Datakom DK-45 User Manual

DK-45 User Manual V1.0 (22.09.2016)

DK-45

COMPRESSOR

CONTROLLER

The DK-45 is a high-tech product providing control and
protection of screw or piston type air compressors
driven by electric motors.

The controller incorporates all functions needed in a
compressor control panel. Thus no additional modules
are necessary resulting in lower panel cost.

The “early start” function analyzes the air consumption

trend and runs the compressor so that the pressure
never falls below the low limit.

The controller is directly supplied from the 230/400V
utility network. It provides fail contact and sensor
supplies internally, removing the need for a supply
transformer in the panel.

Utility mains voltages and frequency can be read on
the controller. It offers low/high voltage and phase
order protections.

The 2.9” wide, 128x64 pixels graphical screen displays

values in bigger size and with graphic support.
The logic level Modbus RTU communication port of the

controller allows computer connection providing
monitoring and program parameter adjusting.

Optically isolated digital inputs feature noise filtering
allowing fault-free operation in electrically noisy
environments.

The controller provides 5 relay outputs rated at 5
Amps.

The controller configuration may be done through the
front panel or using the free PC software. The PC
software is available for free download at
manufacturer’s website.

It is possible to monitor and record the controller using
the free RAINBOW+ software.

● Graphical LCD screen: 128x64 pixels, 2.9”

● Automatic operation from output pressure

● Voltage protection relay function

● Phase order protection relay function

● Analog speed control output

● Multiple compressor support

● Flexible motor hours calculation algorithm

● Early start function preventing pressure drop

● Dryer control function

● History records

● 5 independent service counters

● Supports various topologies

● Displays utility mains voltages

● No external transformer needed

● Star / Delta start-up

● Load solenoid control

● 5 programmable relay outputs

● Optically isolated, programmable digital inputs

● 2 pressure sensor inputs

● 2 temperature sensor inputs

● Adjustable sensor characteristics

● Logic level serial port

● MODBUS-RTU communications

● Password protected front panel programming

● Low panel depth, easy installation

● Wide operating temperature range

● Sealed front panel (IP65 with gasket)

DESCRIPTION

FEATURES

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Any unauthorized use or copying of the contents or any part of this document is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

This document describes minimum requirements and necessary steps for the successful installation of
the DK-45 family controllers.

Follow carefully advices given in the document. These are often good practices for the installation of
compressor controllers which reduce future issues.

For all technical queries please contact Datakom at below e-mail address:

[e-mail]

If additional information to this manual is required, please contact the manufacturer directly at below e­mail address:

[e-mail]

Please provide following information in order to get answers to any question:

- Device model name (see the back panel of the controller),

- Complete serial number (see the back panel of the controller),

- Firmware version (read from the display screen),

- Measuring-circuit voltage and power supply voltage,

- Precise description of the query.

REVISION

DATE

AUTHOR

DESCRIPTION

01

19.06.2015

MH

First edition, firmware version 1.0

CAUTION: Potential risk of injury or death.

WARNING: Potential risk of malfunction or material damage.

ATTENTION: Useful hints for the understanding of device operation.

REVISION HISTORY

TERMINOLOGY

QUERRIES

ABOUT THIS DOCUMENT

COPYRIGHT NOTICE

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 Electrical equipment should be installed only by qualified

specialist. No responsibility is assured by the manufacturer or
any of its subsidiaries for any consequences resulting from the
non-compliance to these instructions.

 Check the controller for cracks and damages due to

transportation. Do not install damaged equipment.

 Do not open the controller. There are no serviceable parts inside.
 Fuses must be connected to the power supply and phase voltage

inputs, in close proximity of the controller.

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

 Disconnect all power before working on equipment.

 When the controller is connected to the network do not touch

terminals.

 Short circuit terminals of unused current transformers.

 Any electrical parameter applied to the device must be in the

range specified in the user manual. Although the controller is
designed with a wide safety margin, over-range parameters may
reduce lifetime, alter operational precision or even damage the
controller.

 Do not try to clean the device with solvent or the like. Only clean

with a dump cloth.

 Verify correct terminal connections before applying power.
 Only for front panel mounting.

SAFETY NOTICE
Failure to follow below instructions
will result in death or serious injury

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1. INSTALLATION INSTRUCTIONS

1.1. FRONT AND REAR PANELS

1.2. MECHANICAL INSTALLATION

1.3. ELECTRICAL INSTALLATION

1.4. CONNECTION DIAGRAM

2. PUSHBUTTON FUNCTIONS

3. SCREEN SCROLLING

4. MODES OF OPERATION

5. ALARMS AND WARNINGS

5.1. SERVICE ALARM OPTIONS

5.2. LIST OF FAULT CODES

6. OTHER FEATURES

6.1. RESETTING SERVICE COUNTERS

6.2. MODIFYING MOTOR RUN HOURS

6.3. SELECTION OF MOTOR HOURS COUNTING METHOD

6.4. CONNECTION TOPOLOGIES

6.5. PREVENTING PRESSURE LOSS

6.6. ALARM HISTORY

6.7. DRYER FUNCTION

6.8. VARIABLE UNLOAD TIMER

6.9. PID CONTROL AND ANALOG OUTPUT (PWM)

6.10. MOTOR PTC INPUT

7. MULTI-COMPRESSOR OPERATION

8. DIGITAL INPUTS

9. RELAY OUTPUTS

10. PROGRAMMING

10.1. ENTERING THE PROGRAMMING MODE

10.2. LIST OF PARAMETERS

11. MODBUS COMMUNICATIONS

11.1. DESCRIPTION

11.2. MODBUS REGISTER LIST

11.3. ALARMS, WARNINGS, SERVICE REQUESTS

12. DECLARATION OF CONFORMITY

13. TECHNICAL SPECIFICATIONS

TABLE OF CONTENTS

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Before installation:

 Read the user manual carefully, determine the correct connection diagram.
 Remove all connectors and mounting brackets from the controller, then pass the controller

through the mounting opening.

 Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure.
 Make electrical connections with plugs removed from sockets, then place plugs to their sockets.
 Take into consideration that supply inputs are isolated from measurement inputs.
 Be sure that adequate cooling is provided.
 Be sure that the temperature of the environment will not exceed the maximum operating

temperature in any case.

Below conditions may damage the device:

 Incorrect connections.
 Incorrect power supply voltage.
 Voltage at measuring terminals beyond specified range.
 Overload or short circuit at relay outputs
 Connecting or removing data terminals when the controller is powered-up.
 High voltage applied to communication ports.
 Ground potential differences at non-isolated communication ports.
 Excessive vibration, direct installation on vibrating parts.

Below conditions may cause abnormal operation:

 Power supply voltage below minimum acceptable level.
 Power supply frequency out of specified limits

1.1 INSTALLATION INSTRUCTIONS

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WALL

40mmmin 60mm

Panel Cutout Dimensions Required Panel Depth

1.1. FRONT AND REAR PANELS

1.2. MECHANICAL INSTALLATION

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

 ALWAYS remove plug connectors when inserting wires with a screwdriver.
 Fuses must be connected to the power supply and phase voltage inputs, in

close proximity of the controller.

 Fuses must be of fast type (FF) with a maximum rating of 6A.
 Use cables of appropriate temperature range.
 Use adequate cable section, at least 0.75mm2 (AWG18).
 Follow national rules for electrical installation.
 Connect only the provided serial port adapter to the serial communication

port.

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

1.3. ELECTRICAL INSTALLATION

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1.4. CONNECTION DIAGRAM

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Three pushbuttons on the front panel allow access to programming and measuring screens.

BUTTON

DESCRIPTION

FUNCTION

MENU

Displays the next parameter.
Reset alarms.
PROGRAMMING: Save the adjusted parameter.

RUN

Reset alarms and run the compressor.
PROGRAMMING: Increase parameter value.

STOP

Reset alarms and stop the compressor.
PROGRAMMING: Decrease parameter value.

2. PUSHBUTTON FUNCTIONS

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When the controller powers-on, the top part of the display will show (P1) the first pressure sensor (or first
pressure switch). The pressure unit may be displayed as PSI or Bar following program parameter setting.

The upper visual bar fills up in relation with the current pressure level.
The right end of the bar is always set to the maximum displayable pressure, which is E.03 High Pressure

Alarm Limit.
The left end of the bar is set to the minimum displayable pressure level.

The (start) icon on the bar indicates the E05. Starting Pressure, the (stop) icon indicates the E04.
Stop Pressure and the icon indicates the E.03 High Pressure Alarm Limit.

The bottom part of the display shows (T1) the first temperature sensor. The temperature unit may be °C
(degrees celcius) or °F (degrees Fahrenheit) following program parameter setting.

The lower visual bar fills up in relation with the current temperature.
The right end of the bar is always set to the maximum displayable pressure, which is E.08 High

Temperature Alarm Limit. The left end of the bar is set to the minimum displayable temperature.
The icon indicates the E.08 High Temperature Alarm Limit.

If a relay output is set as the Fan Relay (see chapter 9), when this relay is active a fan icon will appear at
the bottom right corner of the display screen.

Through parameter setting in the programming menu, (P2) second pressure value or the differential
pressure P2-P1 (DP), (T2) second temperature sensor or the differential temperature T1-T2 (DT) may be
displayed in a second pressure/temperature screen.

All measurement screens are scrolled by depressing the MENU pushbutton.

First Pressure/Temperature Screen

Second Pressure/Temperature Screen

3. SCREEN SCROLLING

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Phase-to-Neutral voltage screen

Phase-to-Phase voltage screen

Run Hours Screen

Service Timers Screen

This screen shows remaining time to services A,B, C, D and E in hours. Service timers operate on a
decremental basis. Service bars are emptied with relation to timer values.

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Information Screen

If the E.47 Motor Control PWM Signal is enabled, then instead of start/stop pressures, this screen will
show the E.48 Motor Control PWM Set Pressure (DRVR SET PRS) parameter.

Alarm history Screen

Alarm history will be described in detail in chapter 6.6.
Above screens or values shown in screens may not be displayed depending on program parameter

setup.

Display of some values are selected with program parameters.
Display screens may differ following compressor
manufacturers.

When an alarm occurs, the display will show the alarm code
and alarm symbol.

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Below is the description of some abbreviations displayed on the screen:

ABBREVIATION

DESCRIPTION

P1

First pressure sensor value or first pressure switch position

P2

Second pressure sensor value or second pressure switch position

DP

P2-P1 differential pressure (Delta pressure)

T1

First temperature sensor value

T2

Second temperature sensor value

DT

T1-T2 differential temperature (Delta temperature)

L-1

Voltage between phase L1 and neutral

L-2

Voltage between phase L2 and neutral

L-3

Voltage between phase L3 and neutral

L12

Voltage between phases L1 and L2

L23

Voltage between phases L2 and L3

L31

Voltage between phases L3 and L1

FRQ

Frequency

RUN H.

Total motor run hours (On-load + off-load)

LOAD H.

On-load motor run hours

LD/RUN

(On-load) / (Total) motor hours ratio

STRTS/h

Maximum number of starts per hour

DRVR SET PRS

Motor control PWM signal set pressure

STRT PRES

Compressor’s starting pressure

STOP PRES

Compressor’s stop pressure

MASTR DEV. ADR

Master device address (multi-compressor operation)

NUM OF DEVICES

Number of devices (multi-compressor operation)

SOFTWARE VER.

Device firmware version

msec

milisecond

sec

second)

min

minute

h (hour)

hour

V

Volt

Hz

Hertz

%

percent

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Below is the description of some icons displayed on the screen:

ICON

DESCRIPTION

OFF, disabled, not-OK

Remote Start

Reset, cancel, disable

Enabled, adjusted, action complete, OK

Enter / change password

Motor PTC

Pressure-2 in Separator filter

Waiting the pressure in separator filter to drop
Remote Start / Stop

Waiting input signal

Max Slaves

Auto restart register, PORO

Dryer function

Insufficient pressure (run the compressor)

Sufficient pressure (stop the compressor)

Remaining hours to service

Run hour counters

Programming

Remote Stop

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Selecting the mode of operation:

When powered-up, the device turns-on all lights during 3 seconds for verification. Then it goes into STOP
mode and the STOP led turns on.

The compressor may be run with the REMOTE START signal ( icon displayed during 5 seconds) or
by depressing the RUN pushbutton.

If the E.27 Safety Timer is not expired, then the RUN led will flash until the expiration of the timer. Then
the motor will run is the output pressure is below E.05 Start Pressure.

The compressor is usually stopped with REMOTE STOP signal ( icon is displayed during 5 seconds)
or by depressing the STOP pushbutton.

Stop procedure:

STOP led starts flashing.
If the compressor is under load, the load relay will release and the motor continues to run during E.27

Safety Delay Timer or E.25 Unload Timer (whichever is longer). During this period the RUN mode may
be resumed by depressing the RUN pushbutton.

If the STOP pushbutton is depressed again during off-load running, then the compressor will stop
immediately.

The STOP led will continue to flash until the complete stop.

4. MODES OF OPERATION

If an alarm occurs the compressor will stop immediately and
the screen will display the alarm code and related icon.
Please see chapter_5 for the complete list of alarm codes.

If the compressor is running off-load and the STOP pushbutton
is depressed, it will continue to run until the expiration of the
E.25 Unload Timer.
By depressing again the STOP pushbutton the compressor may
be stopped immediately.

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Start-up procedure:

If utility mains voltages and frequency is between set limits and the phase order is correct, the the LINE
led will turn on. The compressor can run only when the LINE led is on. Otherwise it cannot be run by any
means.

The RUN mode is selected by depressing the RUN pushbutton or by setting the REMOTE START
signal (if enabled). At this stage the compressor will run only when the output pressure falls below the
E.05 Start Pressure (or when the pressure switch closes).

Before the compressor runs, the STAR relay will be activated. After the expiration of E.15 Delay
Between Relays Timer the MAIN relay will be active. Thus the motor will start-up in STAR configuration.

After the expiration of E.22 Star Timer the STAR relay will release. After the expiration of E.23 Star Delta
Timer the DELTA relay will be active.

After the expiration of E.24 Time Before Load, the LOAD relay will become active and the compressor
starts producing compressed air.

Unloading and reloading of the compressor:

When the output pressure reaches E.04 Stop Pressure limit (or the pressure switch opens) the load
relay will release and the motor will run off-load during E.25 Unload Timer. If the pressure falls below the

E.05 Start Pressure before expiration of the timer, then the LOAD relay will be activated again.

Stopping and restarting following output pressure:

If the output pressure stays over the E.05 Start Pressure during E.25 Unload Timer, then the DELTA
relay relases. After E.15 Delay Between Relays the MAIN relay releases and the compressor stops.

In this position the RUN led is flashing.
The maximum number of start cycles that the compressor is allowed to perform in 1 hour is defined by the

F.01 Max Starts per Hour program parameter.
If the maximum number of starts is reached, then following stop cycles will be skipped until the expiration

of 1 hour period.

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Abnormal conditions of a compressor are divided into 3 categories, being WARNINGS, ALARMS and
SERVICE REQUESTS.
Warnings are the lowest priority fault conditions and result only in visual warnings.
Alarms are highest level fault conditions and cause the compressor to stop immediately, the alarm relay
to operate (if enabled) and the controller give visual warning.

When a fault condition occurs, the related fault code and icon will appear on the screen. If the fault
condition is an alarm, then the ALARM led will turn on. If the fault is a service request then the SERVICE
led turns on.

Warnings may be cancelled by depressing the MENU pushbutton. Alarms cannot be cancelled with
pushbuttons. The alarm signal must also be removed. However the depression of the MENU

pushbutton will cause the large alarm icon to disappear and the alarm goes to the upper right corner of
the screen.

5. ALARMS AND WARNINGS

When the MENU pushbutton is depressed, the display will
rever to the “measurements” screen.

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Following the selection of the program parameter F.02 Stop Service Request, the expiration of a service
timer may simply cause a visual warning and the activation of the alarm relay, or it may also cause below
behaviour:

TIME TO SERVICE

ACTION TAKEN

> 100 hours

No warning occurs

100 hours

Service request warning is given and the service led turns on. The
compressor continues normal operation.

0 hours

The compressor stops. Service request warning is given and the service led
turns on. The compressor may be run again by depressing the RUN

pushbutton.

-100 hours

The compressor stops. Service request warning is given and the service led
turns on. The compressor may be run again by depressing the RUN

pushbutton.

Between -120 and -200 hours,
every 20 hours

The compressor stops. Service request warning is given and the service led
turns on. The compressor may be run again by depressing the RUN

pushbutton.

Between -210 and -300 hours
and every 10 hours

The compressor stops. Service request warning is given and the service led
turns on. The compressor may be run again by depressing the RUN

pushbutton.

-300 hours

The compressor stops. Service request warning is given and the service led
turns on. The compressor will run only after service is performed.

5.1. SERVICE ALARM OPTIONS

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ICON

CODE

DESCRIPTION

FAULT LEVEL

ALARM 01

01

Pressure Safety Switch Open

ALARM

ALARM 02

02

High Pressure

ALARM

ALARM 03

03

Pressure sensor failure

ALARM

ALARM 04

04

High temperature Alarm

ALARM

ALARM 05

05

High Temperature Warning

WARNING

ALARM 06

06

Temperature sensor failure

ALARM

ALARM 07

07

Low temperature Alarm

ALARM

ALARM 08

08

Fan motor high temperature

ALARM

ALARM 09

09

Motor PTC high temperature

ALARM

ALARM 10

10

Voltage unbalance

ALARM

ALARM 11

11

High voltage

ALARM

ALARM 12

12

Low voltage

ALARM

ALARM 13

13

High frequency

ALARM

ALARM 14

14

Low frequency

ALARM

5.2. LIST OF FAULT CODES

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ICON

CODE

DESCRIPTION

FAULT LEVEL

ALARM 15

15

Phase order failure

ALARM

ALARM 16

16

Air filter clogged

WARNING

ALARM 17

17

Max starts per hour exceeded

WARNING

ALARM 18

18

Emergency stop

ALARM

ALARM 19

19

Internal failure

WARNING

ALARM 20

20

High differential pressure

ALARM

ALARM 21

21

Sensor-2 high pressure

ALARM

ALARM 22

22

Pressure sensor-2 failure

ALARM

ALARM 23

23

Sensor-2 high temperature
/ Delta_T (tS2-tS1) Alarm

ALARM

ALARM 24

24

Temperature sensor-2 failure

ALARM

ALARM 25

25

Sensor-2 low temperature alarm

ALARM

ALARM 26

26

Air in separator filter

WARNING

ALARM 27

27

Delta temperature sensor-2

WARNING

ALARM 28

28

Motor thermic protection switch open (Motor
Overload)

ALARM

ALARM 29

29

Sensor-2 low pressure

ALARM