartAir Master or to an analog Warning Dew point
input of an extension module. Warning External

In addition, two further parameters are programmable

Timer control for the digitial inputs to each function:

The various timer control channels can be set here. A delay, which avoids, that the appropriate
The current date and time can also be set in this menu. message is indicated to early.
The condition of the digital input, which indicates
the programmed message (input open or closed).
Profiles
Programmable functions of digital outputs DO-1..2:
The various profile parameter settings can be
programmed here No use
Collective warning
In a profile the following parameters can be set: Collective fault
Coll. warning/fault
Max./Min. pressure warning Warning Line press. max.
These values are limits which trigger warning Warning Line press. min.
signals. Warning Compressor
Fault Compressor
Max./min. pressure Warn/Fault Compr.
Pressure range within which the SmartAir Master Warning Dryer
regulates the line pressure. Warning Filter
Warning Bekomat
Receiver volume Warning External
Volume of the receiver into which the compressors Coll. warn. Temperature
pump the compressed air. The volume of the pipes Warn. Temperature 1..8 max.
is not included. Warn. Temperature 1..8 min.
Coll. warn. Dew point
Compressor priorities Warning Dew point 1..8
In a profile each compressor can be set to an Compr. on load
individual priority. Compr. motor running
Profile 1 / 2 / .. / 12 active
Station off
Events / Statistics
Programmable functions of analog inputs AI-1..2:
Here the various statistics counters and event lists can
be reset or deleted. Analog input AI-1
Line pressure 1

Analog input AI-2

No use
Line pressure 2
Volume flow 1..8
Temperature 1..8
Dew point 1..8

25
5. Operation

RS485 interface

Communication with the RS485-3 interface reserved for

the customer can be configured here.

The "Protocol/Module" menu item defines whether

communication is via ModBus-RTU or PROFIBUS
module.

If "ModBus-RTU" is set, the baudrate and address

settings can be changed.

If "PROFIBUS module" is set, the baudrate and address

settings cannot be changed because they are
automatically set to the requirements of the PROFIBUS
module.

Adjustments Compressors
The various compressor settings can be defined here
and new compressors can be added or existing
compressors deleted.

Adjustments extension modules

The extension module parameters can be set here.

Language
The flag on the key shows the current language setting.
Touching this key opens the language selection screen.

Code
The code for locking and unlocking settings can be
entered here (for more information see section 5.9
"Codes").

26
5. Operation

5.8 Messages Warning Temperature 1 min

The temperature 1 has fall below the programmed
minimum limit.
Status messages
Warning Dew point
SMARTAIR MASTER IS SWITCHED OFF A digital input has indicated, that the dew point has
The SmartAir Master shows the status of the been exceeded.
compressors but does not control them.
Warning Dew point 1
Air station off The measured dew point on an analog input has been
The compressor station has been switched off by the exceeded.
timer control.
Warning External
Current profile: 1 An external device is indicating a warning signal.
The current profile is profile 1.
Warning Battery
The internal battery of the SmartAir Master has run
Fault messages down and needs to be replaced.

Fault Sensor Line press. 1 Warning C1 Remote load

Fault Sensor Vol. flow 1 Compressor 1 was switched to load, but no
The sensor of the appropriate programmed function has corresponding feedback signal has been received.
a fault, so that the compressors will not be regulated by
the SmartAir Master. Warning C1 Remote off-load
Compressor 1 was switched to off-load, but no
Fault VSD-module corresponding feedback signal has been received.
A compressor module (VSD) has a fault. The reasons
could be: Warning Sensor Line press. 1
Warning Sensor Vol. flow 1
The type of analog input AI-1 of the compressor Warning Sensor Temperat. 1
module (VSD) has not been defined correctly with Warning Sensor Dew point 1
the jumper at terminals 21 to 24. The sensor of the appropriate programmed function has
a fault. The compressors are still regulated by the
The line pressure sensor of the compressor at SmartAir Master.
analog input AI-1 of the compressor module (VSD)
has a fault. Signal at DI-1
A signal is being indicated at input 1 of the SmartAir
Power loss Master, but the input is set to the function "No use".
The power supply to the SmartAir Master has failed.
Signal at DI-1 Ext.mod.1
A signal is being indicated at input 1 of Extension
Warning messages module 1, but the input is set to the function "No use".

Warning Line press. max.

The line pressure has exceeded the "Max. pressure
warning" limit of the current profile.

Warning Line press. min

The line pressure is lower than the "Min. pressure
warning" limit of the current profile.

Warning Dryer 1
Dryer 1 is indicating a warning signal.

Warning Filter 1
Filter 1 is indicating a warning signal.

Warning Bekomat 1
Bekomat 1 is indicating a warning signal.

Warning Temperature 1 max

The temperature 1 has exceeded the programmed
maximum limit.

27
5. Operation

5.9 Codes

To prevent unauthorized program changes, the settings

are code-protected.

By touching the "Code“ key in the main menu, a code

can be entered to change the parameter settings.

The symbol on the key indicates whether the access

code is locked or unlocked:

Code is locked, parameters cannot be changed.

In the SmartAir Master there are different codes:

Code "7070"

This code allows

Settings in the menu to be locked

(see section 5.7 "Settings")

The "Service“ status of a compressor to be

switched on or off
(see section 5.3 "Compressor information")

After the code is unlocked, the code will be locked

again

automatically after 15min

or by a power loss

Code "7555"

This code allows the "Service“ status of a compressor

to be switched on or off
(see section 5.3 "Compressor information").

After the code is unlocked, the code will be locked

again

automatically after 15min

or by a power loss

Code "7777"

With this code, the SmartAir Master can be reset to the

factory settings and the commissioning assistant can be
started.
(see chapter "5.1 First commissioning").

28
 6. Compressor module (STD)

6. C ompr ess or module (STD)

6.1 Functions Connection to the SmartAir Master

Interface: RS485
The compressor module (STD) is used to connect any Cable type: 2x2x0.5..1.5mm²
compressor with fixed speed or half/full load regulation twisted pair and screened
to the SmartAir Master. Wiring length: max. 1200m
Address: Adjustable from 1..12 by DIP switches
The status of the compressor is detected by the digital Bus termination: 120 Ohm (by DIP switches)
inputs of the compressor module and sent to the
SmartAir Master via its RS485 interface.
Ambient temperatures
In addition, the commands to control the compressor
Operation: 0 .. 55°C
are transmitted via the RS485 interface from the
Storage: -25 .. 75°C
SmartAir Master to the compressor module and are
executed by the digital outputs.
EMC conformity

6.2 Technical data Immission: DIN EN 61000-6-3

Immunity: DIN EN 61000-6-2

Electrical connection Dimensions (W x H x D)

Voltage: 110..230V AC/DC +/-10% 100 x 110 x 70 mm
Power: 1VA

Type of construction / Protection

Digital inputs
Plastic housing / IP30
Voltage: 24..230V AC/DC +/-10%
Note which terminals are used
Mounting
"Operation" Compressor available or
collective fault signal DIN rail TS35
Terminals 6 / 7 / 8

"Motor" Compressor motor is running

Terminals 9 / 10 / 11 6.3 Scope of delivery
"Load" Compressor is on load
Terminals 12 / 13 / 14 After receipt, check the scope of delivery:
Compressor module (STD)
Digital outputs
"Remote load Remote load enable
enable" Terminals 21 / 22 / 23

"Remote load" Remote load

Terminals 26 / 27 / 28

"Remote half Remote half load

load" Terminals 31 / 32 / 33

Type: Potential-free relay outputs

(change-over contacts)

Load: max. 240VAC / 1A

29
6. Compressor module (STD)

6.4 Connection to the SmartAir Master 6.5 Connection to the compressor

The module is connected to the SmartAir Master via the Note

built-in RS485 interface.
The connection of the compressor module (STD) as
The wiring diagram showing how to connect the RS485 shown in this document is intended as a guide for the
interface to the SmartAir can be found in the annex. majority of compressor control systems in use. Some
compressors differ in terms of operation and/or function;
The DIP switch settings for addressing the module and consult your compressor supplier/specialist for advice.
for switching bus termination on and off are also listed
there. Wiring diagrams with examples showing how to connect
a compressor control to the module can be found in the
annex.

Danger
Switch off the power supply to the compressor,
before connecting the compressor module (STD) to
the compressor control.

Digital inputs

The module detects the compressor status via three

digital inputs, which are indicated via three LEDs on the
module.

A voltage in the range from 24 to 230V AC or DC can

be connected at each input.

Each input is routed to three terminals:

"24..48VUC" terminal
"110..230VUC" terminal
"COM" terminal

Note that the voltage used signal must be routed to the

appropriate terminal.

Important
Do not connect voltages of more than 250V to the
inputs.

If the voltages used exceed 250V, an auxiliary

contact must to be used to switch a suitable voltage
to the inputs.

The inputs may only be connected to power circuits

with appropriate fuse protection.

30
6. Compressor module (STD)

"Operation" digital input Digital outputs

A signal must be connected to this input to indicate that Danger

the compressor is ready to produce compressed air
after sending a remote load signal. When a compressor module (STD) is installed, the
compressor's pressure switch can no longer
On compressor controls which do not provide such a provide over-pressure protection.
signal the input can be connected to the collective fault
signal of the compressor. For compressors that are not equipped with
This will indicate to the SmartAir Master that there is no independent over-pressure detection, it is
fault at the compressor. recommended that a pressure switch be
incorporated in the compressor fault circuit(s) such
A parameter on the SmartAir Master can be used to that any local over-pressure condition will stop the
define whether or not a voltage at the input signals compressor independently from the SmartAir
availability. Master.

The compressor is controlled by two or three digital

"Motor" digital input outputs. The status of these outputs is indicated via
three LEDs.
Contacts A1 and A2 of the main contactor coil can be
connected directly to this input. These digital outputs are change-over contacts and can
be adapted to the requirements of the compressor
If the compressor control energizes the coil of the main control by selecting the appropriate terminals.
contactor, the compressor module detects the voltage
over the coil and indicates to the SmartAir Master that Wiring diagrams with examples showing how to connect
the motor is running. a compressor control with line pressure sensor or line
pressure switch can be found in the annex.
On compressor controls without a main contactor, any
output can be used which indicates that the motor is
running, e.g. a fan contactor or a soft starter signal. "Remote load enable" digital output

A parameter on the SmartAir Master can be used to Do not use this input to switch the compressor on and
define whether or not a voltage at the input signals that off.
the motor is running.
This output should cause a change-over from internal
regulation to the control via the digital outputs of the
"Load" digital input compressor module.

The contact regulation valve coil can be connected

directly to this input. "Remote load" digital output

If the compressor control energizes the coil of the Do not use this input to switch the compressor on and
regulation valve, the compressor module detects the off.
voltage over the coil and indicates to the SmartAir
Master that the compressor is on load. This output switches the compressor to load.

On compressors with half/full load regulation, this input This remote load signal should then be effective when
should indicate whether the compressor is in half or full the "remote load enable" output is sent to the
load. compressor control.

Any output which indicates that the compressor is on

load could also be used. "Remote half load" digital output

A parameter on the SmartAir Master can be used to Do not use this input to switch the compressor on and
define whether or not a voltage at the input signals the off.
compressor load.
On compressors with half/full load control, this output
should switch the compressor to half load.

This remote load signal should then be effective when

the "remote load enable" output is sent to the
compressor control.

31
6. Compressor module (STD)

6.6 Parameters

To control a compressor with fixed speed using a

compressor module (STD), the following parameter
settings must be made.

These parameters can be set from the menu on the

corresponding compressor.

Address

The address set here must be the same as that set at

the compressor module (STD).

Control

This must be set to "Compress. module (STD)".

FAD

Free air delivery of the compressor.

Hours

Since the operating hours can not be read from the

compressor control, they must be entered manually
(total hours and loaded hours).

Type

This menu item indicates whether the compressor is a

standard or a half-/full load compressor.

Connection

Invert signals
This parameter specifies whether voltage at the
corresponding inputs indicates a signal or not.

Full load command

This parameter specifies how the compressor module
(STD) sends a load command (for standard
compressors) or full load command (for half-/full load
compressors) to the compressor:

"Half and full load" setting

To send a full load command, both outputs
("Remote load" output and "Remote half load"
output) of the compressor module (STD) are
activated.

"Full load only" setting

To send a full load command, only the "Remote
load" output of the compressor module (STD) is
activated.

32
 7. Compressor module (VSD)

7. C ompr ess or module (VSD)

7.1 Functions Analog input AI-1

Type: 4..20mA / 0..10V / 0..5V
The compressor module (VSD) is used to connect any (depending on jumper)
speed regulated compressor to the SmartAir Master. Function: Detection of line pressure
at the compressor
The status of the compressor is detected by analog and
digital inputs on the compressor module and sent to the
SmartAir Master via its RS485 interface. Analog output AO-1

Speed regulation is obtained by manipulating the line Type: 4..20mA / 0..10V / 0..5V
pressure signal by means of the analog output. This is (depending on jumper)
connected to the analog input of the compressor control Burden: Active sensor: 94 Ohm
which is normally connected to the line pressure Passive sensor: 650 Ohm max.
sensor. Function: Manipulated line pressure
at the compressor
The appropriate command is transmitted via the RS485
interface to the compressor module and is executed by
means of the digital and analog outputs. Connection to the SmartAir Master
Interface: RS485
Cable type: 2x2x0.5..1.5mm²
7.2 Technical data twisted pair and screened
Wiring length: max. 1200m
Required compressor drive Address: Adjustable from 1..12 by DIP switches
Bus termination: 120 Ohm
Motor type: Three-phase asynchronous motor Switchable by DIP switches
Rating current: max. 500A
Ambient temperatures
Electrical connection Operation: 0°C .. 55°C
Voltage: 110..230V AC/DC +/-10% Storage: -25 .. 75°C
Power: 1VA
EMC conformity
Digital inputs Immission: DIN EN 61000-6-3
Voltage: 24..230V AC/DC +/-10% Immunity: DIN EN 61000-6-2
Note which terminals are used

"Operation" Compressor available or Dimensions (W x H x D)

collective fault signal 100 x 110 x 70 mm
Terminals 6 / 7 / 8

"Warning" Compressor sends a warning signal

Type of construction / Protection
Terminals 9 / 10 / 11
Plastic housing / IP30
"Load" Compressor is on load
Terminals 12 / 13 / 14
Mounting

Digital outputs DIN rail TS35

"DO-1" Optional use
Terminals 1 / 2

"DO-2" Optional use

Terminals 3 / 4

Type: Potential-free relay outputs

(change-over contacts)

Load: max. 240V / 1A

33
7. Compressor module (VSD)

7.3 Scope of delivery 7.5 Connection to the compressor

After receipt check the scope of delivery: Note

Compressor module (VSD) The connection of the compressor module (VSD) as

shown in this document is intended as a guide for the
Current transducer LEM HTA500S majority of compressor control systems in use. Some
(Measuring range 500A) compressors differ in terms of operation and/or function;
consult your compressor supplier/specialist for advice.
Cable (1.5m) to connect the current transducer to
the compressor module (VSD) Note
The compressor module (VSD) can only be connected
to compressors with a three-phase asynchronous motor
with a max. rating current of 500A.

7.4 Connection to the SmartAir Master Wiring diagrams with examples showing how to connect
a compressor control to the module can be found in the
The module is connected to the SmartAir Master via the annex.
built-in RS485 interface.

The wiring diagram showing how to connect the RS485 Danger

interface to the SmartAir can be found in the annex.
Switch off the power supply to the compressor
before connecting the compressor module (VSD) to
The DIP switch settings for addressing the module and
the compressor control.
for switching bus termination on and off are also listed
there.
Digital inputs

The module detects the compressor status via three

digital inputs, which are indicated via three LEDs on the
module.

A voltage in the range from 24 to 230V AC or DC can

be connected at each input.

Each input is routed to three terminals:

"24..48VUC" terminal
"110..230VUC" terminal
"COM" terminal

Note that the voltage used signal must be routed to the

appropriate terminal.

Important
Do not connect voltages of more than 250V to the
inputs.

If the voltages used exceed 250V, an auxiliary

contact must be used to switch a suitable voltage to
the inputs.

The inputs may only be connected to power circuits

with appropriate fuse protection.

34
7. Compressor module (VSD)

"Operation" digital input Digital outputs

A signal must be connected to this input to indicate that The use of digital outputs is optional.
the compressor is ready to produce compressed air
after sending a remote load signal. The status of these outputs is indicated via three LEDs.

On compressor controls which do not provide such a These digital outputs are change-over contacts and can
signal the input can be connected to the collective fault be adapted to the requirements of the compressor
signal of the compressor. control by selecting the appropriate terminals.
This will indicate to the SmartAir Master that there is no
fault at the compressor. Wiring diagrams with examples showing how to connect
a compressor control with line pressure sensor or line
A parameter on the SmartAir Master can be used to pressure switch can be found in the annex.
define whether or not a voltage at the input signals
availability.
Digital output DO-1

"Warning" digital input Do not use this input to switch the compressor on and
off.
A warning message can optionally be connected at this
input. This output can be used for a "remote load enable"
signal if required.
If no warning message is required or available, this
input can be left open.
Digital output DO-2
A warning message has no influence on the regulation
of the compressor. A warning message that is received Do not use this input to switch the compressor on and
is simply displayed on screen and is stored in the event off.
list for the compressor.
This output can be used for a "remote load" signal if
required.
"Load" digital input

The contact regulation valve coil can be connected Analog inputs

directly to this input.
Analog input AI-1
If the compressor control energizes the coil of the
regulation valve, the compressor module detects the This analog input detects the line pressure at the
voltage over the coil and indicates to the SmartAir compressor.
Master that the compressor is on load.
This is done by removing the compressor's line
Any output which indicates that the compressor is on pressure sensor from the compressor control and
load could also be used. connecting it to analog input AI-1 on the compressor
module.
A parameter on the SmartAir Master can be used to
define whether or not a voltage at the input signals the This is necessary for the following reasons:
compressor load.
The line pressure at the compressor can be
monitored and if it is getting too high, the
compressor can be set to off-load.

If the SmartAir Master or the compressor module

fails, an internal relay will short circuit the analog
input and the analog output. This will cause an
automatic connection of the line pressure sensor to
the compressor control to allow the compressor to
continue to operate.

The relay short circuits terminals 25 and 28.

35
7. Compressor module (VSD)

Analog input AI-2 Note

This analog input detects the speed of the compressor. On connection of analog input AI-1 and analog output
AO-1, the line pressure measured at the line pressure
To measure the speed of the compressor, one phase of sensor will be displayed correctly at the compressor
the motor leads has to be wired through the current control even if power is lost at the compressor module
transducer supplied. This must be connected to the (VSD).
compressor module using the cable supplied.
Note
This enables the module to measure the current of the
An amplifier can be connected between analog output
compressor motor and to calculate the speed using the
AO-1 and the analog input of the compressor control if
parameter settings in the SmartAir Master.
necessary.

Analog output AO-1

Danger
For compressors that are not equipped with
independent over-pressure detection it is
recommended that a pressure switch be
incorporated in the compressor fault circuit(s) such
that any local over-pressure condition will stop the
compressor independently from the SmartAir
Master.

The analog output is used for regulating the speed of

the compressor motor.

This is done by connecting the analog output to the

analog input at the compressor control which is
normally used to connect the line pressure sensor.

If the compressor module changes the signal of the

analog output to reduce the line pressure, the speed of
the compressor will be increased and vice versa.

Fig. 11 shows the relation between the analog inputs

and outputs on the compressor module and the
compressor control.

Compressor control

Analog input
Line pressure sensor

AO-1
Compressor module
Compressor module
(VSD)

AI-1

Compressor
line pressure sensor

Fig. 11 – Relation between analog inputs and outputs

36
7. Compressor module (VSD)

7.6 Parameters Feedback control circuit

Danger
To control a speed regulated compressor using a
compressor module (VSD), the following parameter Do not set too high a value for the "Safety
settings must be made. pressure" parameter. This value must be the
maximum pressure of the corresponding
These parameters can be set from the menu on the compressor.
corresponding compressor.
Safety pressure
If the line pressure that is measured from the line
Address pressure sensor of the compressor exceeds this value,
the load of the compressor will be interrupted and it will
The address set here must be the same as that set at be switched over to internal regulation of the
the compressor module (VSD). compressor, so that the speed will be automatically
reduced.

Control Off-load pressure

The line pressure value at which the compressor is
This must be set to "Compress. module (VSD)". switched to off load.
This value is necessary in order to have a defined set
point for switching the compressor to off-load.
FAD max. and min.
Target pressure
Maximum and minimum free air delivery of the The line pressure value which is the target pressure of
compressor. the compressor control.
The SmartAir Master regulates the compressor speed
to the off-load pressure and target pressure.
Hours
Load pressure
Since the operating hours can not be read from the The line pressure value at which the compressor is
compressor control, they must be entered manually switched from standby to load to produce compressed
(total hours and loaded hours). air.
This value is necessary in order to have a defined set
point for switching the compressor to load when it is on
Connection standby.

Invert signals Max. and off load speed

This parameter specifies whether voltage at the Indicates the maximum and minimum speed, i.e. the
corresponding inputs indicates a signal or not. regulation range of the compressor.

Type line pressure sensor Number of pole pairs

This shows whether the type of line pressure sensor is Indicates the number of pole pairs of the compressor
4..20mA or 0..5V or 0..10V. motor to detect correctly the speed.

37
 8. Extension module

8. Extension modul e

8.1 Function
Connection to the SmartAir Master
An extension module is used to expand the number of
programmable inputs and outputs of the SmartAir Interface: RS485
Master. Cable type: 2x2x0.5..1.5mm²
twisted pair and screened
The RS485-2 interface of the SmartAir Master can Wiring length: max. 1200m
connect a maximum of 4 extension modules. Address: Adjustable from 1..4 by DIP switches
Bus termination: 120 Ohm
The extension modules are available in two versions Switchable by DIP switches
which differ only in terms of their power supply:
Ambient temperatures
Version 1: 230V AC / 50-60Hz
Version 2: 110V AC / 50-60Hz Operation: 0°C .. 55°C
Storage: -20 .. 70°C
An extension module adds

8 digital inputs (DI-1..8)

EMC conformity
2 digital outputs (DO-1..2)
2 analog inputs (AI-1..2) Immission: DIN EN 61000-6-3
Immunity: DIN EN 61000-6-2
to the SmartAir Master.

8.2 Technical data Dimensions (W x H x D)

180 x 180 x 74 mm
Electrical connection
Voltage: 230V AC +/-10%
Type of construction / Protection
110V AC +/-10%
Plastic housing / IP64
Internal fuses
F1 (Primary): T0.16A (5x20mm)
Mounting
F2 (Secondary): T0.5A (5x20mm)
Wall mounting
Digital inputs Weight: 1.5 kg / 3.3 lbs
Number: 8
Input voltage: 24V DC

8.3 Scope of delivery

Digital outputs
Number: 2 After receipt check the scope of delivery:
Type: Potential-free relay outputs
(change-over contacts) Module in plastic housing
Load: max. 240V / 1A
Cable (1m) to connect the extension module to the
SmartAir Master
Analog inputs
Number: 2

Type: 4..20mA
Input voltage: 18V DC

Type: Passive / Active

(depending on jumper)
Burden: < 100 Ohm
Wiring length: max. 500m
>500m: use amplifier

38
8. Extension module

8.4 Connection to the SmartAir Master 8.5 Connection of external signals

The module is connected to the SmartAir Master via the The sensors and switches for digital and analog inputs
built-in RS485 interface. are connected directly to the extension module.

The extension module will be delivered with a 3 wire The appropriate terminals can be found in the annex.
connection cable (1m ).
This will be connected to the RS485-2 of the SmartAir After connecting an extension module, the inputs and
Master. outputs can be programmed in the “Adjustments
Extension module" menu.
For longer distances, the cable should be removed and
an appropriate cable is to create.
Digital inputs
If several extension modules are used, they are
connected in the same way as the compressor controls Programmable functions of digital inputs DI-1..8:
in a bus structure.
No use
Activate profile 1 / 2 / .. / 12
SmartAir Warning Dryer 1..4
Master
Warning Filter 1..4
Extension Extension Warning Bekomat 1..4
Extenstion module 1 module 2 Warning Dew point
Warning External

The wiring diagram showing how to connect the RS485 In addition, two further parameters are programmable
interface to the SmartAir can be found in the annex. for the digitial inputs to each function:

The DIP switch settings for addressing the module and A delay, which avoids, that the appropriate
for switching bus termination on and off are also listed message is indicated to early.
there. The condition of the digital input, which indicates
the programmed message (input open or closed).

Digital outputs

Programmable functions of digital outputs DO-1..2:

No use
Collective warning
Collective fault
Coll. warning/fault
Warning Line press. max.
Warning Line press. min.
Warning Compressor
Fault Compressor
Warn/Fault Compr.
Warning Dryer
Warning Filter
Warning Bekomat
Warning External
Coll. warn. Temperature
Warn. Temperature 1..8 max.
Warn. Temperature 1..8 min.
Coll. warn. Dew point
Warning Dew point 1..8
Compr. on load
Compr. motor running
Profile 1 / 2 / .. / 12 active
Station off

39
8. Extension module

Analog inputs

Programmable functions of the analog inputs:

No use
Line pressure 3..8
Volume flow 1..8
Temperature 1..8
Dew point 1..8

Note that a line pressure sensor that is connected to an

extension module cannot be used to regulate the line
pressure. Pressure regulation and subsequent
switching of the compressors can only be done from
sensors which are connected at analog inputs AI-1 or
AI-2 of the SmartAir Master.

For the connection of a volume flow meter applies:

Detection of the volume flow and subsequent switching
of the compressors can also be done from a sensor
which is connected to an analog input of an extension
module.

The values measured at the analog inputs of an

extension module can therefore only be used for
monitoring.

Either active or passive sensors can be connected to

the analog inputs. Jumpers J1 and J2 must be set
accordingly. An overview of the jumpers can be found in
the annex.

40
 9. Webserver module

9. Webser ver module

9.1 Function Type of construction / Protection

Plastic housing / IP64
The Webserver module provides an interface for the
customer, which allows the visualization of the SmartAir
Master via network. Mounting

For this visualization, no special software has to be Wall mounting

installed, but is done with the help of a webbrowser as Weight: 1,5 kg / 3.3 lbs
e.g. Microsoft Internet Explorer or Mozilla Firefox.

The Weberserver module is available in two versions 9.3 Scope of delivery

which differs only in terms of their power supply:

Version 1: 230V AC / 50-60Hz After receipt, check the scope of delivery:

Version 2: 110V AC / 50-60Hz
Module in plastic housing

SD card (1GB) within the SD card reader of the

9.2 Technical data Webserver module

Cable (1m) to connect the Webserver module to

Electrical connection
the SmartAir Master
Voltage: 230V AC +/-10%
110V AC +/-10% Ethernet cable (3m)
(Cat.5E, Type 100Base-TX)

Internal fuses
F1 (Primary): T0.5A (5x20mm)
F2 (Secondary): T0.5A (5x20mm)

Connection to the SmartAir Master

Interface: RS485
Cable type: 2x2x0,5..1,5mm²
twisted pair and screened
Wiring length: max. 1200m
Bus termination: 120 Ohm
Switchable by jumper J1 and J2

Connection to the network

Interface: Ethernet
10Base-TX / 100Base-TX
Connection: RJ45

Ambient temperatures
Operation: 0° .. 55°C
Storage: -40 .. 70°C

EMC conformity
Immission: DIN EN 61000-6-3
Immunity: DIN EN 61000-6-2

Dimensions (W x H x D)
180 x 180 x 74 mm

41
9. Webserver module

9.4 Connection to the SmartAir Master 9.5 Connection to the net work

The module is connected to the SmartAir Master via the The Webserver module will be delivered with an
built-in RS485 interface. installed Ethernet connection cable (Cat.5E, Type
100Base-TX, 3m).
The Webserver module will be delivered with a 3 wire
connection cable (1m). When installing this cable, it is necessary to ensure that
This will be connected to the RS485-3 of the SmartAir it is not bent or stretched and the shield and the locking
Master. lugs of the plug are not damaged.

For longer distances, the cable should be removed and For longer distances, the cable should be removed and
an appropriate cable is to create. an appropriate cable is to create.

The wiring diagram that shows how to connect the To ensure the continued water protection, the cable
RS485 interface to the SmartAir Master can be found in must be leaded through a suitable M20 gland before the
the annex. assembly.

After the connection of the Webserver module, the

RS485-3 interface of the SmartAir Master has to be 9.6 Access via browser
adjusted to enable the communication to the SmartAir
Master.
Within the Webserver module a HTTP-Server is
There, in the menu "Adjustments SmartAir Master" – integrated which can be accessed via web browser.
"RS485 interface" the menu item "Protocol/module" has
to be adjust to "Webserver module". Suitable are (inter alia) the current versions of

Microsoft Internet Explorer

Mozilla Firefox

Also the Adobe Flash Player has to be installed (version

9.0 or higher). It is to find for the appropriate web
browser and for the appropriate operating system

either onto the CD, which will be delivered with the

SmartAir Master

or in the internet.

9.7 Configuration

For the first configuration of the Webserver module a

fixed IP address can be forced.

Therefore the DIP switches 1 and 2 must be set to „On“

and then the module must be reboot.
After this, the module is accessible at the IP address
„192.168.2.1“ and can be reconfigured.

The following parameters can be adjusted:

Hostname
Switch on and off the usage of DHCP
IP address
Netmask
Gateway
DNS server

After the configuration, the DIP switches can be reset

and the module must be reboot.

42
 Annex

Annex

Annex A: Wiring diagrams

SmartAir Master terminals

Terminal strip X0 Function

1 L
2 Infeed N
PE PE

Terminal strip X5 Function

1 24V AC
2 24V AC
Control voltage
3 0V AC
4 0V AC
5 (-)
Analog input AI-1
6 (+)
7 (-)
8 Analog input AI-2 (+)
9 GND
10 +24V DC
11 +24V DC
12 +24V DC
Digital inputs DI-1..3
13 DI-1
14 DI-2
15 DI-3
16 COM
17 Digital output DO-1 NO
18 NC
19 COM
20 Digital output DO-2 NO
21 NC

Terminal strip X1 Function

1 GND
2 RS485-1 B(-)
3 Compressors A(+)
4 PE

Terminal strip X2 Function

1 GND
2 RS485-2 B(-)
3 Extension modules A(+)
4 PE

Terminal strip X3 Function

1 GND
2 RS485-3 B(-)
3 Customer A(+)
4 PE

Terminal strip X4 Function

1 GND
2 B(-)
3 A(+)
4 PROFIBUS module 24V AC
5 0V AC
6 PE
7 PE

Connections on control transformer

240V Terminal 5 + 1
230V Terminal 5 + 2
220V Terminal 5 + 3
120V Terminal 4 + 1
110V Terminal 4 + 2
100V Terminal 4 + 3

43
Annex

Compressor module (STD) to a compressor

Note
The connection of the compressor module (STD) as shown in this document is intended as a guide for the majority of
compressor control systems in use.
Some compressors differ in terms of operation and/or function; consult your compressor supplier/specialist for advice.

Connection of the compressor status messages

Translations Compressor module (STD)

Supply Operation Motor Load

16+17: 6+7: 110..230VUC 9+10: 110..230VUC

12+13: 110..230VUC
110..230VUC 6+8: 24..48VUC 9+11: 24..48VUC
12+14: 24..48VUC

Supply "Operation“ or Line Regulation

voltage Collective fault contactor valve
signal

Controlling a compressor with line pressure sensor and electronic compressor control (examples)

Translations Compressor module (STD)

Remote Remote Remote

load load half load
enable

21 23 26 28 31 33

Digital input Digital input Digital input

Remote load Remote load Remote half load
enable

Electronic compressor control

Compressor module (STD)

Remote Remote Remote
load load half load
enable

21 23 26 28 31 33

+V Digital input Digital input Digital input

Remote load Remote load Remote half load
enable

Electronic compressor control

44
Annex

Controlling a compressor with line pressure switch (example)

Translations Compressor module (STD)

Remote Remote
load load
enable

21 22 23 26 27 28

Pressure switch
(High press. prot.)

+V

Compressor Regul. valve

Press. switch

Compressor module (STD)

Remote Remote
load load
enable

21 22 23 26 27 28

Pressure switch
(High press. prot.)

+V

Regul. valve
Compressor
Press. switch

Regul. valve

Danger
When a compressor module (STD) is installed, the compressor's pressure switch can no longer provide over-
pressure protection.

For compressors that are not equipped with independent over-pressure detection it is recommended that a
pressure switch be incorporated in the compressor fault circuit(s) such that any local over-pressure condition
will stop the compressor independently from the SmartAir Master.

45
Annex

Compressor module (VSD) to a compressor

Note
The connection of the compressor module (VSD) as shown in this document is intended as a guide for the majority of
compressor control systems in use.
Some compressors differ in terms of operation and/or function; consult your compressor supplier/specialist for advice.

Connection of the compressor status messages

Translations Compressor module (VSD)

Supply Operation Warning Load

(optional)
12+13: 110..230VUC
16+17: 6+7: 110..230VUC 9+10: 110..230VUC
12+14: 24..48VUC
110..230VUC 6+8: 24..48VUC 9+11: 24..48VUC

Supply "Operation“ or "Warning“ signal Regulation valve

voltage Collective fault
signal

Connection of the current transducer for speed detection

Current transducer Compressor module (VSD)

Translations HTA500-S
1 31 (+15V)
2 32 (-15V )
3 33 (Signal)
4 34 (GND)

Compressor motor
(Three-phase asynchronous motor
with max. 500A rating current)

Danger
The current transducer supplied is designed for a maximum current of 500A. Ensure that the current flowing
through the current transducer does not exceed 500A.

46
Annex

Connection of the compressor line pressure sensor

Compressor control

Analog input Compressor module (VSD)

Line pressure sensor

Analog output AO-1

Analog input AI-1

Compressor Type adjustment AI-1 / AO-1:

Line pressure sensor 4-20mA: Jumper 21-22
0-10V: Jumper 22-23
0-5V: Jumper 24-23

Internal relay AI-1 with AO-1

short circuits terminals 25-28

Example of a compressor with a passive 4..20mA line pressure sensor

Compressor control

Analog input
Line pressure sensor
Compressor module (VSD)
+UB Sensor GND IN

25 (OUT) AO-1
21
26 (GND)

28 (IN) AI-1 22

+ -
Compressor
Line pressure sensor

Danger
For compressors that are not equipped with independent over-pressure detection it is recommended that a
pressure switch be incorporated in the compressor fault circuit(s) such that any local over-pressure condition
will stop the compressor independently from the SmartAir Master.

47
Annex

Annex B: Module settings

Compressor module (STD)

Terminals

Terminal Function
1
2
3 Not used
4
5
6 COM
Digital input
7 110..230VUC
"Operation"
8 24..48VUC
9 COM
Digital input
10 110..230VUC
"Motor"
11 24..48VUC
12 COM
Digital input
13 110..230VUC
"Load"
14 24..48VUC
16 Power supply (~) (+)
17 110..230V AC/DC +/-10% (~) (-)
21 COM
Digital output
22 NC
"Remote load enable"
23 NO
26 COM
Digital output
27 NC
"Remote load"
28 NO
29 COM
Digital output
30 NC
"Remote half load"
31 NO

Address
The following table shows the necessary DIP switch settings:

DIP switches
Address
12345
1 10000
2 01000
3 11000 1 = ON (up)
4 00100 0 = OFF (down)
5 10100
6 01100
7 11100
8 00010
9 10010
10 01010
11 11010 The DIP switches are
12 00010 behind this cover.

Baudrate / Protocol
No adjustments necessary.

Bus termination
DIP switches 9 and 10 to “ON” to switch on bus termination.

48
Annex

Compressor module (VSD)

Terminals

Terminal Function
1 COM
Digital output DO-1
2 NO
3 COM
Digital output DO-2
4 NO
6 COM
Digital input
7 110..230VUC
"Operation"
8 24..48VUC
9 COM
Digital input
10 110..230VUC
"Warning"
11 24..48VUC
12 COM
Digital input
13 110..230VUC
"Load"
14 24..48VUC
16 Power supply (~) (+)
17 110..230V AC/DC +/-10% (~) (-)
21 Adjustment AI-1 / AO-1
22 4-20mA: Jumper 21-22
23 0-10V: Jumper 22-23
24 0-5V: Jumper 24-23
25 OUT
Analog output AO-1
26 GND
27 +15V
28 Analog-input AI-1 IN
29 GND
30 Screen
31 +15V
32 Analog-input AI-2 -15V
33 SIGN
34 GND

Address
The following table shows the necessary DIP switch settings:

DIP switches
Address
12345
1 10000
2 01000
3 11000 1 = ON (up)
4 00100 0 = OFF (down)
5 10100
6 01100
7 11100
8 00010
9 10010
10 01010
11 11010
12 00010 The DIP switches are
behind this cover.

Baudrate / Protocol
No adjustments necessary.

Bus termination
DIP switches 9 and 10 to “ON” to switch on bus termination.

49
Annex

Extension module

Terminals

Terminal Function
1 Power supply L1
2 230V AC / 50-60Hz N
3 110V AC / 50-60Hz PE
4 COM
5 Digital output DO-1 NC
6 NO
7 COM
Digital output DO-2
8 NO
9 GND
10 DI-1
11 DI-2
12 DI-3
13 DI-4
14 DI-5
15 DI-6
16 DI-7
17 DI-8
Digital inputs DI-1..8
18 GND
19 24V DC
20 24V DC
21 24V DC
22 24V DC
23 24V DC
24 24V DC
25 24V DC
26 24V DC
27 18VDC / GND
28 Analog input AI-1 AI-1
29 Screen
33 18VDC / GND
34 Analog input AI-2 AI-2
35 Screen
32 GND
36 Screen
RS485
37 B(-)
38 A(+)

50
Annex

Drawing

Jumper for analog inputs

Analog-Eingang AI-1 (Terminal 27)

J2 18V DC

J2 GND

Analog-Eingang AI-2 (Terminal 33)

J1 18V DC

J1 GND

51
Annex

Address
The following table shows the necessary DIP switch settings:

DIP-Schalter
Adresse
1234567
1 1000000
2 0100000 1 = ON (oben)
3 0010000 0 = OFF (unten)
4 0001000

Baudrate
DIP switch 8 to OFF (bottom).

Protocol
No adjustments necessary.

Bus termination
Set jumpers J3 and J4 accordingly.

Bus termination on

Bus termination off

52
Annex

Webserver module

Terminals

Terminal X1 Function
1 Power supply L1
2 230V AC / 50-60Hz N
3 110V AC / 50-60Hz PE

Terminal X2 Function
1 +5V
2 A(+)
RS485
3 B(-)
4 GND

Drawing

53
Annex

Annex C: Technical data of the line pressure sensor

Within the scope of delivery of the SmartAir Master.

CompAir ID no. 100003136

Technical data

Measuring range: -1 .. 15bar

Output signal: 4 .. 20mA

Supply voltage: 10 .. 30V DC

Current limitation: 28 mA

Polarity protected

Media temperature: 0 .. 85 °C
Ambient temperature: 0 .. 85 °C

Operating pressure: max. 16 bar

Testing pressure: 24 bar

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Annex

Annex D: Drill templates for mounting

SmartAir Master drill template

260 mm / 10.2"

Weight: 11 kg / 24 lbs
340 mm / 13.4"

340 mm / 13.4"

260 mm / 10.2"

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Annex

Extension module / Webserver module drill template

Weight: 1.5 kg / 3.3 lbs

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Annex

Annex E: Spare parts and accessories

SmartAir Master 10001 6136

Spare parts

Line pressure sensor 10000 3136

Control unit 10001 6064

Battery 3.6V 1.20Ah 10001 6235

Automatic circuit breaker 1A A10235174

Control transformer 10001 6063

Plugs for RS485 interfaces 10001 6066

Plug kit for compressor controls 10001 6137

SD card 1GB 10001 6138

CD-ROM with manuals 10001 6139

Compressor module (STD) 10001 6166

Spare parts

Fuse T1A 250V 5x20mm 10000 4436

Compressor module (VSD) 10001 6222SIM

Spare parts

Fuse T1A 250V 5x20mm 10000 4436

Current transducer 10001 6223
Cable to connect current transducer to the compressor module 10001 6224

Extension module 230V / 50-60Hz 10001 6226

Spare parts

Fuse T0.16A 250V 5x20mm 10001 6883

Fuse T0.5A 250V 5x20mm A11270574
Cable to connect current transducer to the compressor module 10001 6227

Extension module 110V / 50-60Hz 10001 6230

Spare parts

Fuse T0.16A 250V 5x20mm 10001 6883

Fuse T0.5A 250V 5x20mm A11270574
Cable to connect current transducer to the compressor module 10001 6227

PROFIBUS module 10001 6156

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Annex

Accessories ___

RS485/RS232 converter (Flash program adapter) 100004858

USB/RS232 converter (Flash program adapter) ZS1073178

Adapter for software update of compressor module (STD) or (VSD) ZS1047721

Connection plug for compressor module (VSD) for SureScan ZS1055047

Key lock for SmartAir Master ZS1049510

Volume flow sensor (kit) ZS1055781

Dew point sensor (4..20mA) 10001 4803

Temperature sensor (4..20mA) 10001 6229

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Gardner Denver Deutschland GmbH
Argenthaler Str. 11
55459 Simmern
Deutschland

Tel. +49 (0) 6761 832-0

www.compair.com
e-mail: [email protected]

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