DataKom 040 - USER

DK-40 USER MANUAL V2.6 (02.08.
2011)

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datakom@datakom.com.tr
http://www.datakom.com.tr
Tel: +90 216 466 84 60
Fax: +90 216 364 65 65

DK-40 COMPRESSOR CONTROLLER

INTRODUCTION
DK-40 is a state of the art unit for the control
of both screw and piston type compressors.
The unit integrates all functions needed in a
compressor system. Thus no extra units are
required in a compressor panel providing
cost reduction and simplicity.
The unit is directly powered from 230/400 volt
mains. It provides power supply for fault
switches and sensors. Thus external
transformer is not required in the panel.
The unit monitors mains phase voltages and
frequency. It features high/low voltage and
phase order protections.
The standard logic level serial port features
MODBUS communication. The unit allows
monitoring and programming through
computer.

FEATURES
Pressure driven automatic start and stop
Voltage Protection Relay function
Phase Order Protection Relay function
Mains phase voltages display
No need for external transformer
Star / Delta startup
Load solenoid control
1 programmable relay output
Optically isolated configurable digital inputs
2 pressure sensor inputs
2 temperature sensor inputs
Additional motor PTC input
Logic level serial port
MODBUS-RTU communication
Password protected front panel programming
Low panel depth, easy installation
Wide operating temperature range
Sealed front panel (IP54)
2 part connector system for easy installation
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SAFETY NOTICE
Failure to follow below instructions will
result in death or serious injury

Electrical equipment should be installed only by qualified
specialist. No responsibility is assured by the
manufacturer or any of its subsidiaries for any
consequences resulting from the non-compliance to
these instructions.

Check the unit for cracks and damages due to
transportation. Do not install damaged equipment.

Do not open the unit. There is no serviceable parts inside.

Fuses must be connected to the power supply and phase
voltage inputs, in close proximity of the unit.

Fuses must be of fast type (FF) with a maximum rating of
6A.

Disconnect all power before working on equipment.

When the unit is connected to the network do not touch
terminals.

Any electrical parameter applied to the device must be in
the range specified in the user manual.

Do not try to clean the device with solvent or the like.
Only clean with a dry cloth.

Verify correct terminal connections before applying
power.

Only for front panel mounting.

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TABLE OF CONTENTS

Section
1. INSTALLATION
1.1. FRONT / REAR PANELS
1.2. MECHANICAL INSTALLATION
1.3. ELECTRICAL INSTALLATION
1.4. CONNECTION DIAGRAM
2. PUSHBUTTON FUNCTIONS
3. DISPLAY NAVIGATION
4. MODES OF OPERATION
5. ALARMS AND WARNINGS
6. OTHER FEATURES
6.1. RESETTING SERVICE COUNTERS
6.2. MODIFYING HOUR COUNTERS
6.3. SELECTION OF HOUR COUNTING METHOD
6.4. CONNECTION TOPOLOGIES
6.5. PREVENTING PRESSURE LOSS
6.6. ALARM HISTORY
7. INPUTS
8. RELAY OUTPUTS
9. PROGRAMMING
9.1. INTRODUCTION TO PROGRAMMING
9.2. PARAMETER LIST
10. MODBUS COMMUNICATIONS
10.1. DESCRIPTION
10.2. MODBUS REGISTER LIST
11. MULTIPLE CONTROLLER OPERATION
12. DECLARATION OF CONFORMITY
13. TECHNICAL SPECIFICATIONS
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1. INSTALLATION

Before installation:
Read the user manual carefully, determine the correct connection diagram.
Remove all connectors and mounting brackets from the unit, then pass the unit through
the mounting opening.
Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure.
Make electrical connections with plugs removed from sockets, then place plugs to their
sockets.
Note that the power supply terminal is separated from measurement terminals.

Below conditions may damage the device:
Incorrect connections.
Incorrect power supply voltage.
Voltage at measuring terminals beyond specified range.
Connecting or removing data terminals when the unit is powered-up.
Overload or short circuit at relay outputs
Voltage applied to digital inputs over specified range.
High voltage applied to communication port.

Below conditions may cause abnormal operation:
Power supply voltage below minimum acceptable level.
Power supply frequency out of specified limits

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1.1 FRONT / REAR PANELS

1.2 MECHANICAL INSTALLATION

Panel Cutout Required Panel Depth

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1.3 ELECTRICAL INSTALLATION

Do not install the unit close to high electromagnetic noise
emitting devices like contactors, high current busbars,
switchmode power supplies and the like.

Although the unit is protected against electromagnetic disturbance, excessive disturbance
can affect the operation, measurement precision and data communication quality.

ALWAYS remove plug connectors when inserting wires with a screwdriver.
Fuses must be connected to the power supply and phase voltage inputs, in close
proximity of the unit.
Fuses must be of fast type (FF) with a maximum rating of 6A.
Use cables of appropriate temperature range.
Use adequate cable section, at least 0.75mm
2
(AWG18).
Follow national rules for electrical installation.
Use only the appropriate cable and connector for serial port connection.
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1.4 CONNECTION DIAGRAM

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2. PUSHBUTTON FUNCTIONS

Programming and measurement displays are visualized using below buttons:

BUTTON DESCRIPTION FUNCTION

MENU
Displays next parameter.
Resets faults.
Saves adjusted value.

RUN
Run the compressor and reset existing
alarms.
Increase value.

STOP
Stop the compressor and reset existing
alarms.
Decrease value.

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3. DISPLAY NAVIGATION

Usually the upper display shows the pressure-1 value or the pressure switch-1 position.
The lower display shows the temperature-1.
Other values are scrolled by pressing the MENU button. For better clarity, the upper
display will show the parameter name and the lower display will show the parameter value.
Some parameters are longer than 1 display. For these parameters, when MENU button
is presssed the parameter name apeears on the upper display. When MENU button is
released, the parameter value is shown on both displays.

Display of some parameters are selectable with program parameters and
may differ following compressor manufacturers.

In the occurrence of a fault condition, the fault code will appear on the
upper display.

Below is a list of messages shown on the upper display in normal operation,
programming and alarm display modes:
MESSA
GE
DESCRIPTION MODE
bar bar bar bar
set set set set
Start pressure and stop pressure set
values
Display
FrQ FrQ FrQ FrQ
Mains frequency Display
L12 L12 L12 L12
L1-L2 phase-to-phase voltage Display
L23 L23 L23 L23
L31 L31 L31 L31
SH SH SH SHA AA A
Hours remaining to service A Display / Program / Alarm
SHB SHB SHB SHB
Hours remaining to service B Display / Program / Alarm
SHC SHC SHC SHC
Hours remaining to service C Display / Program / Alarm
SHD SHD SHD SHD
Hours remaining to service D Display / Program / Alarm

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MESSA
GE
DESCRIPTION MODE
SHE SHE SHE SHE
Hours remaining to service E Display / Program / Alarm
C-H C-H C-H C-H
Total compressor hours
(ON_LOAD+OFF_LOAD+STOP)
Display
R-H R-H R-H R-H
Total Run Hours
(ON_LOAD+OFF_LOAD)
Display
L-H L-H L-H L-H
Total load time (load contactor active) Display
o/o o/o o/o o/o
Load hours / Run hours percentage Display
E-t E-t E-t E-t
Motor PTC value or switch position Display
t- t- t- t-2 22 2
Temperature-2 value or switch position Display
d-p d-p d-p d-p
Differential Pressure Display
n-- n-- n-- n--
Remaining starts for the last hour Display
rEL rEL rEL rEL
Software version Display
Ah1 Ah1 Ah1 Ah1
Alarm history 1 Display
n-C n-C n-C n-C
Switch closed Display
N-O N-O N-O N-O
Switch open Display
SEP SEP SEP SEP
Waiting for separator filter pressure drop Display
STP STP STP STP
Remote Stop mode Display
RUN RUN RUN RUN
Remote Start mode Display
aL1 aL1 aL1 aL1
Alarm code 01 Display
a99 a99 a99 a99
Alarm code 99 Display
p99 p99 p99 p99
Program parameter 99 Program
usr usr usr usr
Enter password Program
seL seL seL seL
Select parameter Program

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4. MODES OF OPERATION

Selecting the operating mode:
At power-up, the unit will turn all lights on for 3 seconds in order to allow lamp check. Then
it goes in the STOP mode and the stop led turns on.
The compressor may be run through Remote Start signal (upper display shows rUn rUn rUn rUn for 5
seconds) or by pressing the RUN button.
If P28 Safety Timer has not elapsed, the run led will flash until expiration of the timer. Then
if the pressure is below the limit set by P05 Start Pressure, then the compressor will run.

In the occurrence of an alarm the compressor stops
immediately and the upper display shows the alarm code.
A comprehensive list of alarm codes is given in chapter 5.

The compressor may be stopped with Remote Stop signal (upper display shows StP StP StP StP for 5
seconds) or the STOP button.
Stop procedure:
STOP led starts flashing.
If the compressor is loaded, then the LOAD relay will release and the compressor
continues to run during P28 Safety Timer or P26 Unload Timer (whichever is longer).
At this step, operation may be resumed by pressing the RUN button. If STOP
button is pressed during unloaded operation, then the compressor stops immediately.
The stop led flashes until the compressor comes to complete stop.

When STOP button is pressed, if the compressor is
running unloaded, then it will continue to run until
expiration of P26 Unload Timer.
The compressor may be immediately stopped by
pressing again the STOP button.

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Start procedure:
If mains phase voltages and frequency are between preset limits and the phase order is
correct, then the POWER led will turn on. The compressor may run only when the power
led is on. Otherwise it cannot run.
The Run mode of operation is selected by pressing the RUN button or by sending
REMOTE START/STOP signal (if enabled). At this position, when the pressure falls below
P05 Start Pressure (or pressure switch closes) the unit decides to run the compressor.
Befor running the compressor the STAR relay output becomes active. After P15 Delay
between Relays Timer LINE relay will be activated. Thus the motor starts in star mode.
After P23 Star Timer the STAR relay opens and after P24 Star/Delta Transition Timer the
DELTA relay operates.
After P25 Timer before Loading the LOAD relay operates and the compressor starts
producing compressed air.

Unloading and reloading:
When the pressure reaches P04 Stop Pressure (or pressure switch opens) then the LOAD
relay opens and the compressor runs unloaded during P26 Unload Timer. If the pressure
falls below P05 Start Pressure before the expiration of the timer, then the LOAD relay
energizes again.

Stopping and restarting:
If the pressure stays over the P05 Start Pressure limit (or pressure switch opened) during
P26 Unload Timer, then the DELTA relay will release. After P15 Delay between Relays
timer, the LINE relay releases.
In this situation, the RUN led starts flashing.
The maximum number of starts that the compressor may perform in one hour is adjusted
with P37 Maximum Starts per Hour parameter.
If the maximum start count is reached, then the compressor stopping is disabled and it will
continue to run unloaded until the end of 1 hour period.

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5. ALARMS AND WARNINGS

Abnormal situations in the compressor are evaluated under 3 different categories as
ALARMS, WARNINGS and SERVICE REQUESTS.
Warnings are lowest level fault conditions and generate only visual warning, not affecting
the compressor operation.
Alarms are highest level fault conditions and cause the compressor to stop immediately,
the alarm relay to become active (if enabled by programming) and visual warning to occur.
If any fault condition occurs, the fault code will appear on the upper display and the related
fault category led turns on. (WARNING, ALARM or SERVICE)
Alarms and warnings may be reset by pressing the MENU button. The EMERGENCY
STOP alarm cannot be reset by pressing buttons, the alarm signal must be removed.

Service warnings may affect the compressor operation
depending on the amount exceeding the service period.

TIME REMAINING TO
SERVICE
REACTION
> 100 hours No warning given.
100hours
Service warning is given and SERVICE led turns on. The
compressor continues normal operation.
0 hour
The compressor stops. Service warning is given and
SERVICE led turns on. The compressor resumes normal
operation when RUN button is pressed.
-100 hours
-120 to -200 hours,
every 20 hours
-210 to -300 hours,
every 10 hours
-300 hours
SERVICE led turns on. The compressor will not operate
again unless the service counter is reset.

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FAULT CODES LIST

SYMBOL CODE DESCRIPTION TP
AL1 01 Security Pressure Switch Opened ALARM
AL2 02 High Pressure ALARM
AL3 03 Pressure Sensor Fail ALARM
AL4 04 High Temperature ALARM
AL5 05 High Temperature WARNING
AL6 06 Temperature Sensor Fail ALARM
AL7 07 Low Temperature ALARM
AL8 08 Fan Motor High Temperature ALARM
AL9 09 Motor PTC High Temperature ALARM
A10 10 Voltage Unbalance ALARM
A11 11 High Voltage ALARM
A12 12 Low Voltage ALARM
A13 13 High Frequency ALARM
A14 14 Low Frequency ALARM
A15 15 Phase Squence Fail ALARM
A16 16 Air Filter Clogged WARNING
A17 17 Maximum starts per hour exceeded WARNING
A18 18 Emergency Stop ALARM
A19 19 Internal Warning WARNING
A20 20 Pressure Difference ALARM
A21 21 High Pressure-2 ALARM
A22 22 Pressure-2 Sensor Fail ALARM
A23 23 High Temperature-2 / Delta (tS2-tS1) ALARM
A24 24 Temperature-2 Sensor Fail ALARM
A25 25 Low Temperature-2 ALARM
A26 26 Air In Separator WARNING
A27 27 Delta Temperature-2 Warning WARNING
A28 28 Main Motor thermal ALARM
A29 29 Low Pressure-2 ALARM
SHA 100 Service A Period Elapsed SERVICE
SHb 101 Service B Period Elapsed SERVICE
SHC 102 Service C Period Elapsed SERVICE
SHD 103 Service D Period Elapsed SERVICE
SHE 104 Service E Period Elapsed SERVICE
Stp 200 Remote Stop -

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6. OTHER FEATURES

6.1. RESETTING SERVICE COUNTERS

Service counters can only be reset when the compresssor
is in STOP mode.

In order to reset service counters:
- Hold MENU and RUN buttons pressed for 3 seconds. If the high level
password is not entered in the last 90 minutes, the unit will ask the password.
- Enter the password.
- The upper display will show sH sH sH sHA AA A hours remaining for SERVICE A message.
- Press again the MENU button. The hours remaining for SERVICE A will appear
flashing on the display.
- In order to reset the hours remaining for SERVICE A, hold pressed MENU button
for 3 seconds.
- The upper display will show the next service counter which is SHB SHB SHB SHB hours remaining for
SERVICE B message.
- Press again the MENU button. The hours remaining for SERVICE B will appear
flashing on the display.
- In order to reset the hours remaining for SERVICE B, hold pressed MENU button
for 3 seconds.
- By pressing the MENU button again, below counters can be scrolled and reset:
SHC SHC SHC SHC: hours remaining for SERVICE C
SHD SHD SHD SHD: hours remaining for SERVICE D
SHE SHE SHE SHE: hours remaining for SERVICE E

After the last counter, the display will return to pressure-
temperature display mode.

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6.2. MODIFYING HOUR COUNTERS

The unit holds 3 different run hour counters:
MESSAGE DESCRIPTION
C-H C-H C-H C-H
Total compressor hours (ON_LOAD+OFF_LOAD+STOP)
This counter increments while the RUN led is on.
R-H R-H R-H R-H
Total motor run hours
(ON_LOAD+OFF_LOAD)
This counter increments while the motor runs.
L-H L-H L-H L-H
Total load time (load contactor active)
This counter increments while LOAD led is on.

Hour counters can only be modified while the compresor
is in STOP mode.

In order to modify hour counters:
- Hold pressed together MENU , RUN and STOP buttons for 3 seconds. If
the high level password is not entered in the last 90 minutes, the unit will ask password
(USR USR USR USR).
- Enter password.
- The upper display will show C-H C-H C-H C-H message.
- Adjust required hour counter value with RUN and STOP buttons.
- Press MENU button for 3 seconds, the display wil show SEt message and the
counter will be adjusted to the new value. If MENU button is pressed for short
duration, then the value will not be modified and the next hour counter will be displayed.
Same steps are repeated for further modification.

After modifications, the display will return to pressure-
temperature display mode.

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6.3. SELECTION OF HOUR COUNTING METHOD

The unit offers the possibility of incrementing hour counters with a variable coefficient,
depending on air end temperature.
The use of variable coefficient is selected with P89 Variable Hour counting coefficient. If
this parameter is 0, all service and hour counters will increment with a fixed coefficient of
1.00.
If Variable Hour Counting is activated:

Running on load:
below 90 C, coefficient = 1.00
between 90 and 95 C, coefficient = 1.50
above 100 C, coefficient = 3.00

Running off load
below 90 C, coefficient = 0.50
above 100 C, coefficient = 1.50

These coefficients apply to both service and compressor
hour counters.

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6.4. CONNECTION TOPOLOGIES

The unit supports various connection topologies. The topology is selected through
parameter P48.
Different topologies and terminal connections are as below:

P48 = 3

P48 = 1

P48 = 2

P48 = 3
The power supply and measuring terminals
of the unit are isolated. In order to enable
above topology, the unit must be specially
manufactured.

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6.5. PREVENTING PRESSURE LOSS

If the pressure stays above the P05 Start Pressure, during P26 Unload Timer then
the unit will stop the motor. If the pressure falls below P05 Start Pressure then the motor
will run again.
Before the compressor is loaded, a timer equal to P23+P24+P25+P15x3 will be
elapsed.
During this period, depending on the air consumption, the pressure may fall below
P05 Start Pressure.
In most applications, it is required that the pressure never falls below the P05 Start
Pressure limit.
In order to prevent this unwanted situation, the unit offers 3 different operating
modes selected through program parameter P45. The unit calculates dynamically the
restart pressure (Pi)

P45 = 0 No special care taken. Pi = P05.
P45 = 1 When the compressor is loaded, if the pressure is below P05 Start Pressure,
then the Restart Pressure (Pi) is incremented by 0.1 bar.
When the compressor is loaded, if the pressure is above P05 Start Pressure, then the
Restart Pressure (Pi) is decremented by 0.1 bar. Thus the unit tries to load at exactly P05
Start Pressure.
P45 = 2 When the compressor reaches P04 Stop Pressure, the unit measures the air
consumption during 8 seconds, then calculates the Restart Pressure (Pi) again.

At the end of P26 Unload Timer, if the pressure is above
P05 Start Pressure and below Pi Restart Pressure, then the
motor will continue to run unloaded.

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6.6. ALARM HISTORY

The unit keeps the list of 9 most recent alarm records.
A new occurring alarm will appear at the top of the list.
The alarm list may be visualized on the screen or read through Modbus.
The alarm list is kept in a non-volatile memory and is not affected by power failures.
The alarm will be added to the list only if it is different from the previous alarm or the
motor has run at least 6 minutes after its previous occurrence.
In order to visualize the latest alarm in the history press MENU button until
Ah Ah Ah Ah1 11 1 (alarm history 1) comes to the display.
To visualize previous alarms use RUN and STOP pushbuttons.

When the alarm history is scrolled the STOP button
is always active and stops the compressor. However the
RUN button is not active and does not run the
compressor. To scroll the alarm history when the
compressor is running please use only the RUN
button.

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7. DGTAL INPUTS

The unit offers 4 user configurable digital inputs.
The characteristics of these inputs are configured through parameters P73 to P76.
The configuration record consists on 3 parts. The programmed value is the sum of these
3 parts.

Configuration = part_1 + part_2 + part_3

Part_1 = input fault code:
This part determines which fault is generated from this input. The complete fault
code list is given in chapter 5.
Part_2 = input switch type (NO or NC)
NO (normally open) = 256
NC (normally closed) = 0
Part_3 = input detection delay
0.1sec delay = 0
0.5sec delay =512
2.0sec delay =1024
5.0sec delay = 1536
Example 1:
In order to adjust input 2 as EMERGENCY STOP, NC switch and 0.1sec delay:
Part_1 = 18 (refer chapter 5)
Part_2 = 0 (NC switch)
Part_3 = 0 (0.1 sec)
P74 (Input_2 configuration) = 18+0+0 = 18
Example_2:
In order to adjust input 4 as REMOTE START, NO switch, 2.0sec delay:
Part_1 = 200 (refer chapter 5)
Part_2 = 256 (NO kontak)
Part_3 = 1024 (2.0 sn)
P76 (Input_4 configuration) = 200+256+1024 = 1480
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8. RELAY OUTPUTS

The unit provides 5 relay outputs. 4 of them have fixed function, while RL5 has
selectable function.
Relays with fixed function:
RL1 = LINE relay
RL2 = DELTA relay
RL3 = STAR relay
RL4 = LOAD relay

RL5 can be programmed for below functions through parameter P40:

RELAY FUNCTION DESCRIPTION
0 ALARM RL5 operates if alarm exists, releases otherwise.
1 FAN
If the air end temperature equals or greater than P41, then
RL5 is on. If the air end temperature is lower than
(P41-P42), then RL5 is off.
2 LOAD RL5 = RL4
3 NO LOAD RL5 = opposite of RL4
4 MOTOR RUNNING RL5 operates if the main motor runs, releases otherwise.
5 MOTOR STOPPED
RL5 operates if the main motor is stopped, releases
otherwise.
6 FLAR RLE
Released during timer P41
Active during timer P42 .
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9. PROGRAMMING

9.1. INTRODUCTION TO PROGRAMMING

The program menu can be entered only when the
compressor is in STOP mode.

The entry to programming menu is protected by a 2 level password system. The
program parameter set and password levels may differ following compressor
manufacturers. This documents describes the parameter set as available ex-works.

Factory set values:
Low level password = 386
High level password = 741

To enter programming menu:
- When the compressor is in STOP mode, hold pressed MENU and STOP buttons
for 3 seconds.
- The upper display will show USr USr USr USr . Enter the password using RUN and STOP
buttons and press MENU button. For fast increment/decrement, hold pressed RUN
and STOP buttons.
To exit programming menu:
- Hold pressed the MENU button for 3 seconds.
7Modifying program parameters:
- When programming menu is entered the upper display will show the program number and
the lower display will show SEL SEL SEL SEL.
- Select parameter number with RUN and STOP buttons.
- Display parameter value by pressing the MENU button. Adjust the parameter with
RUN and STOP buttons and return to parameter number selection by pressing the
MENU button.

If no key is pressed, the display will return to normal mode
after 1 minute.

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9.2. PARAMETER LIST

Some parameters given in this list may not appear on
device display.

No Description Adjustment Range Factory set
P01 Pressure Control
0: Analog transducer
1: Pressure Switch
If this parameter is set to 1 then
P02 ... P06 parameters are not
displayed.
0
P02
Top Range of Pressure
Transducer
4.2 ... 99.9 15.0 bar
P03 High Pressure Alarm (P02-0.5) ... (P04+0.5) 8.5 bar
P04 Stop Pressure (P03-0.2) ... (P05+0.2) 7.3 bar
P05 Start Pressure 3 ... (P04-0.2) 6.5 bar
P06 Offset Pressure Transducer -2 ... +2 0 bar
P07
Top range temperature
probe
(P08+2) ... 130 130 C
P08
High air end temperature
Alarm
(P09+2) ... (P07-2) 108 C
P09
High air end temperature
Warning
(P10+2) ... (P08-2) 103 C
P10
Low air end temperature
Alarm
-10 ... (P09-2) 0 C
P11
Offset value air end
temperature
-10 ... +10 0 C
P12 Motor PTC Enable
0:Disable
1: Enable
If this parameter is set to 1, then
when the resistance measured at
the Motor PTC input is above
2000 ohms this will generate an
A09 Motor PTC high
temperature alarm.
0

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P13 Automatic Restart
0:Disable (the unit will power-up
always in STOP mode)
1: Enable (the unit will power-up
with the same mode as the
power-down instant)
0
P14
Temperature for Pressure
Compensation
0 ... (P09)
While the air end temperature is
below this limit, instead of P04
Stop Pressure, P05+(P04-P05)/4
value is used.
Thus the compressor stops
before reaching Stop Pressure .
0 C
P15 Delay Between Relays 20 ... 250 200ms
P16 Voltage Unbalance Ratio 0 ...20 5 %
P17
Temp. 2 Sensor operation
mode
0:Disable
1:Absolute temperature
2:Differential temperature
If this parameter is set to 0, the
P18, P19, P20 and P22
parameters will not be displayed.
0
P18 Top range Temp. 2 Sensor (P19+2) ... 200 130 C
P19
Temp. 2 Sensor High Limit
(Delta Alarm Limit)
(P20+2) ... (P18-2)
(Temperature differential alarm
Limit)
110 C
P20
Low Alarm/Delta Warning
Temp. 2
-40 ... (P19-2)
(Temperature differential warning
Limit)
-10 C
P21
Alarm/Warning Duration
time
1 ... 600 10 sec
P22
Offset value Temp. 2
Sensor
-10:+10 0 C
P23 Star Timer 2 ... 20 7 sec
P24 Star /Delta transition Timer 10 ... 50 35 ms
P25 Timer before loading 1 ... 120 1 sec
P26 unload timer 0 ... 10 2 min

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P27
Unload timer fixed or
variable
0: Fixed
1: Variable
If set to 1:
If the stop duration is more than
the unload run duration, the
unload timer is reduced by 1
minute at each run, until an
absolute minimum of 2 minutes.
0
P28 Safety Timer
1 ... 240
Refer to chapter 4 for this
parameter.
30 sec
P29 Service A Period
0 ... 32767
no service A warning is given.
2000 hours
P30 Service B Period
0 ... 32767
no service B warning is given.
4000 hours
P31 Service C Period
0 ... 32767
no service C warning is given.
6000 hours
P32 Service D Period
0 ... 32767
no service D warning is given.
14000 hours
P33 Service E Period
0 ... 32767
no service E warning is given.
20000 hours
P34 Display Extra sensors
0: Disable
1: Enable
1
P35 Low level password 0 ... 999 386
P36 High level password 0 ... 999 741
P37 Maximum Starts per Hour 6 ... 60 20
P38 Low Voltage Alarm Enable
0:Disable
1:Enable
P39 parameter will not be
displayed.
1
P39 Low Voltage Alarm Value 200 ... 600 360 V-AC

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K13D01-E - 27 -

P40 RL5 function selection
0: Alarm
1: Fan
2: Load
3: No load
4: Motor run
5: Motor stopped

Refer chapter 8 for more details.
2
P41 Fan On Temperature (RL5)
30 ... (P09-2)
85 C
P42
Delta T Fan Off
Temperature (RL5)
5 ... 15
10 C
P43 Reserved - 0
P44 Reserved - 0
P45
Pressure loss preventing
method
0: standard operation
1: step increase/decrease
2: dynamic calculation
0
P46 Reserved - 0
P47 Reserved - 0
P48 Connection topology
1: 1 phase
2: 2 phases
3: 3 phases
3
P49 Phase L1 calibration 1 ...32767 1186
P50 Phase L2 calibration 1 ... 32767 1186
P51 Phase L3 calibration 1 ... 32767 1186
P52
Low Frequency Alarm
Enable
0: Disable
1: Enable
displayed.
1
P53 Low Frequency Alarm Limit 10.0 ... 60.0 Hz 48.0 Hz
P54
High Frequency Alarm
Enable
0: Disable
1: Enable
displayed.
1

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P55
High Frequency Alarm
Value
60.0 ... 990.0 Hz 62.0 Hz
P56 Frequency display
0: Disable
1: Enable
1
P57 Phase L1 voltage display
0:Disable
1:Enable
0
0:Disable
1:Enable
0
0:Disable
1:Enable
0
P60 Phase L1-L2 voltage display
0:Disable
1:Enable
1
0:Disable
1:Enable
1
0:Disable
1:Enable
1
P63 MODBUS enable
0: Disable
1: Enable
1
P64 Master/Slave MODBUS
0: Slave
1: Master
0
P65 MODBUS node address
1: Starts multiple controller opr.
2 ... 254: Modbus address
240
P66
Slave Start Timer (Multiple
controller operation)
1..999 sec. 180 sec
P67
Master Change Period
(Multiple operation)
1..999 hours 100 hours
P68 Serial Number Low Word 0 ... 65535 10
P69 Serial Number High Word 0 ... 65535 10
P70 High Voltage Alarm Enable
0: Disable
1: Enable
displayed.
1
P71 High Voltage Alarm Limit 200 ... 650 V 445
P72 Phase Order Check Enable
0: Disable
1: Enable
1

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K13D01-E - 29 -

P73 Input1 configuration register
0 ... 2047
18
P74 Input 2 configuration register
0 ... 2047
28+512=540
P75 Input 3configuration register
0 ... 2047
8+512=520
P76 Input 4configuration register
0 ... 2047
16+256+=1808
P77
Pressure 2 Input
Configuration
0: Disabled
1: Pressure switch
2: Analog transducer
If this parameter is set to 0 or 1,
parameters P78 ... P82 will not be
displayed.
0
P78
Top range pressure 2
transducer
4.2 ... 99.9 Bar 15.0 bar
P79
High Pressure Sensor 2
Alarm Limit
3.7 ... (P78-0.5) 8.8 bar
P80
Differential pressure alarm
limit (press1 press2)
-10.0 ... +10.0 0.5 bar
P81
Differential pressure alarm
delay
1 ... 600 10 sec
P82 Offset pressure transducer 2 -2:+2 0 bar

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K13D01-E - 30 -

P83
Pressure sensor-2 low
pressure alarm limit (if
adjusted to 0.0 then no
alarm is given)
0.. (P79-0.5) 0
P84 Reserved - 0
P85 Reserved - 0
P86 Reserved - 0
P87 Reserved - 0
P88 Service security selection
0: Service request gives warning
only
1:Service request stops the
compressor as explained in
chapter_5.
0
P88 Reserved - 0
P89
Variable Hour counting
method
0: Fixed hour counting coefficient
1: Variable hour counting method

Refer chapter 6.3 for more
details.
0
P90 Pressure Dot Display
0: Enable
1: Disable
pressure is displayed in xx.x
format. This format is useful for
display in bars.
pressure is displayed in xxx
format. This format is useful for
display in psi.
0

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10. MODBUS COMMUNICATION

10.1. DESCRIPTION

The unit offers serial data communication port allowing it to be integrated in automation
systems.
The serial port works with logic levels. With special adapters, it can be converted to RS-232
or RS-485 standards.
The MODBUS properties of the unit are:
-Data transfer mode: RTU
-Serial data: 9600 bps, 8 bit data, no parity, 1 bit stop
-Supported functions:
-Function 3 (Read multiple registers, max 120 registers)
-Function 6 (Write single register)
-Function 10 (Write multiple registers, max 32 registers)
-The answer to an incoming message is sent with a minimum of 4.3ms delay after
message reception.
Each register consists of 2 bytes (16 bits). Larger data structure contain multiple registers.
Detailed description about the MODBUS protocol is found in the document Modicon
Modbus Protocol Reference Guide. ( http://www.modbus.org/specs.php)
Data Reading
The function 03 (read multiple registers) will be used for data reading. The MODBUS
master will send a query. The answer will be one of the below:
-A response containing the requested data
-An exceptional response indicating a read error.
The maximum number of registers read in one message is 120. If more registers are
requested, the unit will send only the first 120 registers.
The query message specifies the starting register and quantity of registers to be read. The
message structure is below:
Byte Description Value
0 Controller address 1 to 254
1 Function code 3
2 Starting address high See below the description of available
registers 3 Starting address low
4 Number of registers high always 0
5 Number of registers low max 78h (120 decimal)
6 CRC low byte See below for the checksum calculation
7 CRC high byte

Here is the sequence to read 16 registers starting from address 20h (32 decimal):
01 03 00 20 00 10 45 CC (each byte is expressed as 2 hexadecimal characters)
The checksum value in the above message may be used for the verification of checksum
calculation algorithm.
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The normal response will be:
0 Controller address same as in the query
1 Function code 3
2 Data lenght in bytes (L) number of registers * 2
3 High byte of 1st register
4 Low byte of 1st register
5 High byte of 2nd register
6 Low byte of 2nd register
....
L+1 High byte of the last register
L+2 Low byte of the last register
L+3 CRC low byte See below for the checksum calculation
L+4 CRC high byte

The exceptional response will be:
1 Function code 131 (function code + 128)
2 Exception code 2 (illegal address)
4 CRC high byte

Data Writing
The function 06 (write single register) or function 10 (write multiple registers) is used for
data writing. A maximum of 32 registers can be written at a time.
The MODBUS master will send a query containing data to be written. The answer will be
one of the below:
-A normal response confirming successful write,
-An exceptional response indicating a write error.
Only some of the available registers are authorized to be written. An attempt to write a write
protected register will result to the exceptional response.
The query message specifies the register address and data. The message structure is
below:
1 Function code 6
2 Register address high See below the description of available registers
3 Register address low
4 Data high byte
5 Data low byte
7 CRC high byte

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Here is the sequence to write the value 0010h to the register 40h (64 decimal):
01 06 00 40 00 10 89 D2 (each byte is expressed as 2 hexadecimal characters)
The checksum value in the above message may be used for the verification of checksum
calculation algorithm
The normal response will be the same as the query:
1 Function code 6
2 Register address high See below the description of available registers
3 Register address low
4 Data high byte
5 Data low byte
7 CRC high byte

The exceptional response will be:
1 Function code 134 (function code + 128)
2 Exception code 2 (illegal address)
or
10 (write protection)
4 CRC high byte

CRC calculation

Here is a procedure for generating a CRC:
1) Load a 16bit register with FFFF hex (all 1s). Call this the CRC register.
2) Exclusive OR the first 8bit byte of the message (the function code byte) with the low
order byte of the 16bit CRC register, putting the result in the CRC register.
3) Shift the CRC register one bit to the right (toward the LSB), zerofilling the MSB. Extract
and examine the LSB. The LSB is the least significant bit of the CRC before the shift
operation.
4) If the LSB is 1: Exclusive OR the CRC register with the polynomial value A001 hex.
5) Repeat Steps 3 and 4 until 8 shifts have been performed. Thus, a complete 8bit byte
will be processed.
6) Repeat Steps 2 through 5 for the next 8bit byte of the message. Continue doing this
until all bytes have been processed.
7) The final contents of the CRC register is the CRC value.
8) Place the CRC into the message such that the low byte is transmitted first. The algorithm
should give the correct CRC for below messages:
01 03 00 20 00 10 45 CC
01 06 00 40 00 10 89 D2

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K13D01-E - 34 -

Error codes
Only 3 error codes are used:
01: illegal function code
02: illegal address
10: write protection (attempt to write a read_only register)

Data types
Each register consists of 16 bits (2 bytes)
If the data type is a byte, only the low byte will contain valid data. High byte is dont care.
For data type longer than 16 bits, consecutive registers are used. The least significant
register comes first.
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K13D01-E - 35 -

10.2. MODBUS REGISTER LIST

CONTROLLER REGISTERS
ADDR. NAME DESCRIPTION LENG. R/W TYPE MUL.
40001 Frequency

16 BIT R-O unsigned word 0.1
40002 Phase L1 Voltage

16 BIT R-O unsigned word 1


40005 Phase L1-L2 Voltage



40008 Pressure Pressure Value 16 BIT R-O unsigned word 0.1
40009 Air end temperature Temperature Value 16 BIT R-O signed word 1
40010 Motor PTC ohm read in ohms 16 BIT R-O signed word 1
40011 Temperature 2 Measured from Sensor 2 16 BIT R-O signed word 1
40012 Pressure 2 Measured from Sensor 2 16 BIT R-O unsigned word 0.1
40013
Service A Counter remaining time to service A 32 BIT R-O signed long 0.1
40014
40015
Service B Counter remaining time to service B 32 BIT R-O signed long 0.1
40016
40017
Service C Counter remaining time to service C 32 BIT R-O signed long 0.1
40018
40019
Service D Counter remaining time to service D 32 BIT R-O signed long 0.1
40020
40021
Service E Counter remaining time to service E 32 BIT R-O signed long 0.1
40022
40023
Total Working Hour
Total controller time
(LOAD + UNLOAD + STOP)
32 BIT R-O unsigned long 0.1
40024
40025
Total Engine Hour
Total Engine working
hour(LOAD+UNLOAD)
40026
40027
Total Load Hour
Total Engine loaded
hour(LOAD)
40028
40029
Alarms
alarm bits (see alarm list at
chapter 10.3)
32 BIT R-O unsigned long 1
40030
40031 Warnings
warnings bits (see alarm list
at chapter 10.3)
40032 Service requests
maintenance register (see
list at chapter 10.3)

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K13D01-E - 36 -

CONTROLLER REGISTERS

40033
Motor Status
Current motor status
0: Compressor in OFF mode
1: Motor star
2: Motor delta (before load)
3: Motor loaded
4: Motor unloaded
5: Motor stopped,
compressor in RUN mode
40034 Fault Code
Current alarm or warning or
service code
40035 Relay status
Current relay status bits
bit 1-3:-
bit 4: Line relay
bit 5: RL5 (alarm/fan)
bit 6: Load relay
bit 7: Delta relay
bit 8: Star relay
bit 9-16: -
40036 - - 16 BIT R-O unsigned word 1
40037 Alarm 1 Alarm 1 in alarm history 16 BIT R-O unsigned word 1
40046 Connection topology
1:Single phase, 2:bi-phase
3: three phase
40047
-
40128
reserved - 16 BIT R-O unsigned word 1

PROGRAM PARAMETERS
40129 P01 See chapter 9.2 16 BIT R/W unsigned word 1
40130 P02 See chapter 9.2 16 BIT R/W unsigned word 0.1
40134 P06 See chapter 9.2 16 BIT R/W signed word 0.1
40135 P07 See chapter 9.2 16 BIT R/W signed word 1

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K13D01-E - 37 -

PROGRAM PARAMETERS

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K13D01-E - 38 -

PROGRAM PARAMETERS
40219
-
40256
reserved reserved registers 16 BIT R/W unsigned word 1

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K13D01-E - 39 -

SENSOR GRAPHS
40385
-
40416
PRESS_SENSOR
GRAPH [32]
Pressure Sensor (mA - Bar)
32*16
BIT
R-O unsigned word 1
40417
-
40448
TEMPERATURE
SENSOR GRAPH
[32]
Temperature Sensor(Ohm -
C)
32*16
BIT
R-O signed word 1
40449
-
40480
MOTOR PTC
SENSOR GRAPH
[32]
Motor PTC Temperature
Sensor(Ohm - C)
32*16
BIT
R-O signed word 1
40481
-
40512
TEMPERATURE 2
SENSOR GRAPH
[32]
Temperature Sensor 2
(Ohm - C)
32*16
BIT
R-O signed word 1
40513
-
40544
PRESSURE 2
SENSOR GRAPH
[32]
Pressure Sensor 2 Graph
(mA - Bar)
32*16
BIT
R-O unsigned word 1

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K13D01-E - 40 -

COMMANDS
40769 C01 Reserved register 16 BIT W-O unsigned word 1
40770 C02
Return to Factory (value =
0xAA55)
16 BIT W-O unsigned word 1
40771 C03
Reset Counter
(value = Counter(1-8)
40772 C04
LOCK KEY
(Value = KEY CODE)
40773
-
40800
Reserved - 16 BIT W-O unsigned word 1
40801 Set service 1
Time to service A
(low 2 bytes)
40802 Set service 2
Time to service A
(high 2 bytes)
40803 Set service 3
Time to service B
(low 2 bytes)
40804 Set service 4
Time to service B
(high 2 bytes)
40805 Set service 5
Time to service C
(low 2 bytes)
40806 Set service 6
Time to service C
(high 2 bytes)
40807 Set service 7
Time to service D
(low 2 bytes)
40808 Set service 8
Time to service D
(high 2 bytes)
40809 Set service 9
Time to service E
(low 2 bytes)
40810 Set service 10
Time to service E
(high 2 bytes)
LOADED+UNLOADED+STOP
time (low 2 bytes)
LOADED+UNLOADED+STOP
time (high 2 bytes)
40813 Set Service 13
Engine run hours
(low 2 bytes)
Engine run hours
(high 2 bytes)
Load run hours
(low 2 bytes)
Load run hours
(high 2 bytes)
40817 C05
Alarm history reset
(Value = 0xAA55 hex)

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K13D01-E - 41 -

10.3. ALARMS-WARNINGS-SERVICE REQUESTS

The ALARM record is 32 bits. Each bit indicates the existence of an alarm.

BIT
NO:
DESCRIPTION
1 Low Voltage Alarm
2 High Voltage Alarm
3 Low Frequency Alarm
4 High Frequency Alarm
5 Thermal Motor Switch Open
6 Thermal Fan Switch Open
7 High Temperature Alarm
8 Temperature Sensor Fail
9 Low Temperature Alarm
10 Security Pressure Switch Open
11 High Pressure Alarm
12 Pressure Transducer Fail
13 Emergency Stop
14 -
15 Motor PTC Sensor Fail
16 Motor PTC High Temperature Alarm
17 Motor PTC Low Temperature Alarm
18 Phase Sequence Fail Alarm
19 Air Filter Clogged
20 Temperature Sensor 2 Fail
21 High Temperature 2 Alarm
22 Low Temperature 2 Alarm
23 Pressure Transducer 2 Fail
24 High Pressure 2 Alarm
25 Differential Pressure Alarm
26-32 -

The warning register is 16 bits. Each bit indicates the existence of a warning.
BIT
NO:
DESCRIPTION
1 Remote Stop
2 Remote Start
3 Parameter out of limits
4 High Temperature
5 No Stop since 1 Hour
6 Start waits separator pressure drop
7 Differential temperature
8-16 -

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K13D01-E - 42 -

The service request register is 16 bits. Each bit indicates the existence of a service request.

BIT
NO:
DESCRIPTION
1 Service A requested
2 Service B requested
3 Service C requested
4 Service D requested
5 Service E requested
6-16 -

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K13D01-E - 43 -

11. MULTIPLE CONTROLLER OPERATION

The multiple controller operation is designed for installations where more than one
compressor have to operate in parallel.
The multiple controller operation allows energy efficiency by running only the
necessary number of compressors in case of low air consumption. It performs equal aging
of compressors as well.
A maximum of 8 compressors can operate in parallel.
The multiple compressor operation is performed through the serial port of the unit.
Controllers will communicate through a common RS-485 bus using RS-485 converters.
The multiple compressor operation is enabled by assigning the P65 Modbus
Address = 1 to one of the controllers. Following numbers must be given to other
controllers in the same group. No gap is allowed.
If a gap exists, controllers coming after the gap will operate independently.

Operation:
1. If the communication between units is lost, then controllers will operate
independently.
2. The controller with the least engine hours will become the master and operate
following P04-P05 parameters. Other compressors will run and stop following their
engine hours.
3. If any of the compressors has P67 Master Change Period less engine hours than
the master controller, then this one becomes the new master.
4. If an alarm occurs at the master controller, then another controller will become
master.
5. If the pressure falls below P05, the master will run immediately. Other compressors
will run with delays of P66/8.
6. If at the expiration of P66 timer, the pressure is above P05 but below (P04+P05)/2,
then compressors will run with P66/4 delays.
7. When the pressure approaches P04, compressors will stop in their respective order
of run hours.

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K13D01-E - 44 -

12. DECLARATION OF CONFORMITY

The unit conforms to the EU directives
-2006/95/EC (low voltage)
-2004/108/EC (electro-magnetic compatibility)
Norms of reference:
EN 61010 (safety requirements)
EN 61326 (EMC requirements)

The CE mark indicates that this product complies with the European requirements
for safety, health environmental and customer protection.

DK-40 USER MANUAL V2.6 (02.08.2011)

K13D01-E - 45 -

13. TECHNICAL SPECIFICATIONS

Supply Voltage: 305 460 VAC (between IN-COMM and IN-400V terminals)
175 - 275VAC (between IN-COMM and IN-230V terminals)
Supply Frequency: 50 - 60Hz nominal ( %10)
Power consumption: < 4 VA
Measurement Input Range:
Voltage: 20 - 520 V AC (L-L)
10 - 300 V AC (L-N)
Frequency: 30 - 100 Hz
Accuracy: Voltage: 0.5% + 1 digit
Frequency: 0.5% + 1 digit
Voltage burden: < 0.1VA per phase
Relay Outputs: 5A @ 250V AC
Digital Inputs: Supply: provided from the unit.
Active level: external switch resistance < 3 K-ohms
solation: opto-isolated, 1000V AC, 1 minute
Pressure Inputs: 4-20mA pressure transducer (optional 0-10V transducer)
Temperature Inputs: 1000-5000 ohms (KTY or NTC or PTC sensor)
Heating current < 0.3mA
Motor PTC input: gives alarm above 2000 ohms
Serial Port: Signal type: logic levels (0/5V)
Communication: Modbus RTU
Data Rate: 9600 baud
Operating Temperature: -30C...+80 C (-22 ... +176 F)
Storage Temperature: -40C...+80 C (-40 ... +176 F)
Maximum Humidity: 95% non-condensing
Degree of Protection: IP 54 (Front Panel)
IP 30 (Back panel)
Enclosure: Non-flammable, ROHS compliant, ABS/PC (UL94-V0)
Installation: Flush mounting with rear retaining plastic brackets
Dimensions: 134x107x54mm (WxHxD)
Panel Cutout: 116x86mm
Weight: 350 gr
EU Directives Conformity:
2006/95/EC (low voltage)
2004/108/EC (EMC)
Norms of reference:
EN 61010 (safety requirements)
EN 61326 (EMC requirements)

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