Manual

Plant Control V / T
 2007

ALMiG Kompressoren GmbH

Adolf-Ehmann-Str.2
73257 Köngen

No part of this manual may be dublicated by machanical or electronic means

without the express written permission from ALMiG Kompressoren GmbH.
Table of contents

1 Overview................................................................................................................... 5
1.1 General structure..............................................................................................................................................5
1.2 Communication of components .........................................................................................................................5
1.3 Plant Control V - Visualisation .......................................................................................................................6
1.4 Plant Control T - Telemonitoring.....................................................................................................................6

2 Installation of the hardware .................................................................................... 7

2.1 Overview ..........................................................................................................................................................7
2.1.1 Plant Control V........................................................................................................................................7
2.1.2 Plant Control T - compressor station ....................................................................................................8
2.1.3 Plant Control T and Plant Control V........................................................................................................9
2.1.4 Plant Control T - Service Centre .........................................................................................................10
2.2 General notes on the RS-485 interface ............................................................................................................11
2.2.1 Wiring of the RS-485 interface.................................................................................................................11
2.3 Connection of the Visualisation PC ................................................................................................................13
2.3.1 Connection of the interface converter ...................................................................................................13
2.3.2 Connection to the PC (directly via RS-232) ..........................................................................................13
2.3.3 Connection to the PC (via Com server/Ethernet)..................................................................................14
2.4 Connection of ALMiG controls .......................................................................................................................14
2.4.1 Verification of the software version .......................................................................................................15
2.4.2 Retrofitting RS-458 interface modules ..................................................................................................16
2.4.3 Connection ............................................................................................................................................18
2.4.4 Configuration.........................................................................................................................................20
2.5 Connection of third-party controls ..................................................................................................................20
2.5.1 Connection............................................................................................................................................21
2.5.2 Configuration ........................................................................................................................................21
2.6 Connection of accessories .............................................................................................................................22
2.6.1 Cable lengths........................................................................................................................................22
2.6.2 Data acquisition module/RS-485 ..........................................................................................................23
2.6.3 Data acquisition module as extension for ALMiG controls ...................................................................24
2.6.4 Terminal assignment MK200/8E-4AE ...................................................................................................26
2.7 System box ....................................................................................................................................................29
2.7.1 Function ................................................................................................................................................30
2.7.2 Connection............................................................................................................................................31
2.7.3 Configuration of the system box ...........................................................................................................34
2.7.4 Setting of the DIP switches ...................................................................................................................40
2.7.5 Software update....................................................................................................................................41
2.7.6 Technical data ......................................................................................................................................42
2.8 Modem ...........................................................................................................................................................43
2.8.1 Suitable modems ..................................................................................................................................43
2.8.2 Installation.............................................................................................................................................44
2.8.3 Safety precautions ................................................................................................................................45
2.8.4 Configuration of the modem..................................................................................................................46

3 Installation of the software ................................................................................... 52

3.1 System requirements .....................................................................................................................................52
3.2 Plant Control V - Visualisation ......................................................................................................................52
3.2.1 Installation.............................................................................................................................................52
3.2.2 System settings ....................................................................................................................................54
3.2.3 Language settings ................................................................................................................................55
3.2.4 Menu items for configuration.................................................................................................................55
3.2.5 Menu item Connect...............................................................................................................................56
3.2.6 Menu item Configuration.......................................................................................................................57
3.2.7 Menu item Options ................................................................................................................................61
3.3 Plant Control T - Telemonitoring...................................................................................................................62
3.3.1 Telemonitoring server ...........................................................................................................................64
3.3.2 Telemonitoring Client ............................................................................................................................66

3
4 Operation of the software Plant Control V .......................................................... 71
4.1 Compressor station..........................................................................................................................................72
4.2 Overview ........................................................................................................................................................73
4.3 Compound control ..........................................................................................................................................74
4.3.1 Operating state of the compressors, current.........................................................................................75
4.3.2 Operating state of the compressors, graphic representation ................................................................76
4.3.3 Remote operation of the compound control ..........................................................................................76
4.4 Compressors..................................................................................................................................................78
4.5 Accessories.....................................................................................................................................................81
4.6 Messages.......................................................................................................................................................82
4.7 Measured values ............................................................................................................................................84
4.7.1 Selection of the measured values to be displayed................................................................................84
4.7.2 Archiving of measured data, configuration............................................................................................85
4.7.3 Archiving of measured data, loading of saved data ..............................................................................86
4.7.4 Operation of the measured values view................................................................................................86
4.8 Copyright note ................................................................................................................................................88

5 Operation of the software Plant Control T........................................................... 89

5.1 Overview ........................................................................................................................................................89
5.2 Messages.......................................................................................................................................................90
5.3 Logging onto a compressor station ................................................................................................................91
5.3.1 Comparison of Plant Control T and Plant Control V..............................................................................91
5.3.2 Dialling ..................................................................................................................................................92
5.3.3 Remote configuration of the system box...............................................................................................93
5.3.4 Data save..............................................................................................................................................94
5.4 Copyright note ................................................................................................................................................95

6 Troubleshooting ..................................................................................................... 96
6.1 Plant Control V ...............................................................................................................................................96
6.1.1 Fault messages referring to the serial interface ....................................................................................96
6.1.2 Transmissions errors to individual controls ...........................................................................................97
6.1.3 Transmission error to all controls..........................................................................................................97
6.1.4 Other communication errors...................................................................................................................98
6.2 Plant Control T ...........................................................................................................................................99
6.2.1 Fault messages of the server................................................................................................................99
6.2.2 Client kann The client cannot establish a connection with the server ...................................................99
6.2.3 Establishment of a connection between Service Centre -» compressor station impossible ................100
6.2.4 Transmission error in the connection between Service Centre ->Ŷ compressor station .....................101
6.2.5 Fault message compressor station -» Service Centre is not functioning ............................................101

4
1 Overview
1.1 General structure

Plant Plant Control allows a compressor station, including accessories, to be monitored

and remote controlled using a standard PC.

1.2 Communication of components

Das The core of communication is the RS-485 bus, via which connected components
exchange information.

RS-485

Component 1 Component 2 Component 3

ALUP components that are provided with an RS-485 interface can be connected to this RS-
485 bus.

Any other components are to be connected as sub-components. In this case, information is

exchanged with the relevant ALMiG components via Ethernet, RS-232 or digital and analogue
signals.

5
1.3 Plant Control V - Visualisation
Plant Control V allows monitoring and operation of a compressor station, including
accessories, using a PC at the location of the compressor station.

Monitoring:

ƒ Representation of the current operating state of the connected controls.

ƒ Graphical representation of service intervals and usage
ƒ Recording and archiving of fault, warning and maintenance messages
ƒ Acquisition, archiving and graphical representation of data measured
ƒ Acquisition, archiving and graphical representation of the operating state
Operation:

ƒ Viewing and changing of parameters

ƒ Depending on the type of control, viewing and changing of additional data such as
timer and fault log
ƒ Acknowledgement of messages on the controls
ƒ Switching compressors on or off

As a precautionary measure, functions for changing values and states can be locked on the
relevant control.

1.4 Plant Control T - Telemonitoring

Plant Control T allows monitoring, remote control and remote diagnosis of a compressor
station, including accessories, from a Service Centre, which communicates with the
compressor station via a modem log-on connection.

The system can be looked after by an ALMiG Service Centre or alternatively by a Service
Centre to be established at the customer's end. The PC software for Plant Control T is only
required in the latter case.

The connection can be established on the part of the compressor station or on the part of the
Service Centre:

1. Automatic establishment of the connection for sending messages

When a message is present in the compressor station, a connection is automatically

established with the Service Centre.

ƒ Can be forwarded as an email

ƒ Acquisition and archiving of fault, warning and maintenance messages in the
Service Centre
ƒ Visual and acoustic signal on the PC
ƒ Forwarding possible in the form of e-mails

2. Manual establishment of the connection from the Service Centre

After having established the connection with a compressor station, the client soft-
ware of Plant Control T can be used like Visualisation at the location of the com-
pressor station for monitoring and operating the compressor station, see section 1.3.
Only archiving and the graphic representation of values are impossible, since the
connection is not permanently established.

6
2 Installation of the hardware
2.1 Overview

Die The illustrations show the relevant maximum extension stage with possible
functions and the components required for them. The detailed interrelationships
and the installation are described in the following subsections.

2.1.1 Plant Control V

ALMiG controls and modules via the interface converter.

The PC (grey) can access ALUP
To this end, the ALUP
ALMiG controls require an RS-485 interface module (green), third-
party compressors can be integrated via digital 24-V inputs using a separate data
acquisition module (dark blue).

RS - 485
for ALMiG controls
Connecting cable
MK200 system bus Data acquisition module(s)
for accessories/extensions
for ALMiG control

7
Accessories can also be integrated via separate data acquisition modules (dark blue) or via extension
modules for ALMiG controls (black). In the latter case, an interface module type MK200 system bus
(pink) is additionally required on the part of the control as well as a connecting cable (blue) and a
direct plug (red) for the connection.

Instead of being connected directly via RS-232 (grey), the PC can also be connected to the control
system via Ethernet (orange). In this case, a Com server (orange) is required additionally.

2.1.2 Plant Control T - compressor station

Plant Control T has the identical structure, but instead of a PC, a system box and a
modem are connected. The PC is installed at the other end of the modem connection in
the Service Centre.

RS - 485 interface
for ALMiG controls
Connection cable
MK200 system bus Data acquisition module(s)
for accessories / extensions
for ALMiG controls

8
2.1.3 Plant Control T and Plant Control V

Plant Control T and Plant Control V can also be used together.

RS - 485 interface
for ALMiG controls
Connecting cable
MK200 system bus Data acquisition module(s)
for accessories / extension
for ALMiG controls

9
2.1.4 Plant Control T - Service Centre

10
2.2 General notes on the RS-485 interface
ALMiG compressor controls and the ALMiG compound control can be networked via their
RS-485 interfaces and - in the simplest case - connected directly to a PC via the interface
converter.

RS-232
RS-485

3 RS-485

8000 h

4000 h

xxxx x xx x xxxx x xx x xxxx

F1 F2 F3 F4

ENTE R INFO

AIR CONTROL 3

ALMiG control must be provided with an RS-485 interface module, which is

To this end, each ALUP
not included in the scope of supply as standard, but available as optional extra.

2.2.1 Wiring of the RS-485 interface

Cabling must be made according to a bus structure: The connection is made from one unit to
not more than the next one in the line. The maximum total length of the RS-485 network is
1000 m.

Use cables with twisted wires and a wire cross-section from 0.14 to 1.5 mm2 for wiring (cross-
section can be connected to the controls). Lead resistance must also be considered when
using long leads. A minimum cross-section of 0.5 mm2 is recommended for a length of 1000
m. The connection must be made as a 3-wire connection with signal A, signal B and signal
ground. Use twisted -pair wires.

A A
B B
GND GND

11
2.2.1.1 Signal ground

Do not connect the signal ground of the RS-485 interface to ground or at more than one point
in the entire RS-485 network.

2.2.1.2 Cable shield

If a shielded cable is used, do not connect the shield to the assembly, but ground it ex-
ternally. Interference currents on cable shields are to be discharged to ground via a
conductive connection to the housing. To prevent these interference currents from becoming
a source of interference themselves, make sure that the connection has a low impedance.
We recommend that the insulation of the shielded cable be stripped without interruption and
the cable be connected to a shield or a protective conductor bar. In this case, the shield is to
be routed to the assembly, but not connected here.

As a rule, cable shields should always be brought into contact at both ends. In the case of
differences between the potentials at the grounding points, a compensating current may flow
through the shield connected at both ends. In this case, an additional equipotential bonding
conductor is required. The shield may, in exceptional cases, also be brought into contact at
one end.

2.2.1.3 Activation/deactivation of matching resistors

Matching resistors should be activated on the first and on the last component within the RS-
485 network; on all the other components, they must be deactivated. The activation for the
various components is described in the following sections.

If an RS-232/RS-485 interface converter is connected, it must be the last component in the

RS-485 network, the interface of which is positively connected to matching resistors.
Otherwise, the order of connected components is optional and is not related to the assigned
addresses.

The terminating resistance of the COM1 interface of the system box is activated as the
default. If the system box is not the first or last appliance in the network, it must be
deactivated (DIP switch 7 to OFF = down, refer also to section 2.7.4).

12
2.3 Connection of the Visualisation PC

2.3.1 Connection of the interface converter

Wiring to a control starts from the RS-485 interface of the converter to the control, from
where it is routed to the other controls in a line structure.

The RS-485 interface of the interface converter is accessible via screw terminals after
removal of the housing cover. The terminal assignment is shown on a label in the housing
cover and in the figure below.

RS-485
GND
B
A

RS-485
RS-485

GND
B
L A
N
RS-232

RXD
TXD
230 V AC GND

RS-232

A cable with a German angled earthing-pin plug is available for the power supply. This
cable is also connected using screw terminals. If the available plug is not suitable,
another cable may be connected using the screw terminals.

2.3.2 Connection to the PC (directly via RS-232)

The interface converter is to be connected to an RS-232 interface of the PC provided for

Visualisation. The interface converter must therefore be installed in the physical vicinity
of this PC. A connecting cable (length 1.5 m) with a 9-pin D-Sub plug, which can be
plugged directly into the PC, is included in the scope of supply.

13
2.3.3 Connection to the PC (via Com server/Ethernet)

Instead of being connected directly to the PC, the interface converter can also be connected
to an optional Com server. The Com server allows the connection to the Ethernet network in
the company. In this case, the Visualisation PC can be located at an optional place within the
company's network.

The manufacturer supplies a separate user manual for connecting and

configuring the Com server. This is not delivered with the Com server,
but is available in electronic form on the Plant Control CD ROM or can be
ordered by email. A summary description of the installation is given below.

2.3.3.1 Connecting the Com server

The RS-232 plug of the interface converter can be plugged directly into the Com server. The
Com server must be supplied with 12 - 34 V DC or 9 - 24 V AC; connection using a 2-pin
plug-in screw terminal. In newer appliances, there is also a power supply unit in the system as
delivered.

The Com server comprises an RJ-45 socket for connection to an Ethernet network 10BaseT
or 100BaseT. The connection to the Ethernet hub can therefore be made using a standard
category 5 patch cable .

The visualization PC can be connected to the company's TCP/IP network using any suitable
method, but is usually connected with an Ethernet card to the local network.

2.3.3.2 Configuring the Com server

The COM server DIP switches must not be altered.

The configuration (IP address, network template, gateway) is described in the DIP switch
documents for the Com server and must not be changed. The IP address, network template
and, if necessary, the gateway can be set via the serial interface on new Com server
releases using the software. A PC with a null modem lead and a terminal program is required
for this. A suitable terminal program (Easyterm) is available on the Plant Control CD ROM or
can be ordered by email.

The serial interface parameters for the Com server will be set automatically by the Plant
Control V visualization software. If the Plant Control V software
is not running, the Com server will still work with its default settings, which are not the same
as the settings for ALMiG controls. The Com server may therefore report errors on the serial
interface via the LED. If this is a problem, the Com server can be set via Telnet to the
following values:

Baud speed: 4800 or 19200, as set on the controls

Data bits: 8
Stop bits: 1
Parity: none
Handshake: none

2.4 Connection of ALMiG controls

All the ALMiG controls, i.e.
ƒ ALMiG compressor controls and
ƒ ALMiG compound controls
can be networked via their RS-485 interfaces.

14
2.4.1 Verification of the software version

The controls are only suitable for Plant Control V and Plant Control T, if their software version
is compatible with the PC software used. Therefore, the software version must be verified
and, if required, a new software installed on the control. At present, versions 2.33, 2.34 and
2.35 of the Plant Control software support the following control versions:

Control Supported software version

Air Control - LC from 1.42 up to and including 1.50
Air Control - LC GLW from 1.41
Air Control - LC II from 2.11
Air Control-LC II GLW from 2.00
Multicontrol from 2.30 and above
Air Control 1 1.81 / with restrictions also from 1.51 and above
Air Control 2.0 94
Air Control 3 1.15 /with restrictions also on 1.12 - 1.13
Multi Control 3 1.06 / with restrictions also on 0.98 - 1.02

The software version can usually be viewed by entering the code 9999 but, in the Air
Control 3 and Multi Control 3, this is done by calling the unit passport.

15
2.4.2 Retrofitting RS-458 interface modules

Each ALMiG control must be fitted with an RS-485 interface module, but this is not included in
the standard scope of supply. For its installation, the housing of the control must be opened.

2.4.2.1 Air Control 1, Air Control 3 und Multi Control 3

To retrofit the interface, the RS-485 module variation L, AlMiG part no. 237.01310 is required.
In the L version, the pin strips have a longer insertion depth than in the standard version.
Only this version can be used for the Air Control 1, Air Control 3 and Multi Control 3 controls.

Plug-in depth

Insertion depth. The RS-485 module can be connected after removing the cover of the
housing to the point provided at the top left of the control board.
The point is directly behind the 4-pin plug-in screw terminal for connecting the interface.

The assembly must be connected so that it is not proud of the baseboard.

The module is plugged into the unfitted side of the board, which is directly accessible, not
into the socket strips on the fitted side. The control board must not be removed to do this.
There are holes drilled in the board, by means of which the module can be plugged from
behind into the socket strips on the other side.

The module must be plugged in so that the side with the jumpers is in line with the plug-in
screw terminal on the outside of the control board.

Jumper

Schnittstelle
4-pin plug-in
screw terminal
for connecting
the interface.

16
 To do this, the pin strips on the module are plugged into the corresponding drilled holes
on the board in the socket strips underneath. There are also more drilled holes than are
required to plug in the module. The correct position of the pin strips is clear from
the following diagram.

Pin strips on the RS-485 module

left 5-pin right 4-pin

If an RS-485 module is available, both DIP switches must be set to OFF, otherwise to ON.

ON ON

1 2 1 2

without RS-485 module with RS-485 module

DIP switch to ON DIP switch to 1/2

2.4.2.2 Air Control 2

The RS-485 module, K variant, ALMiG part no. 237.01318 is required to retrofit the interface.
This is the standard version with the shorter insertion depth for the pin strips. The module is
plugged into the socket strips on the control board provided for this purpose.

17
2.4.2.3 Air Control – LC und Air Control – LC II

The RS-485 module, K variant, ALMiG part no. 237.01318 is required to retrofit the interface.
This is the standard version with the shorter insertion depth for the pin strips. The module is
plugged into the socket strips on the control board.

In controls of the Air Control – LC II type (= versions with flash program memory)
both jumpers, which are found on the control board at the module connection point, are to be
removed before connecting the RS-485 module.

2.4.2.4 Matching resistors

To activate the matching resistors, open the control housing and connect the two
jumpers on the RS-485 interface module as shown on the drawing.

Matching resistors Matching resistors

deactivated (standard) activated (last component)

2.4.3 Connection

The controls are to be connected to the RS-485 network using the connections of signal A,
signal B and GND. For the terminal assignment, see the documentation of the individual
control. With the controls Air Control - LC, Air Control - LC II, Air Control 1 and Air Control
3, the connection is made as follows using the 4-pin plug-in screw terminals:

18
In the Air Control 2 control, a 3-pin plug and screw terminal is used, whose
connection sequence is also a mirror reflection of the 4-pin plug and screw terminal on
other controls.

www.almig.de

GND
A
B

Terminal 18 RS-485 GND

Terminal 19 RS-485 Signal B
Terminal 20 RS-485 Signal A

A A
A A
B B
B B
GND GND
GND GND

For wiring, the cables of the RS-485 may be brought into contact in the control cabinet. From
there, a spur line (< 0.5 m) can be routed to the control. However, branches are not
permitted.

Routing to the control

From the interface converter or from the preceding To the subsequent control
control

19
2.4.4 Configuration

For configuration, some parameters of the control must be changed:

Control Programming
Air Control - LC using code 9950
Air Control - LC GLW using code 9950
Air Control - LC II using code 9950
Air Control - LC II GLW using code 9950
Air Control 1 using code 9950
Air Control 2 using code 9950
Air Control 3 using Configuration/Communication menu
Multi Control 3 using Configuration/Communication menu

A different unit address (e.g. 01, 02, 03,...) must be programmed for each control. The
addresses 1..10 are also used for compressor controls.

You must then, select the RS-485 mode that is used to restrict access rights to the
control. In the simplest case, these will be either "read and write" access (setting 0) or
"read only" access (setting 1).Depending on the control, there is also a further differentiation.
Parameter code levels optional.

From release 2.00 and above of the Plant Control software, a multi-master protocol is used,
so that a number of appliances can be accessed alternately on the compressor controls.
Appliances which can assume a master function are allocated an address for this purpose in
the range 28 .. 31. The following appliances are used at present.

PC with Plant Control V Address 28 (fixed)

Profibus module Address 29 (variable)
System box for remote monitoring Address 30 (fixed)
Air Control 3 as GLW master Address 31 (variable)
Compound control Multi Control 3 Address 31 (variable, must be set to 31 for
Plant Control V

If an Air Control 3 is used as GLW master, the control is assigned two

addresses. An address in range 1 .. 10 as a compressor control and an
address (default 31) for the multi-master function.

2.5 Connection of third-party controls

Third-party controls cannot be directly connected to the RS-485, even if they are fitted with
an RS-485 interface.

To integrate third-party compressors, a separate DE-200 module must be installed. This

module is the same as that used for the acquisition of data for accessories. The module is
provided with an RS-485 interface and can be connected to the RS-485 network of
Visualisation like an ALMiG control. It can be installed at any place, as long as the maximum
cable length of the RS-485 network is not exceeded.The module used has a housing
intended for wall mounting; the power supply is 230 V AC.

20
2.5.1 Connection
Connection is described in the data sheet for the DE200 module used.

2.5.2 Configuration

As with ALMiG compressor controls, the RS-485 address must also be set on the module for
interfacing third-party compressors. This address corresponds to the number of the relevant
compressor in Visualisation; it must therefore be in the order of 1 to 10 and be unequivocal.

The address is set by means of DIP switches which are accessible after opening the cover.

Adress DIP switches 12

1 2 3 4 5
1 ON OFF OFF OFF OFF
2 OFF ON OFF OFF OFF
3 ON ON OFF OFF OFF
4 OFF OFF ON OFF OFF
5 ON OFF ON OFF OFF
6 OFF ON ON OFF OFF
7 ON ON ON OFF OFF
8 OFF OFF OFF ON OFF
9 ON OFF OFF ON OFF
10 OFF ON OFF ON OFF

The baud rate of the module can also be set using DIP switches.

Baud speed DIP switches 8

4800 ON
19200 OFF

The matching resistor of the module can be activated by means of the jumper, if the
module is connected at the end of the RS-485 network.

21
2.6 Connection of accessories

It is an option to acquire data from various accessories via digital and analogue signals
and represent them in Visualisation. To link up the additional signals, the following options
are offered:

A) Data acquisition module/RS-485

Apart from 10 ALMiG compressor controls or modules for third-party compressors and a
compound control, up to 16 additional modules for the acquisition of data from
accessories can be used in the RS-485 Visualisation network. These are the same modules
as that used for interfacing third-party compressors. They are accommodated in a wall-
mounting housing and can be installed at any place, as long as the permitted cable length for
the RS-485 network is not exceeded. They are supplied with 230 V AC.

B) Data acquisition module/extension for ALMiG control

Furthermore, MK200 extension modules can be connected to all ALMiG controls of type Air
Control 1 and Air Control for the acquisition of additional data. The modules are designed for
mounting onto a DIN hat rail in the control cabinet of the compressor and are supplied by the
transformer of the control.
The number of possible modules depends on the power of the transformer used. If the
installed power is sufficient, a maximum of 24 extension modules for the acquisition of data
can be connected to each Air Control 1 or Air Control 3. Each of these modules has 8 digital
inputs and up to 4 analogue inputs 0 .. 20 mA

2.6.1 Cable lengths

The modules to be used (A or B) are selected on the basis of the physical arrangement of
the accessories to be hooked up. It must be noted that the cable lengths between
accessories and the acquisition module must not exceed 30 m for digital signals and 10 m
for analogue signals.

If the accessories to be linked up are located in the vicinity of an ALMiG compressor, solution
B may be selected: MK200 extension modules are accommodated in the compressor and
connected to the compressor control.
If the accessories are installed at greater distance, solution A is required: A separate module
with RS-485 interface is to be installed at the location of the relevant accessories.

22
2.6.2 Data acquisition module/RS-485

2.6.2.1 Configuration of the data acquisition module/RS-485

Connection is described in the data sheet for the DE200 modules used.
.

2.6.2.2 Konfiguration des Datenerfassungsmoduls / RS-485

A maximum of 16 modules is possible, with addresses 11 ..26 being used. Set the address
by means of DIP switches which are accessible after opening the cover underneath at a
lateral opening.

Adress DIP switches 12

1 2 3 4 5
11 ON ON OFF ON OFF
12 OFF OFF ON ON OFF
13 ON OFF ON ON OFF
14 OFF ON ON ON OFF
15 ON ON ON ON OFF
16 OFF OFF OFF OFF ON
17 ON OFF OFF OFF ON
18 OFF ON OFF OFF ON
19 ON ON OFF OFF ON
20 OFF OFF ON OFF ON

The baud speed of the module can also be set using DIP switches.

Baud speed DIP switches 8

4800 ON
19200 OFF

The matching resistor of the module can be activated by means of the jumper, if the
module is connected at the end of the RS-485 network.

23
2.6.3 Data acquisition module as extension for ALMiG controls

The data acquisition modules for the extension for ALMiG controls are MK200 extension
modules 8E-4RA in a 70 mm wide housing for mounting onto DIN hat rails. Depending on
the application at hand, one or several extension modules for other purposes may already
be connected to the control, or the data acquisition module for accessories may be the only
extension.

The following components are required for connecting MK200 extension modules to the
control:

ƒ Interface for MK200 system bus

ƒ MK200 system bus connecting cable

In addition, a

ƒ direct plug, right-hand side, is required for the MK200 extension modules

to connect the supply voltage. If several extension modules are to be connected to a control,
the components mentioned before are required only once. Plug the modules together using
the module connections included in the scope of supply; then, connect the first (left-hand
side) module to the control using the connecting cable, and connect the last (right-hand
side) module to the power supply using the direct plug.

Connection to the control Connection to the voltage supply

24
Connect the voltage supply to the direct plug on the right-hand side for MK200 extension
modules using spring terminals. If the power is sufficient, the modules are supplied via the
18-V winding of the transformer that is available anyway. Otherwise, a larger or sufficient
transformer or a 24 V DC power supply unit is required.

18 V AC / 24 V DC
18 V AC
GND
RS-485 A (+)
RS-485 B (-)

If the power supply is provided by a transformer, the latter must be connected to the two
upper terminals with the designation 18 V AC, and the module ground at the GND
connection. In case the power is provided by a power supply unit, the positive pole must be
connected to the terminal with the designation 24 V DC and the ground connected
(earthed) to GND.

If more than 6 modules are used, the supply voltage can no longer looped through all the
modules, but must be connected separately for a maximum of 6 modules each. In this
case, the data connection between separate modules must be established as well (RS-485
A and RS-485 B). Additional direct plugs are therefore required.

18 V AC
18 V AC
GND

RS-485 A
RS-485 B

25
2.6.4 Terminal assignment MK200/8E-4AE

The data acquisition modules used are of type MK200/8E-4AE and include 8 digital inputs
and 4 analogue inputs 0 .. 20 mA

The module can be supplied with 24 V DC or 18 VAC. The supply voltage and the serial bus
cable (MK200 system bus, RS-485) are connected by means of direct plugs at the lower
printed circuit board of the module. For this, direct plug-in connectors are available for
connecting two modules, as well as direct plugs with spring terminals.

The 24 V DC supply voltage is to be connected to the uppermost terminal (24 V DC) and the
central terminal (GND). The 18 V AC supply is to be connected to the two upper terminals
(designation 18 VAC).

26
Digital inputs MK200/8E-4AE:

Terminal Designation Function

1 Input 1 Digital input 24 V DC
2 Input 2 Digital input 24 V DC
3 Input 3 Digital input 24 V DC
4 Input 4 Digital input 24 V DC
5 Input 5 Digital input 24 V DC
6 Input 6 Digital input 24 V DC
7 Input 7 Digital input 24 V DC, can
also be used as PTC input
8 Input 8 Digital input 24 V DC, can
also be used as PTC input
9 Encoder voltage 24 V DC Encoder voltage for digital
inputs 1 - 8
10 Encoder voltage 12 V DC Encoder voltage for PTC
inputs 7 - 8
11 Ground Functional earthing; signal
ground

Connect the module to ground at terminal 11 (at least 1.5 mm2 , functional earthing).

Analogue inputs MK200/8E-4AE: (0 .. 20 mA)

Terminal Designation Function

12 GND Signal ground for analogue
input 1
13 Analogue input 1 Analogue input 1
14 GND Signal ground for analogue
input 2
15 Analogue input 2 Analogue input 2
16 GND Signal ground for analogue
input 3
17 Analogue input 3 Analogue input 3
18 GND Signal ground for analogue
input 4
19 Analogue input 4 Analogue input 4
20 Encoder voltage 18 V DC, Encoder voltage for sensor
90 mA max. supply
21 Ground
22 Ground

27
2.6.4.1 Configuration of the data acquisition module as extension
for ALMiG controls

The module addresses are set using the first 5 DIP switches. Addresses
in the range 8 .. 31 are used. Addresses are to be entered in ascending
order beginning with 8,. The number of connected modules is entered
in the control.

Adress DIP switch Module type Use

12345
8 00010 8E-4AE Data acquisition module 1
9 10010 8E-4AE Data acquisition module 2
10 01010 8E-4AE Data acquisition module 3
11 11010 8E-4AE Data acquisition module 4
12 00110 8E-4AE Data acquisition module 5
13 10110 8E-4AE Data acquisition module 6
14 01110 8E-4AE Data acquisition module 7
15 11110 8E-4AE Data acquisition module 8
16 00001 8E-4AE Data acquisition module 9
17 10001 8E-4AE Data acquisition module 10
18 01001 8E-4AE Data acquisition module 11
19 11001 8E-4AE Data acquisition module 12
20 00101 8E-4AE Data acquisition module 13
21 10101 8E-4AE Data acquisition module 14
22 01101 8E-4AE Data acquisition module 15
23 11101 8E-4AE Data acquisition module 16
24 00011 8E-4AE Data acquisition module 17
25 10011 8E-4AE Data acquisition module 18
26 01011 8E-4AE Data acquisition module 19
27 11011 8E-4AE Data acquisition module 20
28 00111 8E-4AE Data acquisition module 21
29 10111 8E-4AE Data acquisition module 22
30 01111 8E-4AE Data acquisition module 23
31 11111 8E-4AE Data acquisition module 24

0 = OFF (down)
1 = ON (up)

DIP switches 6 and 7 are spare and must always be set to OFF, i.e. they must be
down.

DIP switches 9 and 10 connect the interface terminating resistors.

These are normally de-activated (OFF = down).

28
2.7 System box
The system box is required for Plant Control T only. The controls are to be connected via
RS-485 to the system box that can establish a log-on connection to a Service Centre via an
external modem - see section 2.8.
Systembox

3 RS-485
RS-232

8000 h

Modem
4000 h

xxxx xxxx xxxx xxxx xxxx

F1 F2 F3 F4

ENTER INFO

AIR CONTROL 3

The system box checks the connected control at regular intervals for messages and, if re-
quired, logs onto the Service Centre. An establishment of the connection is equally possible
on the part of the Service Centre in order to monitor the operating state of controls or to
change settings.

If Plant Control T and Plant Control V are to be implemented, the PC can be connected to
a further interface of the system box at the place of installation of the compressor station.

RS-232 RS-485
RS-485

Systembox

3 RS-485
RS-232

8000 h

Modem
4000 h

xxxx x xxx x xx x x xx x xxx x

F1 F2 F3 F4

ENTER INFO

AIR CONTROL 3

29
2.7.1 Function

The system box is provided with three serial interfaces, some of which can optionally be used
as RS-485, RS-232 or RS-422 interface.

Designation Type *) Use

COM1 RS-485 Connection of controls

COM2 RS-485, RS-232 Connection of the modem

COM3 RS-485, RS-232, RS-422 Connection of a PC for

visualisation (optional)

*) Standard use for ALMiG Plant Control is printed in bold

When connected to the COM1 interface, the system box acts as master in relation to the
connected controls. The status of the controls is automatically queried at short intervals.

A multi-master protocol is implemented at the COM1 interface of the system box from
software release 1.04 and above. The system box can thus be operated with other masters
(Compound control, Profibus module, visualization PC) on an RS-485 network and access
the compressor controls alternately with this. The system box is also permanently assigned
the address 30, i.e. this must not be used by other appliances.

The baud speed of the system box can be varied by means of a DIP switch to 4800 bauds or
19200 bauds from software version 1.04 and above; in earlier versions, this was set
permanently to 4800 bauds. Setting is described in section 2.7.4. The setting is to be such
that the baud speed on all appliances is identical.

When connected to the COM2 and COM3 interfaces, the system box usually acts as slave.
The data received here are passed on to the COM1 interface in a transparent manner and
the replies by the controls are fed back to the COM2 or COM3 interface. Due to the syn-
chronisation feature of the system box it is possible to access the controls in parallel directly
from the connected PC and via the modem connection. In this context, the COM2 interface is
provided for the connection of a modem. This interface outputs the log-on commands in case
a message is to be sent to the Service Centre.

30
2.7.2 Connection

The voltage supply and the interfaces are to be connected by means of screw terminals. An
adapter cable for connecting the modem is included in the scope of supply.

10
11
1
2
3
4
5
6
7
8
9
24 V DC 12 V RX TX GND 12 V RX TX GND
18 V AC
COM 2 RS-232 COM 3 RS-232

Power

COM 1 2 3 Systembox II

COM 1 COM 2 COM 3

RS-485
RS-485 RS-485 RS-422 RX RS-422 TX
A(+) B(-) GND A(+) B(-) GND A(+) B(-) A(+) B(-) GND
21
12
13
14
15
16
17
18
19
20

22

31
2.7.2.1 Connection of the supply voltage

The system box can optionally be supplied with 24 V DC or 18 VAC.

Terminal Function

1 Supply voltage 18 V AC, potential-free

2 Supply voltage 18 V AC, potential-free
3 Functional earth

or

1 Supply voltage, + 24 V DC
2 not connected
3 Supply voltage, ground (earthed)

2.7.2.2 Connection of interface COM 1 (controls)

The COM1 interface can only be used as RS-485.

RS-485
Terminal Function

12 Signal A (+)
13 Signal B ()
14 Signal ground

Signal A is to be connected to signal A of all controls, signal B to signal B, and

signal ground to signal ground.

The matching resistance of the COM1 interface of the system box is activated as the default.
If the system box is not the first or last appliance in the network, it must be deactivated
(DIP switch 7 to OFF = down, refer also to section 2.7.4)

2.7.2.3 Connection of interface COM2 (modem)

The COM2 interface can optionally be used as RS-232 or RS-485. To this end, it can be
connected either to terminal 4-7 or terminal 15-17, but never to both at the same time. For
Plant Control T, COM2 is used as RS-232 for connecting the modem.

RS-232
Terminal Function

4 not connected
5 RX
6 TX
7 Signal ground

As a rule, the connection needs not to be made by hand. The system box comes with a cable
connected with Sub-D plug, which can be plugged into the modem cable.

32
2.7.2.4 Connection of interface COM3 (PC for Plant Control V)
The COM3 interface can optionally be used as RS-232, RS-485 or RS-422. To this end, it
can be connected either to terminal 8-11 or terminal 18-22, but never to both at the same
time. In general, the RS-485 interface is used to link up a PC located at a distant place. For
this, an additional interface converter is required. Signal A is to be connected to signal A of
the interface converter, signal B to signal B, and ground to ground.

RS-485
Terminal Function

20 Signal A (+)
21 Signal B ()
22 Signal ground

The RS-232 interface can be used, if a PC without interface converter is to be connected

directly.

RS-232
Terminal Function

8 not connected
9 RX
10 TX
11 Signal ground

The RS-422 interface is not required for Alup Plant Control.

33
2.7.3 Configuration of the system box

The system box can be configured using a separate configuration program or, during
operation, using the visualisation software Plant Control V or Plant Control T.

The separate configuration program can be used to configure a system box that is not in-
tegrated in an installation for Plant Control V or Plant Control T. To this end, the system box
must be connected to a serial interface of the relevant PC, either directly via interfaces
COM2 or COM3 or via an interface converter. In addition, the voltage supply of the system
box must, of course, also be connected. If installed on the relevant PC, the configuration
program can be called in the start menu by selecting ALMiG > Config > System box.

ALMiG

How to install the software is described in section 3. After having called the program, you
have first to select the interface of the PC to which the system box is connected.

Select 30 as address and 4800 or 19200 (depending on the baud speed set using the
DIP switches, see section 2.7.4). After the dialogue box has been closed, the main
window appears and the current data are loaded from the system box.

34
 The main window of the software is subdivided into several "tabs", in which the settings can
be viewed and changed. The number of "tabs" depends on the capabilities of the available
system box version.

Click the Read out button to transfer the settings of the system box to the PC; click the Set
button to transfer the changed settings to the system box.

2.7.3.1 Telephone numbers

In the box Telephone number of the Service Centre you have to enter the telephone
number that the system box is to dial automatically in the case of a fault. You need not only
enter the number itself, but, if required, also a number for direct outward dialling in the case
of private branch exchanges or also further special characters, if necessary. In some cases,
private branch exchanges require dial pauses that can be realised by entering a comma at
the relevant place. You can find further notes on reliable characters in the manual of your
modem.

The entry of the Telephone number of the system box is required in order that the PC in
the Service Centre can clearly identify the calling system box. Actually, any string of char-
acters could be used, but it has to be entered identically in the PC software for the Service
Centre. To obtain a clear and understandable identification, we recommend the use of the
call number of the modem port in international characters, preceded by the national code.

These settings can also be made in the same way for compressor controls that are suitable
for automatic fault signalling without system box. This configuration is no longer used on new
systems. However, the configuration software in the system box can still be used for con-
figuring relevant compressor controls, if, instead of address 30, the address set in the control
is used. If you do not enter a telephone number, automatic fault signalling for the relevant
unit is deactivated. You may always enter a telephone number for only one unit. If several
controls are available, the data for fault signalling are in any case transferred by the system
box; in this case, no telephone number may be set in the controls.

35
2.7.3.2 Dialling parameters

The Waiting time after failed connection is the time, after which the system is to redial the
number of the Service Centre after a failed call. The possible range of values is 1 minute to
255 minutes.

Take care that the waiting time is not set too short. For reasons of approval, modems are
fitted with a dial lock that prevents dialling at short subsequent intervals.

When the option shown here is activated, the waiting time entered is activated for the first re-
tried call only and is doubled after each subsequent dialling. The maximum waiting time is,
however, limited to 255 minutes.

To prevent endless retried calling processes - for example in case telephone numbers were
incorrectly entered, the Maximum number of retried calls is limited. The possible range of
values that can be set is 1 to 255 tries.

36
2.7.3.3 Available controls
Here you can set, which controls are connected to the COM1 interface of the system box.
The components entered here will be automatically queried by the system box for any
present messages.

To add further controls to the list, click Add. A dialogue window will open, in which you can
enter the RS-485 address and the Type of control.

Address 30 cannot be used as RS-485 address for a control to be connected to the system
box, since the system box itself uses this address.

37
2.7.3.4 Data acquisition modules
Messages from third-party compressors and accessory components are supported from
version 1.02 of system box II. To this end, you have to set, which modules are available for
acquiring signals, and in the case of which signals the Service Centre is to be called.
.

If you wish to add a new data acquisition module you have to select the module type first.
The setting Extension module for ALMiG control refers to MK200 modules, which can be
connected to the extension bus of an Air Control 1 or Air Control 3. These modules can be
used to link up accessories that are physically installed in the vicinity of an associated
compressor. In this case, you have to enter both, the address of the compressor control (1-
10) in the RS-485 network and the address of the module (8-31) in the extension bus.

38
In contrast to this, the setting Data acquisition module/RS-485 refers to modules in a
separate housing for wall-mounting, which are directly integrated into the RS-485 network.
These modules can be used to link up third-party compressors and accessories. In this case,
only the address of the module (1-10 for compressors from other manufacturers and 11-26
for accessories) in the RS-485 network must be specified.

You can select for each digital input of a module, whether it is provided with a normally-
closed contact (NC) or a normally-open contact (NO), and whether dialling is to be triggered
when the input is active. For the designation of the normally-open and normally-closed
contacts it is assumed that the switching contact between the input and the encoder voltage
is connected. In the example shown here, the inputs assume the following function:

ƒBeim With input 1 dialling is triggered, when it is connected to the encoder voltage
through the normally-open contact.

ƒWith input 2 dialling is triggered, when it is disconnected from the encoder voltage
through the normally-closed contact.

39
2.7.4 Setting of the DIP switches

At the right-hand, lower section of the system box, behind a cover, you can find a DIP switch
that is required for configuring the RS-485 interfaces. Changes to these settings are usually
not required, nevertheless, they are described here for reasons of completeness.

1 2 3 4 5 6 7 8 9 10

Number Function Factory setting

1 Not all of the DIP switches 1-5 should OFF
2 be set to ON during operation (this is ON
3 the setting for software updates, refer to ON
4 next section) ON
5
ON

DIP switch 5 baud speed

ON = 4800 bauds for COM1/3
OFF = 19200 bauds for COM1/3
(from release 1.04 and above of the
system box)

6 Matching resistor COM2*) ON = activated

ON = activated
OFF = de-activated
7 Matching resistor COM1*) ON = activated
ON = activated
OFF = de-activated
8 Interface type COM 3 **) ON = RS-485
ON = RS-485 OFF = RS-
422
9 Irrelevant for this application OFF
10 OFF

*) On units that are not labelled with a serial number or whose serial number is less than
5, DIP switches 6 and 7 must be set to OFF. The serial number (S/N) can be found on a
sticker on the underside of the module. The last 5 digits form the serial number. The
COM3 matching resistor is always activated.

**) Changing over between RS-485 and RS-422 refers to the assignment of terminals 18-
22. COM3 can be used as RS-232, independently of the setting, by connecting
terminals 8-11.

40
2.7.5 Software update

System box II is fitted with a flash program memory. You can upload the software to the
system via the serial interface COM1 using the program Flash programming. How to
operate this program is described in the instructions for updating the compressor controls.

ƒ Switch off or disconnect the voltage supply of the system box

ƒ Disconnect all the interfaces of the system box that are not required for updating the
software

ƒ An A DIP switch is located at the right-hand, lower side of the system box, behind a
cover. To update the software, set the first 5 DIP switches to ON.

DIP switches 1-5 to

ON

ƒ PC Connect the PC to serial interface COM1 of the system box (using an

interface converter or a flash programming adapter)

ƒ Start the software for flash programming on the PC, enter the interface
used on the PC and set the baud speed to 19200. Open the software for the
system box in the PC program.

ƒ Switch on or connect the voltage supply of the system box. When the first
5 DIP switches are set to ON, the system box changes over to the software
updating mode when the voltage supply is switched on (the two LEDs on the
left-hand side of the system box light up).

ƒ Start the download in the PC program within 10 seconds.

The LED on the right-hand side of the system box flashes during the download, the
progress is shown in the PC program.

Note: If the download is not started within 10 seconds, the software update mode
is exited and the normal program executed. In this case, the voltage supply must
again be switched off and on.

After downloading of the software the voltage supply of the system box must be switched off
and on again or disconnected and reconnected in order that the programming mode is exited
and the downloaded program can be executed.

To prevent the system box from changing over to the software update mode each time when
the voltage supply is switched off, the first 5 DIP should be brought to another position.

41
2.7.6 Technical data

Voltage supply

18 V AC oder 24 V DC

Serial interfaces

COM 1
RS-485, 4800 baud 8-N-1

COM 2
RS-232 oder RS-485, 4800 baud 8-N-1

COM 3
RS-232, RS-485 or RS-422, 4800 baud 8-N-1

Housing

MK200 housing for mounting onto DIN hat rail

Dimensions: 71 x 108 x 71 mm (W x H x D)

108
71
75

57
TX GND

A(+) B(-) GND A(+) B(-) A(+) B(-) GND

11 22
RS-232

Systembox II

RS-422 RX RS-422 TX

10 21
RS-485
COM 3

9 20
RX

COM 3
GND 12 V

8 19
3

7 18
RS-232

71

6 17
TX

COM 2
1
COM 2

5 16
RX

RS-485
Power

COM
12 V

4 15
A(+) B(-) GND

3 14
COM 1

2 13
24 V DC
18 V AC

RS-485

1 12

42
2.8 Modem
For Plant Control T modems must be provided in the compressor station and in the Service
Centre. The modem in the compressor station must be connected to the system box, the
modem in the Service Centre to the server PC.

2.8.1 Suitable modems

Although various modems could be employed, we recommend that the specified types be
preferably used in both, the compressor station and in the Service Centre. These modems
can be configured with the help of the software - see section 2.8.4 - that is included in the
scope of supply; other modems may have to be configured manually. In addition, the
Security Callback function is only available in conjunction with these modems (except for the
GSM modem).

ƒ Analogue modem BM-14k4

The BM-14k4 modem is no longer available. The BM-1000 modem can be used as
substitute.

ƒ Analogue modem BM-1000 or BM-1000 Pro

The BM-14k4 modem is no longer available. The BM-1000 modem can be used as
substitute.

ƒ Analogmodem BM-1000 oder BM-1000 pro

Euro-ISDN (CTR21)
Approval in the EU and in Switzerland
230 VAC voltage supply via plug-in power supply unit (included in the scope of supply)
Security Callback possible

43
 ISDN-Modem BM-33k6 / ISDN, BM-33k6 / ISDN II oder BM-33k6 / ISDN pro

Euro-ISDN (EDSS-1)
Approval in the EU and in Switzerland
230 VAC voltage supply via plug-in power supply unit (included in the scope of supply)
Security Callback possible

This modem can establish connections with ISDN modems and analogue modems

Note on ISDN modems: when these are used with additional system functions the
with system telephones is sometimes beset with problems. The system must generally be
unconfigured, but this is not invariably successful. If an appropriate system is available, the
use of an analogue system port and an analogue modem is preferable.

If only one ISDN port is available, this must be configured by a service engineer for use
with an ISDN modem. If the ISDN modem still does not work, an analogue modem must
be connected to the ISDN port via an a/d adapter (for example Telekom TA Basic).

ƒ GSM-Modem CommuCont Dual

for GSM mobile networks with 900 MHz and 1800 MHz, comes with aerial 230 VAC
voltage supply Security Callback not possible

This modem can establish connections with analogue modems only.

In addition, a mobile phone contract is required with data services cleared for incoming and
outgoing calls.

The modem is factory-configured; when the order is placed, the PIN number of the SIM card
must be indicated.

2.8.2 Installation

The analogue modems come with telephone cables for connection to a TAE socket. For the
connection to telephone networks outside Germany, additional adapters for the existing
telephone sockets may be required.

The modems' scope of supply also includes cables for the serial interface (9-pin Sub-D).
These can be directly plugged into the PC or the cable of the system box.

The modems are addressed directly via the serial interface; the installation of drivers is not
required for the operability of the Plant Control T software. However, since the automatic
hardware recognition feature of Windows recognises the modems during start-up and
proposes the installation every time, the modem drivers should nevertheless be installed. A
CD-ROM with the drivers accompanies the modems.

If internal modems or ISDN cards are used, they must provide virtual serial interfaces.

Caution: When ISDN modems are used on private branch exchanges with additional
functions, the protocol of the relevant connection may have to be changed over. In
this case, please contact your telephone specialist or the manufacturer of your
telephone system.

44
2.8.3 Safety precautions

Since parameters of the control can be changed via the modem connection and the con-
nection is established from outside, remote configuration may represent a security risk. Even
though the required special PC software offers a certain level of security, it is useful to take
further precautions.

The Security Callback procedure prevents unauthorised parties from logging on by permit-
ting only connections with known telephones (telephone numbers). With this procedure, one
or several telephone numbers are saved in the modem, which can be called back auto-
matically when a call comes in. The call-back number is selected through the transmission of
a password. The data connection is only cleared after the callback came in so that only
authorised telephone numbers can log onto the unit.

Changing of parameters can also be ruled out completely by making corresponding settings
in the controls.

45
2.8.4 Configuration of the modem

The following settings are required on the part of the modems at the compressor station and
in the Service Centre:

ƒ Interface: 4800 baud, 8 data bits, 1 stop bit, no parity, no handshake

ƒ Modem feedback signals on
ƒ Automatic answering after the first ring signal
ƒ Dial tone recognition off

The settings must be made in the modem using AT commands and saved. Settings in a
possibly installed Windows modem driver are irrelevant, since it is not used.

The software of ALMiG compressors includes a program for the simple configuration of
modem types BM-14k4, BM-1000, BM-33K6/ISDN and BM-33K6/ISDN II, which can be
used to set the required values. In this program you can also enter call-back numbers and
passwords for the Security Callback function. All the settings are positively saved in the
modem so that they are maintained when the power supply is switched off.

With the GSM modem Commucont GSM Dual, configuring by the user is impossible and not
required, since this modem is delivered in a preconfigured condition. With this modem, a
Security Callback function is not available.

For configuration, these modems must be connected to the serial interface of a PC. The
modem in the compressor station that is connected to the system box during operation must
also have been configured with a PC. This configuration can only be carried out on site with
the modem being connected directly to the PC; remote configuration from the Service Centre
is impossible.

All the programs on the PC that possibly access the serial interface are exited. This is valid in
particular for the software for Plant Control V and Plant Control T.

If installed on the relevant PC, the configuration program can be called in the start menu by
selecting ALMiG > Config > Modem.

ALMiG

How to install this software is described in section 3.

46
When the program is called for the first time, a window opens in which the interface param-
eters can be set.

As interface you have to set the interface used by the PC and select 4800 as baud speed.
In the menu Settings this window can be opened at any time, if changes in the settings are
required.

When the program is started, previous settings of the modem are read out and the modem
type is established. This process takes a while; the status can be observed in the progress
bar at the bottom right in the status bar.

The settings of the modem are assigned to several "tabs". The setting options available
depend on the type of modem. For example, the setting of the MSN number is required for
ISDN modems only.

47
The tab box of AT commands lists the commands for the default settings of the modem that
are sent to the modem when it is being configured. The meaning of the commands is
described in the modem manual. Usually, changes need not to be made here. The con-
figuration may only have to be edited, if another modem is used.

The page Settings includes modem settings that must be edited by the user. For the
application at hand, the Modem feedback signals must be activated for both modems, in
the compressor station and in the Service Centre, and the modems must be set to
Automatic answering.

48
The page Call-back contains the settings for the Security Callback function. This page is
only available, if the function is supported by the selected or automatically recognised
modem.

If the Security Callback function is to be used, save a call-back number with the associated
password (by clicking the New button) and tick Activate call-back in the selection box. The
possible number of telephone numbers depends on the type of modem. The passwords must
have a minimum length of 6 characters and a maximum length of 12 characters, with only the
letters from A to Z and numbers from 0 to 9 being permitted.

The modem in the Service Centre must be configured without Security Callback. The
modems in the compressor station can be configured with or without Security Callback. If the
modem was configured with Security Callback, the password used must be saved in the
Plant Control T software.

As "telephone number" you can send not only the actual string of numbers, but also
additional control characters. In the case of foreign calls or for operation with a private branch
exchange, dial pauses may be required between the figures. The pause can be configured
by entering a comma between the relevant figures, for example between the figure for
outward dialling and the actual telephone number. You can find further notes on possible
characters in the manual of your modem.

Some companies still use private branch exchanges that do not support tone dial. As far as
supported by the modem, a changeover to pulse dial is possible, if you precede the
telephone number with a P.

49
The page AT saving commands contains the AT commands that the modem requires for
permanently saving the settings made. If the modem types provided are used, changes are
not necessary here.

For ISDN modems, the MSN numbers and their use for the various services must be set. In
the simplest case, all services are assigned to one number, the modem will then answer all
calls for this number. The MSN number is an integral part of the own telephone number; in
conjunction with telephone systems it is in most cases the extension. For more details,
please refer to the manual of the ISDN modem.

50
Click the -button in the toolbar to send the new settings to the modem.
During this, the page Feedback signals appears, which shows the commands sent to the
modem and the replies given by the modem. The replies sent should always be OK
messages, but never ERROR messages. If no OK messages are listed or ERROR messages
appear, it was not possible to configure the modem correctly. In this case, the cause should
be found and eliminated before the modem is used.

Click the - button to read out the settings of the modem and to determine
the modem type. This function is called automatically when the program is started. It can
be called manually, if the take-over of changes made is to be checked or if a new modem
was connected for configuration purposes.

51
3 Installation of the software
3.1 System requirements
The software can be installed on IBM-compatible PCs that must meet the following
requirements:

Operating system Windows 9x / ME, Windows NT 4,

Windows 2000 or Windows XP
User memory t 64 MB
Graphic Resolution t 800 x 600 / t 256 colours
Parallel port
free parallel interface LPT1, LPT2 or LPT2 for dongle
(for Plant Control V and Plant Control T server from release 2.35
and above)

Plant Control V requires a PC with free RS-232 interface or, if a Com server is used, a PC
with connection to the LAN. The necessary free hard disk space depends on the number of
measured values to be archived and the frequency of archiving.

Plant Control T requires as server a PC with free RS-232 interface and connection to the
LAN, and as client a PC with connection to the LAN. If messages are to be passed on in the
form of e-mails, an SMTP server must be connected to the LAN.

The TCP/IP network protocol must be installed on the PCs. If no network is available, it is
possible to install, for example, dial-up networking (Windows set-up).

3.2 Plant Control V - Visualisation

3.2.1 Installation

Visualisation can be installed by double-clicking the Visu-xxx.exe file, with xxx standing
for the version number, or by selecting the menu system of the CD-ROM.

ALMiG Kompressoren GmbH

52
During the installation the entry ALMiG is added to the Start menu, in which the program Plant
Control Vis included. In addition, a shortcut is placed on the desktop.

ALMiG

Before booting the visualization software for the first time, the dongle supplied with it must be
plugged into a free parallel interface LPT1-LPT3. Without the dongle connected, the software
can only run for a short time and will be restricted (from release 2.35 and above).

If a Com server is used, drivers must be installed on the Visualisation PC for the virtual serial
interface. The drivers and the installation instructions can be found in the directory Plant
Control V/Com-Server on the CD-ROM or called via the menu system on the CD-ROM.

53
3.2.2 System settings

Visualisation is optimised for a resolution of 800x600 or 1024x786 in the full screen mode.
Higher resolutions are possible, but do not offer any advantages with regard to the
representation. The minimum size of the visualisation window is 800x600.

The properties of the task bar should be set so that the visualisation window is not hidden by
the task bar. The settings can be made in the start menu.

54
3.2.3 Language settings

The language can be selected online - either via the info menu "?" or by selecting the icon of
the national flags in the toolbar.

ALMiG

3.2.4 Menu items for configuration

The visualisation software can be configured in the menu Settings.

ALMiG

Menu item Connect Setting of the serial interface

Menu item Configuration Selection of the connected components, selection of the
connected accessories and other, unit-related settings

Menu item Server Menu Relevant for Plant Control T only.

item System box Menu Relevant for Plant Control T only.
item Options General settings of Visualisation

55
3.2.5 Menu item Connect

This setting window for the configuration of the connection opens automatically when the
software is started for the first time, otherwise it can be opened by selecting menu Settings >
Connection.

In this window you have to select the serial interface of the PC, to which the interface
converter is to be connected. When a Com server is used, you have to select the virtual
interface that was installed for the Com server.

56
3.2.6 Menu item Configuration

The menu item Configuration allows unit-related settings to be made.

3.2.6.1 General

The first tag General is not essential for direct visualisation; the related boxed need not to be
completed.

3.2.6.2 Compound control and compressors

The most important tab is Compound control and compressors. Here, you can select the
existing controls - one compound control and up to 10 compressor controls.

The numbering of the compressors refers to the RS-485 address of the controls.

57
 In the case of third-party compressors, it is possible to determine in an additional setting
window, which functions are to be assigned to the inputs and outputs of the data acquisition
module used.

The inputs of the module are read by the compound control and by Visualisation. The out-
puts of the module are controlled by the compound control and read back by Visualisation.

You can select for each digital input of a module, whether it is provided with a normally-
closed contact (NC) or a normally-open contact (NO). For the designation of the normally-
open and normally-closed contacts, it is assumed that the switching contact between the
input and the encoder voltage is connected. With the setting "NC" the input is active, when it
is disconnected from the encoder voltage. With the setting "NO" the input is active, when it is
connected to the encoder voltage.

3.2.6.3 Accessories

In the tab Accessories you can enter the accessories that are available in the compressor
station. Accessories are classified in the categories

ƒ Condensate management
ƒ Saving/miscellaneous
ƒ Drying and
ƒ Filtration

58
The accessories already entered are shown in a list.

It can be edited with the help of the following buttons:

The window shown here opens so that a new

New
accessory item can be entered

Delete The accessory item highlighted in the list is removed

Edit The window shown here opens and the list of the
55 highlighted accessories can be edited

59
On the first page you can enter general details such as designation, description and type.
The entry box for the designation must be completed. Apart from this, you can configure
analogue and digital signals for each accessory item that can be acquired by additional
modules. These signals are then represented in Visualisation.

You have to set for each input, with which module it is to be acquired. For this, extension
modules for ALMiG compressors and separate data acquisition modules with RS-485 interface
are available. In the case of extension modules, the address of the module at the extension
bus of the compressor must be specified additionally.

You can select for each digital input of a module, whether it is provided with a normally-
closed contact (NC) or a normally-open contact (NO). For the designation of the normally-
open and normally-closed contacts, it is assumed that the switching contact between the
input and the encoder voltage is connected. With the setting "NC" the input is active, when it
is disconnected from the encoder voltage. With the setting "NO" the input is active, when it is
connected to the encoder voltage.

60
 For analogue inputs, enter the measuring range of the relevant module input and parameters
for the conversion into actual measured values.

In addition, you can configure two date values, for example for the last maintenance and next
maintenance. The data values can be entered in Visualisation and are saved on the hard
disk of the PC.t

3.2.6.4 Unit data

On the tab /Unit data you can enter data of the unit in the form of optional texts.

3.2.7 Menu item Options

In this setting window you can select, whether in the case of a fault message an acoustic
signal is to be output via the loudspeakers of the PC.

61
3.3 Plant Control T - Telemonitoring

The software for Plant Control T consists of 4 programs:

ƒ Configuration software for modem (file Modem-xxx. exe)

ƒ Configuration software for system box (file Sysbox-xxx.exe)

The configuration software is required for commissioning the modem and the system box
in the compressor station; its operation is described in section 2.

Client software for the Service Centre (file Client-xxx. exe)

This software can be installed on several local computers within the local network and is used
for displaying current and archived fault messages and for remote monitoring and remote
operation of the controls like in Visualisation. The communication with the unit takes place via
the server

Server software for the Service Centre (file Server-xxx. exe)

This software must be installed on a server PC in the network that runs 24 hours a day.
Connect the modem to this PC. It records incoming messages, makes them available for
clients and, if required, passes them on in the form of e-mails. Furthermore, upon request,
the server establishes a modem connection to a compressor station to allow remote
monitoring and remote controlling by a client.

The client software and the server software are usually installed on separate computers that
are networked. In this way, it is possible to utilise the Telemonitoring function from each
workstation computer.

Client

Systembox

Server

Modem Modem

It is, however, also possible to install the client and the server on one computer.

62
The software can be installed by executing the specified files, with xxx standing for the
relevant version number, or by selecting the installation program on the CD.

ALMiG Kompressoren GmbH

After the installation, you can call the software from the start menu. In addition, an Autostart
entry is created for the server

ALMiG

63
3.3.1 Telemonitoring server

Before booting the server for the first time, the dongle supplied with it must be plugged into a
free parallel interface LPT1-LPT3. Without the dongle connected, the software
software cannot run. (from Version 2.35 and above).

After the call, the status window of the server appears first. You can close the window by
clicking OK.

The settings of the server can be called by clicking the icon in the Taskbar Notification Area
in the task bar to the left of the clock with the right mouse-button.

64
After having called the program for the first time, you have to select first, to which interface
the modems are connected.

We have to distinguish between two types of modems:

ƒ Modem for acquiring fault messages

ƒ Modem for calling a compressor station via the Service Centre for telemonitoring
and remote controlling of the controls

If you wish to use only one modem, you can enter the same serial interface twice. In this
case, fault messages cannot be acquired as long as a connection is established.

The network settings usually need not to be changed. The server is automatically active on
all IP addresses of the server PC and is set to port 502 as a standard. This is the port, which
is provided for the protocol used, Modbus/TCP. If there are conflicts with other server
programs on the PC, you can change the port number at any time. However, this change
must also be made in the client software.

65
3.3.2 Telemonitoring Client

The client software can be configured in the menu Settings.

ALMiG

3.3.2.1 Connection
This setting window for the configuration of the connection opens automatically when the
software is started for the first time, otherwise it can be opened by selecting menu Settings >
Connection.

In the entry box Host you have to enter the IP address or the host name of the server PC. If
the server and the client run on one PC, you can enter 127.0.0.1.

You have to change the entry box Port only, if the port was changed in the server software.
The settings must be identical for the client and the server.

66
3.3.2.2 Forwarding as e-mail

The server software is able to forward incoming messages to an e-mail address. The settings
required for this can be remotely entered through the client software.

E-mail address
Address, to which the messages are to be forwarded

SMTP server
For sending e-mails, you require an SMTP server. At this point you have to enter the
IP address or the host name of the server.
N.B.: the Plant Control software does not currently support SMTP authentication. Hence
an SMTP server is required which accepts emails without the user name and codeword.

Sender address
Address that is shown in the "from" box of the sent e-mail. In the case of an automatically
created e-mail, this may not be useful, but the SMTP server may require a valid sender
address

Forward the following messages only

Here, you can determine, whether only faults or also maintenances and
maintenance requirements are to be forwarded

Forwarding active
Here, you can determine, whether, and if so, under which time-related conditions
incoming messages are to be forwarded in the form of e-mails.

The setting Never corresponds to a deactivation of forwarding. The setting Always

can be used, for example, during holidays. The setting Day-to-day basis can be used
to activate forwarding at weekends or after business hours. By clicking the Details
button you can open another window in which you can set the exact time for the
activation.

67
3.3.2.3 Menu item Locations

The menu item Settings>Server>Locations allows the entry of unit-related settings. First of
all, you have to select the unit to be edited or create a new unit configuration. The
configuration profiles are saved on the server.

The configuration profiles of the units are necessary

ƒto manage the data required for the modem connection such as telephone number
and password for the Security Callback

ƒto manage the data required for operating the controls such as existing control types

ƒin order to manage data required for Visualisation, especially details of connected
accessories

ƒfor logging fault messages in order to be able to identify the "calling" compressor
station. This takes place byway of a comparison of transmitted ID numbers that are
saved in the system box with the ID number in the configuration profile of the
compressor station.

The required settings are largely identical with those for the visualisation software Plant
Control V and are described in section 3.2.6.

The settings required specifically for Plant Control T are described on the next page.

68
 The tab page General contains important settings for teleservice.

Designation
Here, you can enter optional text that identifies the compressor station. When the fault
messages of a compressor are transferred and shown in tabular form, this designation is used
instead of the ID number in order to facilitate its readability. This designation is also used for
the selection of a compressor station that is to be called by the Service Centre.

ID number
The ID number is a number or string of characters that clearly identifies the calling com-
pressor station. It is useful to enter, for example, the telephone number of the modem in
international notation. The ID number is saved in the system box and transferred together
with the fault messages.

Telephone number
"Telephone number" of the modem in the compressor station, with any required special
characters for pulse or tone dialling and dial pauses.

Password for Security Callback

The password saved in the modem for call-backs by the Service Centre.

Activate Security Callback

This function must be activated if it has been activated in the compressor station modem.

69
3.3.2.4 Menu item Options
In this setting window you can select, whether in the case of new fault messages an acoustic
signal is to be output via the loudspeakers of the PC.

70
4 Operation of the software Plant Control V
After the Visualisation software was called, the screen that appears first is Compressor
station.

ALMG

The other screens can be opened by

ƒclicking the tabs at the bottom left or

ƒselecting the menu View

To return to the Compressor station view, press the ESC key.

The buttons shown in the toolbar vary depending on the view selected. The figure below
shows the buttons in the view Messages.

71
4.1 Compressor station
The view Compressor station shows an exemplary compressor station. It is not identical with
your actual compressor station.

ALMiG

To get to the individual detailed views of the components connected to Visualisation, click the
coloured squares.
When you click the squares, a menu pops up that prompts you to select the individual
component. After having selected the component, you get to the view of this component.

Components that are actually present in the compressor station, but are not shown on the
Visualisation PC, are either not connected or not correctly configured.

72
4.2 Overview
The view Overview shows the operating condition of the connected components. Fault
messages, warnings and maintenance requirements, if any, are displayed here.

In the Overview you can also check, whether the communication between Visualisation
and all the controls functions properly. In the case of a communication failure,
"transmission error" is displayed next to the control concerned.

ALMiG

73
4.3 Compound control
The tab Compound control appears only, if a compound control is connected to Visualisation.
The Compound control view is split into two sections:

ALMiG

The current data of the compound control are displayed on the right-hand side. The
following is shown here:

ƒ The display of the control

ƒ The operating state in plain text,
ƒ The operating state of the connected compressors and
ƒ Fault messages in the event of a fault

The section on the left-hand side shows the measured vales and the operating state of the
compressors as a function of time in the form of a graphic. It is possible to have current
and archived measured values displayed. The graphic representation can be configured
using the toolbar and is described in the section "Measured values".

74
4.3.1 Operating state of the compressors, current

Detail of the display

The current operating state of the compressors is shown on the bottom right-hand
side. The representation provides information to help you determine whether a compressor is
in load or idle.

.
Total, sum, all up 820 m³/h

There are two compressors in the example depicted, both under load. The second
compressor is a governed compressor, currently operating at 100% loading. Depending on
compound control, compressor control and configuration, the following messages can be
distinguished:

x Off
x Ready
x No load
x Under load
x Fault

If available, the display also shows the percentages for the governed compressors and their
delivered volumes.

Simplified display

If there is a large number of compressors and low screen resolution, space is inadequate as
a result, or with simple GLWs, there are insufficient status signals available, then a switch is
made to simplified display mode.

Under load d
No load
Fault

There are four compressors in the example depicted (bright grey squares in the lines), of
which two are under load (squares highlighted blue in the first line) and those remaining are
ready for operation. Compressors which are not ready for operation have been shown as red
highlighted squares in the third line. Accordingly, it is clear from the illustration

Under load
Fault
ƒ which compressors are under load or are being called
ƒ which compressors are ready for operation or are not ready for operation.

It is impossible to distinguish between disconnected compressors and compressors which

are faulty, both statuses being displayed in the third line as a fault.

Which operating statuses can be displayed depends on the compound control used and its
configuration. Sometimes the signals for messages in the second line (No load) and/or the third
line (Fault/Off) are not available, so that, in the simplest case, the compressor load criteria in the
first line only can be displayed.

75
4.3.2 Operating state of the compressors, graphic representation

Up to two readings from the composite control, network pressure and delivered volume, can
be displayed as a graph on the left page. In addition, the bar diagrams underneath
indicate the following states:

dark grey = Off

green = Ready
bright blue = No load
dark blue = Under load
red = Fault
bright grey = No data for this period

Which messages can be displayed depends on the compound control options (see
description in the preceding section).

4.3.3 Remote operation of the compound control

Click on the Data button in the toolbar to open the compressor settings window.

The tab General shows the software version and the operating status of the control. In
addition, the compound control can be switched on or off or any fault messages present can
be acknowledged, provided that this is permitted by the control.

76
When you select the tab Parameters you can have the parameters of the control displayed
and change them. Changing of parameters is code-protected. Click the Code button to enter
a code, which then allows changes to parameters.

Depending on the compound control available, additional data and diagrams can be
displayed. The meaning of the readings and parameters is described in the documentation
for the relevant controls.

77
4.4 Compressors

The view Compressors allows compressor controls to be monitored and remote controlled.

ALMiG

The left-hand section shows the schematic of an ALMiG screw compressor.

The right-hand section shows the display of the compressor control, the current operating
state in plain text as well as some operating data (info menu of the control).

You can quickly change over to the view of another compressor by clicking on the title bar
with the designation of the compressor and then selecting the relevant compressor.

ALMiG

By clicking
ƒthe Data button in the toolbar,
ƒon the display of the compressor control or
ƒon the compressor schematic
you can have additional information about the compressor displayed, change parameters or
switch the compressor on or off.
78
Since, depending on the control type, a large amount of data must be loaded, it can take
some seconds until the window opens and all the required data are available. During this
time, the buttons of the window are deactivated.

The tab General of the setting window provides information about the control type, the
software version and the current operating state. If the compressor is fitted with an Air
Control 1 or an Air Control 3, the compressor type is shown additionally. Furthermore, the
compressor can be switched on or off and any messages present can be acknowledged in
this screen. Switching the compressor on and off via Visualisation is only possible, if this
function has been enabled in the compressor control and the digital remote control input of
the control was properly connected for this purpose.

When you select the Parameters tab you can have the parameters of the control displayed
and change them. Click the Code button to enter a code, which then allows changes to
parameters.

The Usage tab shows the operating hours and the on-load and off-load hours of the
compressor in a graphic form. If an Air Control 3 is connected, the off hours are displayed
additionally.

79
The Service tab displays information about service intervals and remaining operating times
for individual components before the next service.
The bar labelling includes the remaining time until the next service and the corresponding
service interval as a value in parentheses.

The colours in the bars have the following meaning:

80
 Green Time remaining until next maintenance
Dark grey Time elapsed since last servicing Less
Light green/dark green, Less than 100 hours until next service
flashing
Red/dark green, flashing Maintenance interval elapsed or exceeded

To indicate that the number of hours is not within the limit values of - 500 to 5000, the
relevant bar is extended slightly beyond the limit value, but the lettering of the bar shows
the exact values.

4.5 Accessories
The Accessories view allows monitoring of the connected accessories.

The left-hand section shows a schematic illustration of the relevant type of accessories, the
right-hand section lists data and signals of the selected accessory item.

ALMiG

By clicking the Edit button in the toolbar you can edit possibly configured dates, either by
direct editing of the numerical values

Last service
Next service
or by opening the dialogue for the selection of the date

Last service
Next service
Pressure

81
 The dates entered are saved on the hard disk of the PC.

You can quickly change over to the view of other accessories by clicking to the title bar with
the designation of the accessories and then selecting the relevant accessory item.

ALMiG

It is, of course, also possible to return to the basic view of the compressor station and to
select another accessory item here.

4.6 Messages
The Messages view shows current or archived fault messages, warnings and maintenance
requirements.

ALMiG

82
After Visualisation was called, this window is empty for the time being. As soon as a fault,
warning or maintenance message is present, it is printed in bold in the above list and
archived on the hard disk.

When you click the Archive button in the toolbar you can load the messages of an optional
period. To return to the view of the current messages, click the Current button.

When you click the Acknowledge button, all the messages shown are marked as "read", i.e.
the messages are no longer shown in bold and the warning tone, if activated, is switched off.

All the messages shown are marked with colours. The colours have the following meaning:

Red Fault
Orange Warning
Green Maintenance requirement
Blue Measured value (relevant for teleservice only)

Grey Other fault (relevant for teleservice only)

To print the messages shown on the screen in the form of a list, click the Print button in the
toolbar or select menu item Messages > Print.

83
4.7 Measured values
The view Measured values allows the representation of up to two measured values of the
connected compressors.

ALMiG

4.7.1 Selection of the measured values to be displayed

The measured values can be selected in the setting window shown below and the selection
is called
ƒby clicking the Selection button of the toolbar,
ƒby selecting menu item Measured values > Selection or
ƒby clicking with the right mouse-button in the area of the measured values, menu item
Selection

84
 It is possible to display two values in the measured value diagram that are independent of
one another.

For the selected measured value, it is, in addition, possible to adjust the range of values
shown (upper and lower value of the scale for graphic representation). The selected
Dimension must be identical with the dimension set on the control, otherwise, incorrect
values will be displayed.

4.7.2 Archiving of measured data, configuration

Visualisation saves the measured values as well as the set pressure band and the status of
the compressors on the hard disk at regular intervals. The saving interval can be determined
in the setting window shown below. The window for setting the saving interval can be called

ƒby selecting the menu Measurement >Data Acquisition

or
ƒby clicking with the right mouse-button in the area of the measured values, menu
item Data Acquisition

When supplied, the software is not configured for archiving measured data. An archiving
interval must therefore be set manually for all measured values as required. Since old
measured data are not automatically cleared, a hard disk space of several 100 MBs per year
may be required, depending on the number of measured data to be archived and the
archiving intervals. It is therefore essential to check at regular intervals whether the hard disk
space is sufficient. If necessary, you must manually delete measured data that are no longer
required (e.g. using Windows Explorer).

Measured data are saved in the subdirectory Data\Local\Meas of the installation folder,
usually in the directory

C:\Programs\ALMiG\Visualisation\Data\Local\Meas

In this directory, further subdirectories are created for the measured data of one year that can
be designated, for example ..\Meas\Year2001. The directory of one year is again subdivided
into subdirectories for the individual measured data. They are named with the designation of
the measured data and the RS-485 address of the relevant control; for example, the directory
..\Meas\Year2001\MEAS_VTEMP$4 contains the measured data of the compressor
temperature of compressor 4.

It is now possible to delete either the complete directory of a year, the directory of individual
measured values or individual files contained therein - every day, a new file is created with
measured data.

85
4.7.3 Archiving of measured data, loading of saved data

Usually, the graphic or the representation in tabular form show the current measured values
of the current hour. The measured values of a previous period can be loaded by

ƒ clicking the Archive button of the toolbar,

ƒ selecting the menu Measured values > Archive or
ƒ by clicking with the right mouse-button in the area of the measured values, menu item
Archive

Enter the period for displaying archived data in the dialogue box.

If several thousand values are selected, this represents a heavy workload for your PC and
can therefore cause delays in the representation. The Period should be selected sensibly in
dependence upon the Archiving intervals. For printouts, the loading should be limited to a
few hundred values.

4.7.4 Operation of the measured values view

4.7.4.1 Display of current and archived data

In the default setting, the current measured values are shown in a graphic form over a period
of one hour. The time axis is re-scaled at intervals of 15 minutes. The display always shows
the current quarter of the hour and the preceding three quarters of the hour.

If older data are to be displayed, these can be loaded from the hard disk, provided that
archiving of the relevant measured values was selected before. You can load archived
measured values by

ƒclicking the Archive button of the toolbar,

ƒselecting the menu item Measured values > Archive or
ƒby clicking with the right mouse-button in the area of the measured values, menu
item Archive

and return to the display of current measured values by

ƒclicking the Current button of the toolbar,
ƒselecting the menu item Measured values > Current or
ƒclicking with the right mouse-button in the area of the measured values, menu
item Current

When archived data are loaded, the time axis is scaled in accordance with the selected
period of time.

86
4.7.4.2 Representation in graphic and tabular form
You can change over from graphic to tabular representation by

ƒ
clicking the Table button of the toolbar,
ƒ
selecting the menu item Measured values > Table or
ƒ
clicking with the right mouse-button in the area of the measured values, menu
item Table

and return to the graphic representation by

ƒclicking the Graphic button of the toolbar,
ƒselecting the menu Measured values > Graphic or
ƒclicking with the right mouse-button in the area of the measured values, menu
item Graphic

4.7.4.3 Zoom and und Pan functions

Some zoom and pan functions allow you to change the time and value ranges shown in the
graphic representation. These can be called via

ƒ the toolbar
ƒ the menu Measured values or
ƒ the right mouse-button menu in the measured value range

The following functions are available.

Zooming in only on the time axis by creating a window with the mouse

Zooming in only on the value axis by creating a window with the mouse

Zooming in on the time and the value axis by creating a window with the
mouse

Shifting the time range on the time axis with the mouse

Reset to the values saved for the time and the value axis under the measured
values

During zooming in, the time axis is no longer automatically updated.

The current measured values can be displayed again by resetting the zoom function
by selecting "Undo".

4.7.4.4 Cursor

To facilitate reading of the values in the graphic, a cursor is provided. The cursor is shown
automatically above the graphic when the mouse pointer is moved within the graphic.

87
4.7.4.5 Printing function

You can print the measured values currently displayed by

ƒ
clicking the Print button,
ƒ
selecting the menu item Measured values > Print or
ƒ
via the popup menu in the area of measured values (right mouse-button), menu
item Print

In the tabular view, the values are printed in the form of a list, in the graphic representation in
the form of a graphic. In the graphic mode, the current zoom settings are also taken over for
the printout.

4.8 Copyright note

This software was created using Internet Direct (Indy) Components,

for which the following notes must be observed:

Portions of this software are Copyright (c) 1993 - 2002, Chad Z. Hower (Kudzu) and the
Indy Pit Crew - http://www.nevrona.com/Indy/

License

Redistribution and use in source and binary forms, with or without modification, are
permitted provided that the following conditions are met:

- Redistributions of source code must retain the above copyright notice,

this list of conditions and the following disclaimer.

- Redistributions in binary form must reproduce the above copyright notice,

this list of conditions and the following disclaimer in the documentation,
about box and/or other materials provided with the distribution.

- No personal names or organizations names associated with the Indy project

may be used to endorse or promote products derived from this software without
specific prior written permission of the specific individual or organization.

THIS SOFTWARE IS PROVIDED BY Chad Z. Hower (Kudzu) and the Indy Pit Crew "AS IS"
AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO,
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE REGENTS OR
CONTRIBUTORS BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL,
EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,
PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR
PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY
OF LIABILITY, WHETHER IN CONTRACT, STRICT LIABILITY, OR TORT (INCLUDING
NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF THIS
SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.

88
5 Operation of the software Plant Control T

5.1 Overview
The software Plant Control T allows telemonitoring and remote operation of controls in the
compressor station from a Service Centre. In the Service Centre, with software version 1.50,
each workstation PC can access the compressor station. For this, the modem must be
connected to a server that is running around the clock. The server archives incoming
messages, forwards them as e-mails, if required, and establishes the connection with a
compressor station upon request. Data are exchanged between the clients and the server via
the local network.

To this end, the software Plant Control T- Client must be installed on the workstation PC.
The installed software can be called in the start menu by selecting Programs > ALMiG >
Teleservice > Client and can be used simultaneously by several PCs within the network.

89
5.2 Messages
As long as no connection has been established with a compressor station, the client software
only shows the page with the fault, alarm and maintenance messages.

ALMiG

In case a message is output, the system box in the compressor station automatically calls the
Service Centre. The server answers the call, records the messages and archives them. The
client checks at short, regular intervals whether new messages have been received by the
server. Furthermore, messages of optional periods of time can be loaded from the server. To
do this, click the Archive button or select menu item Messages > Archive. To return to the
display of current messages, click the Current button or select menu item Messages >
Current.

The reported faults and warnings of all compressor stations are shown in the order of their
receipt (new messages at the end). Apart from faults, warnings and maintenance
requirements, the measured values of pressures and temperatures for all compressor
controls are transmitted and displayed with each call. Each message is sent together with the
indication of the location of the compressor- as a rule, the designation of the unit. If the ID
number transmitted by the system box is unknown, the ID number is indicated directly.

If new messages are being transferred, they are highlighted in the table by being represented
in bold. By selecting Settings > Options you can determine wither a signal tone is to be
output additionally. When you click the Acknowledge button, all the messages shown are
marked as "read" and the signal tone is switched off.

90
 All the messages shown are marked with colours. The colours have the following meaning:

Red Fault
Orange Warning
Green Maintenance requirement
Blue Measured value (pressure, temperature)
Grey Error (for example, communication error when messages are called)

5.3 Logging onto a compressor station

From a client, a modem connection with the compressor station can be established via a
server. In this case, monitoring and operation of the control are similar to the visualisation
software Plant Control V at the place of installation of the compressor station.

Except for a few points, the client software for Plant Control T is identical with the visuali-
sation software for Plant Control V. The individual functions and display options are
documented in section 4. The specific functions of the client software for Plant Control are
described in the following.

5.3.1 Comparison of Plant Control T and Plant Control V

When compared with Visualisation, the client software for Plant Control T basically shows the
following differences:

ƒ There is no permanent connection with the controls. The connection with the unit is
made via a teleservice server by selecting the Connect button, and is interrupted by
clicking the Disconnect button.

ƒ The messages are received by the teleservice server. The view Messages of the
client software also shows the messages of all units connected, not only of the unit
with which the connection is currently established.

ƒ The function of acquiring measured values by a PC is not available, since it is not

permanently connected with a unit. A graphic representation of Measured values is
therefore impossible.

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5.3.2 Dialling

You can establish the connection by clicking the Connect button in the client software or
select the menu command File > Connect. The window shown below appears in which you
can select a compressor station.

The status of dialling is shown in the bar above the buttons. Dialling is completed when the
text "Connection established" appears here. Then you can close the dialling window. The
client software can now be used like Visualisation for monitoring the state of the unit and
changing parameters, see section 4.

The connection can be terminated by clicking the Disconnect button or by selecting menu
item File > Disconnect; the modem at the server will then hang up. An established
connection should be disconnected as soon as possible: Even if only one modem is
connected, telephone charges incur and fault messages cannot be logged.

An established connection is shown at the bottom left in the status bar of the client main
window. However, this indication cannot be absolutely reliable, since the modem can
disconnect the connection also without intervention by the software, for example in the case
of a connection interrupt or by an inactivity timer. When the software indicates transmission
errors although the connection is supposedly established, it can be disconnected and
reconnected.

From time to time, the modem connection is automatically disconnected from the server in
order to save unnecessarily high telephone charges and to keep the modem free for
incoming fault messages. If the connection is still required, it can be re-established after a
short waiting time.

For reasons of telecommunications laws, modems use a dial lock which prevents frequent
dialling at short intervals. In this case, dialling should be retried after a pause of about a
minute. The exact implementation of the dial lock depends on the modem used.

92
5.3.3 Remote configuration of the system box

When a connection is established, the system box can be remote configured using the client
software. To this end, you have to call the program for configuring the system box by
selecting menu item Settings > System box of the client software.

Procedure:

ƒEstablish a modem connection (Connect in the client software)

ƒCall the configuration program (menu item Settings > System box)

First, a setting window opens, which contains the same settings (server, port) as the
client software.

ƒTo configure a system box, enter address 30

The software can also be used for configuring a compressor control for automatic fault
signalling without system box. In this case, you have to enter the address of the
relevant compressor control (1-10). However, this configuration is no longer used for
new systems.

ƒClose the window by clicking OK. The program for the software configuration opens.
The operation of this program is described in section 2.7.3.

ƒ Disconnect the modem connection (Disconnect in the client software)

93
5.3.4 Data save

As a standard, the software is installed in the following directories:

Programme\ALMiG\Client
Programme\ALMiG\Server

The client software can be called from the start menu and used without requiring any
knowledge of the related configuration and program files. The same is valid for the server
software, but here, you should know the created files:

Programs\ALMiG\Visualisation\Data\Local\Meas

The transmitted messages of all compressor stations are saved in this directory. For each
month, a file is created with the title yyyy-mm.msg. These files can be copied manually in
order to save them in case a computer problem arises. The files can also be deleted
manually, if they are no longer required, or they can be copied to another computer, if this
one is to be used as server in the future.

Programs\ALMiG\Server\Modem

Data entered for any of the compressor stations are saved in this directory. These data are
required for the acquisition of fault messages and for establishing a modem connection.

A configuration file (*.ini), the name of which is irrelevant, is created for each compressor
station. The data can be entered in interactive dialogue boxes, but the files can also be
created or copied manually.

To rule out loss of data in the case of computer problems, it is highly recommend that they be
saved manually. The files can also be deleted manually, if they are no longer required, or
they can be copied to another computer, which is to be used as server in the future.

94
5.4 Copyright note

This software was created using Internet Direct (Indy) Components,

for which the following notes must be observed:

Portions of this software are Copyright (c) 1993 - 2002, Chad Z. Hower (Kudzu) and the
Indy Pit Crew - http://www.nevrona.com/Indy/

License

Redistribution and use in source and binary forms, with or without modification, are
permitted provided that the following conditions are met:

- Redistributions of source code must retain the above copyright notice,

this list of conditions and the following disclaimer.

- Redistributions in binary form must reproduce the above copyright notice,

this list of conditions and the following disclaimer in the documentation,
about box and/or other materials provided with the distribution.

- No personal names or organizations names associated with the Indy project

may be used to endorse or promote products derived from this software without
specific prior written permission of the specific individual or organization.

THIS SOFTWARE IS PROVIDED BY Chad Z. Hower (Kudzu) and the Indy Pit Crew "AS IS"
AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO,
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE REGENTS OR
CONTRIBUTORS BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL,
EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,
PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR
PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY
OF LIABILITY, WHETHER IN CONTRACT, STRICT LIABILITY, OR TORT (INCLUDING
NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF THIS
SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.

95
6 Troubleshooting
6.1 Plant Control V

6.1.1 Fault messages referring to the serial interface

When Visualisation is called - or when interface settings are being changed - one of the
following messages may appear:

Message/possible cause Check/remedy

The wrong interface was set in Correct the setting.

visualisation see section 3.1

The PC cannot access the interface, since Close other programs,

it is or was used by another program If required, restart your PC and open
Visualisation only

The PC is in the energy-saving mode, in Restart your PC and immediately call

which the interface is deactivated Visualisation

Please check, whether

x the Com server is connected

to the network
x the voltage supply to the Com
server is OK.
The Com server with the assigned IP x the IP address in the Com
address cannot be addressed. server and in the interface
driver are set correctly
x Netmask and gateway are set
correctly in the Com server

For more detailed information, please refer

to the documentation of the Com server.

96
6.1.2 Transmissions errors to individual controls

No connection can be established with one of the connected controls. The overview screen
of Visualisation shows the message transmission error. In contrast to this, a connection can
be established with other controls.

Possible cause Check/remedy

The control has an invalid software version Check software version,
see section 2.4
Wrong address setting or interface Check setting,
deactivated see section 2.4
Incorrect component type selected in Check setting,
Visualisation see section 3.2
Control is not provided with an RS-485 Retrofit interface module,
interface module see section 2.4
Jumper or switch for TTL interface Remove jumper or turn switch to OFF, see
set incorrectly section 2.4
Matching resistors Check the setting of the jumpers on the
interface module, see sections 2.2 and
2.4
Wiring defective Cable break, short-circuit, cables
interchanged, signal ground not looped
through, signal ground connected to earth at
several points
see page 2.2

6.1.3 Transmission error to all controls

No connection can be established with any of the connected controls. The overview screen
of Visualisation shows the message transmission error several times.
In addition to the reasons described before, this may have the following possible causes.

Possible cause Check/remedy

The interface converter is connected to the Use another interface or change the setting,
wrong interface. see sections 2.3 and 3.2
The cables in the interface converter are not Disconnect the interface converter from the
properly connected power supply, open the housing and check
the connection, see section 2.3
A fuse in the interface converter is defective Disconnect the interface converter from the
power supply, open the housing and check
fuses

97
6.1.4 Other communication errors

The communication with a control does not function properly in all aspects. The overview
screen does not show the message transmission error, but when parameters are being
loaded or written, error messages are in some cases be displayed and a part of the shown
data is obviously incorrect or settings are not executed as intended.

Possible cause Check/remedy

The control has an invalid software version Check software version,
see section 2
The setting option on the control is Whether parameters can be changed or the
deactivated compressor switched on or off from
Visualisation, depends on the setting in the
control.
Check and, if required, change the settings;
see documentation of the controls

98
6.2 Plant Control T

6.2.1 Fault messages of the server

When the server starts up or when settings are being changed, a fault message appears.

Possible cause of fault messages Check/remedy

If the server was not started twice by
mistake, the port is used otherwise.

In this case, select another port, see

section 3.3

It is also possible that no TCP/IP protocol

is installed. In this case, the protocol must
be installed using the Windows system
control.

see section 5.1.1

6.2.2 The client cannot establish a connection with the server

The status bar of the client signals that a connection cannot be established with the server.

Possible cause Check/remedy

The setting of the IP address or the port Check setting,
number is not identical with that of the see section 3.3
server
Server program not active Start server program provided for this
purpose on the computer, see section 3.3
Network connection interrupted Check other network services and network
connections; if required, restart your
computer

99
6.2.3 Establishment of a connection between Service Centre -» compressor station
impossible

During dialling a message appears indicating that it has been impossible to establish a
connection.

Possible cause Check/remedy

The wrong serial interface is set on the Check setting,
server in the Service Centre see section 3.3
Modem at the server in the Service Centre Check modem connection
is not switched on or not properly Use another software, for example dial-up
connected networking, to check, whether connections
can be established at all
Modem in the Service Centre has no direct Check settings of the telephone system
outward dialling permission
Modem in the compressor station has no Check settings of the telephone system
permission to answer external incoming
calls
Modem in the compressor station is not Check by other means, whether the
switched on or not properly connected modem in the compressor station answers
calls; with analogue modems, for example,
by calling it from a telephone.
Check modem connection
Modem in the compressor station is not Check by other means, whether the
configured for automatic answering modem in the compressor station answers
calls; with analogue modems, for example,
by calling it from a telephone.
Configure modem, see section 2
If a GSM modem is used in the compressor Check the state of the GSM modem (LED)
station: Check the state of the GSM modem (LED)
and, if required change position of the aerial
Ŷ SIM card is not properly inserted Select a suitable mobile telephone contract
or have the data connection cleared
Ŷ GSM modem is not hooked up to
the network

Ŷ Mobile telephone contract does

not allow a data connection for
external incoming calls.

Wrong telephone number In case a telephone system is used,

ensure that outward dialling numbers and,
if required, dial pauses are entered

With GSM modems, a special telephone

number must in most cases be used for
the data connection

100
6.2.4 Transmission error in the connection between Service
Centre ->Ŷ compressor station

During dialling a message appears indicating that the connection has been established.
However, a communication is impossible with the controls; a transmission error is indicated.

Possible cause Check/remedy

Modem in the compressor station is not Configure modem,
correctly configured see section 2
System box in the compressor station is not Check settings of the connected
correctly configured components, see section 2
Transfer error to individual controls, see
also section 5.1.2
Transfer error to all controls, see also
section 5.1.3

6.2.5 Fault message compressor station -» Service Centre is not functioning

It is possible to establish a connection from the Service Centre to the compressor station, but
any occurring errors are not signalled automatically to the Service Centre.

Possible cause Check/remedy

System box in the compressor station is not Check settings of the telephone number
correctly configured and the connected components, see
section 2
Wrong telephone number In case a telephone system is used,
observe outward dialling number and, if
required, ensure that dial pauses are taken
into account
Modem in the compressor station is not Configure modem,
correctly configured see section 2
Modem in the compressor station has no Check settings of the telephone system
direct outward dialling permission
Modem in the Service Centre has no Check settings of the telephone system
permission to answer incoming calls

101
D
ALMiG Kompressoren GmbH
Tel.: +49 (0)7024 9614-0
Fax: +49 (0)7024 9614-106
Internet: www.almig.de
E-mail: info@almig.de
Adolf-Ehmann-Str. 2
73257 Köngen
DEUTSCHLAND