ELEKTRONIKON® BASIC

ON G7-15
GUIDELINES & FAQ – ED 00
Product Company Brendola

February 2018, Thomas Berto

Atlas Copco IT
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COMMITTED TO SUSTAINABLE PRODUCTIVITY

We stand by our responsibilities towards our customers,

towards the environment and the people around us.
We make performance stand the test of time. This is
what we call – Sustainable Productivity.
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ELEKTRONIKON® BASIC ON G7-15

Agenda

 GENERAL INFO
 Q & A from the field
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NEW ELEKTRONIKON® BASIC

Why the new controller?
Objectives for new controller:
The New Controller in addition to ES99 will have:
• Icon based display, pressure settings, temperature reading
• Running hours / working hours @ load
• Service warnings for aftersales business improvement
• Pressure and element outlet temperature reading
• Easy interchangeability with ES 99 (retrofit kit)
Current Controller (ES99)

ES 99:
• Designed in 1995
• Led status visualization
• No display for an easy and intuitive visualization
• No running/load hours
• No service advices
• No pressure setting, Electro-Pneumatic machine
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NEW ELEKTRONIKON® BASIC

Introduction

 Elektronikon® Basic is an electronic control with layout based on MK5

 The board has 4 output signals
– Line contactor KL  relays controlled
– Star contactor KY  relays controlled
– Delta contactor KD  relays controlled
– Solenoid valve (Load/Unload)  Triac controlled

 The outputs must be capable of switching 12A, 250V, AC-1.

– Outputs 1 to 3 are RC snubber protected, maximum current 10A
– Output 4 is capable of switching 14.5VA, rated voltage & frequency 24VAC & 50/60Hz

 Technical features
– Power supply 12VAC (±15%): 12VDC is not allowed
– Protection Grade (IP grade) IP54 front, IP20 back
– Connections via connectors
– Temperature Range:
‒ Operating -10°C…+60°C
‒ Storage -20°C…+70°C
– Permissible Humidity RH 85%, no condensation @ nominal reference
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NEW ELEKTRONIKON® BASIC

Introduction

 4 KEYS for function of:

– Start / Stop / Escape
– Up
– Down
– Enter / Reset

 3 LED ’s
– Red (alarm led), software controllable
– Yellow (service led), software controllable = lit when the service interval is elapsed
– Green (power led), not software controllable = lit when power to controller is OK
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NEW ELEKTRONIKON® BASIC

Main Functions

 The control panel allows to manage all

following operations:

1. Controlling the compressor

2. Protecting the compressor
3. Monitoring components subject to service
4. Advanced functions:
1. Automatic Restart After Voltage Failure (standard
OFF)
2. Remote Start & Stop (standard OFF)
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NEW ELEKTRONIKON® BASIC

Compressor control

 The main control board has 4 digital inputs

– Emergency Stop (NC)
– Overload Motor
– Temperature switch Element outlet (TSHH11 + TSHH12)
– Remote Start/Stop

Minimum voltage/current in the contacts in order to read them correctly: 12VDC/8mA

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NEW ELEKTRONIKON® BASIC

Advanced Control
 The regulator maintains the net pressure between
programmable limits by automatically loading and
unloading the compressor
– A number of programmable settings are taken into account
 Unloading and loading pressures
 Minimum stop time
 Maximum number of motor starts

 The regulator stops the compressor whenever possible to

reduce the power consumption and restarts it automatically
when the net pressure decreases.
– If the expected unloading period is too short, the compressor is
kept running to prevent too short stand-still periods
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NEW ELEKTRONIKON® BASIC

How the Load & Unload algorithm works

 Two different working areas:

– UNLOAD area
– STOP area

 Virtual algorithm → Weight value

– Value increased by each start
– Time decreases the value
 Load
 Stop

 The compressor unloads at the maximum

pressure and it loads at different pressure based
on the algorithm. The load pressure could be
higher then the minimum pressure of the band

It is not possible change the pressure band of the algorithm!

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LOAD & UNLOAD – EXTRA DETAILS

 Loading
 As long as the working pressure is below the preset maximum, the solenoid valve is energized by allowing control air
to the unloader
– Inlet valve opens completely and unloading valve closes completely
– Compressor runs fully loaded (100% output)
‒ In order to reduce the pressure drop, the compressor in stand-by restarts at 0,2bar/3PSI over the loading pressure

 Unloading
 When the working pressure reaches the maximum value, the solenoid valve is de-energized by venting the control air
– Inlet valve closes completely and unloading valve opens completely
– Compressor runs unloaded (0% output).
 Elektronikon basic will stop the compressor after a variable period of unloaded operation using following rules:
– If the unloading pressure is reached after the first start and if there is no air consumption, the compressor will run unloaded during
30 seconds and then stops
– If the compressor is stopped manually, it stops after 30 seconds of unloaded operation
– To reduce the energy consumption, the compressor stops as soon as a certain time is elapsed → it is calculated as follows:
‒ Compressor cannot go over the number of hourly activation (10#/hr = cycle of 6 minutes)
‒ If the calculated virtual temperature of the motor (that increases each motor start) is above the safety limit, the compressor still goes in unload mode
until it is decreased below the safety limit
‒ If there is no pressure request at the end of the cycle & the pressure is > 2/3 of pressure band, compressor stops
‒ If there is a pressure request at the end of the cycle & the pressure is < 2/3 of pressure band, compressor goes in loading mode
 The compressor will automatically restart when the net pressure drops to the minimum limit
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NEW ELEKTRONIKON® BASIC

Service Diagram

 Temperature POWER LINE 12V

sensor

 Pressure
transducer

 Other Inputs
– Emergency Stop
– Overload Motor
– Auxiliary Relay
– Remote Start/Stop
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UNIT PROTECTION & OTHERS

Service Diagram

 Temperature switch for

redundancy
 Additional temperature
switch

 Power contactors
Activators

 Options
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UNIT PROTECTION
Shut Down Conditions

 The compressor will be shut down:

– in case the airend outlet temperature exceeds the programmed shut-down level (factory set at 115 ˚C /
239 ˚F)
– Detected by temperature sensor (TT11) or temperature switch (TSHH11\TSHH12)
– before the interruption, the warning LED (5) is FLASHING (110°C / 230 °F)
– This is LED is FIXED when temperature between 110°C/230°C and 115°C/239°F
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UNIT PROTECTION
Shut Down Conditions

 The compressor will be shut down:

– in case of error from outlet pressure sensor (PT20) or temperature sensor (TT11)

– in case of motor overload (M1): warning LED (5) is FLASHING

1) Switch off voltage
2) Troubleshooting
3) When problem is solved, restart the compressor

– In case of oil element overheating (TSHH11 or TSHH12)

– The compressor will shutdown
– Alarm LED (5) will flash
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SERVICE WARNING
What’s new?

 The new controller has the service warning function in order to inform customer about service
plan
 When the timer exceeds the programmed service interval, alarm LED (6) is blinking with a
following screen
– SErU means “SERVICE”
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GENERAL OVERVIEW
Access the MAIN MENU

 Press ENTER button (7) for 3 sec to enter

into MENU and you will find:
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GENERAL OVERVIEW
Structure of the MAIN MENU

PROGRAMMING
•
DATA •
REGULATION PRESSURE
TIMER (MAINTENACE) TEST INFO
• DISPLAY
• CONTROL
• ES99 MODE
• UNLOADING
• WIZARD
• PASSWORD
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GENERAL OVERVIEW
dAtA
 d.1: Calling up running
hours
– Tot nr of working hours (time
of output line=on)

 d.2: Calling up motor starts

– Nr of motor activation
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GENERAL OVERVIEW
dAtA
 d.3: Calling up module hours
– Tot nr of hours with controller
powered

 d.4: Calling up loading hours

– Tot nr of load working hours
(time of output valve=on)
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GENERAL OVERVIEW
dAtA
 d.5: Calling up load relay
– Tot nr of solenoid valve
activation

 d.6: Calling up the service

timer
– D.6 Service time interval
(similar to d.1)
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GENERAL OVERVIEW
dAtA – sum up

 d.1: Modifying running hours

‒ Select dAtA->d.1
‒ Press ENTER button (7) for 5 seconds (till PASS is blinking)
‒ Select PASS3 = 4321
‒ You are able to change the d.1 by UP (4) and DOWN (8) buttons

 d.2: Modifying motor starts: same procedure

 d.3: Modifying module hours: same procedure
 d.4: Modifying loading hours: same procedure
 d.5: Modifying load relay: same procedure
 d.6: Reset the service timer
‒ Select dAtA->d.6
‒ Press ENTER button (7) for 5 seconds (till PASS is blinking)
‒ Select PASS1 = 9989
‒ You are able to reset the d.6
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GENERAL OVERVIEW
ProG
 rEG.P: Calling up / Modifying pressure band selection – PrSL

 rEG.P: Calling up / Modifying pressure band settings – LPr.1, uPr.1, LPr.2 and uPr.2
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GENERAL OVERVIEW
ProG

 diSP: Calling up / Modifying unit of temperature – tEMP

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GENERAL OVERVIEW
ProG

 diSP: Calling up / Modifying unit of pressure – PrES

 diSP: Calling up / Modifying time backlight – bC.LG [0, 240] sec

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GENERAL OVERVIEW
ProG

 After any power failures and before restarting, the compressor will wait for a fixed time.
– Factory set up for delay is 30 seconds (editable ONLY with password up to 120 seconds)
– The display will show the countdown:
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NEW ELEKTRONIKON® BASIC

In case of CONTROLLER REPLACEMENT

Write down the During the first start Restore the

compressor Replace the old configure the unit compressor
counters controller with the controller counters
new one
• Running hours • WIZARD • Running hours
• Time to Service PROCEDURE • Time to service
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WIZARD PROCEDURE
It is possible reinitialize the controller through the WIZARD procedure

 In case of wrong initialization during the controller replacement

 In case of pressure changes
 Check if the unit is compatible with the new pressure
 Apply the pressure conversion kit (if available)

MENU CHOOSE THE

• PROG PROGRAM WAIT FOR THE END OF
STOP THE UNIT
• PASS (password 4321) • Scroll UP/DOWN botton PROGRAMMING
• WIZ + confirm YES • Push Enter to select the
correct program

WARNING: DO NOT SHUT DOWN THE POWER SUPPLY DURING PROGRAMMING!

In case of interruption during this phase the controller will be not fully programmed
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WIZARD PROCEDURE
Guidelines
 Check the dataplate
– Unit version: FF (with dryer) or PACK (without dryer)
– MAX working pressure and SCALE
– Version of electrical standard

– Check if it is APH unit from the unit description (Look at

documentation and/or part number)

 In case of pressure changes

 Check if the unit is compatible with the new pressure
 Apply the pressure conversion kit (if available)

WARNING: DO NOT SHUT DOWN THE POWER SUPPLY DURING THE PROGRAMING.
In case of interruption during this step, the controller will be NOT full programmed.
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WIZARD PROCEDURE
How to choose the correct «program»

STAR
T

1) IS THISNO
AN «APH» UNIT? YES

BAR
2) WHAT PSI
IS THE PRESSURE PSI
UNIT? BAR

1 3) SEE TABLE
2 3 4
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WIZARD PROCEDURE
MAX PRESSURE BAR
TABLE 1 PACK 7,5 10 13
G7 G11 G15
FF 7,25 9,75 12,75
MAX PRESSURE PSI
PACK d107 d132 d157 d182
G7 G11
FF d103 d128 d153 d178
TABLE 2
PACK S107 S132 S157 S182
G15
FF S103 S128 S153 S178
MAX PRESSURE
PSI
FOR APH UNITS
PACK S107 S132 S157 S182
TABLE 3 G7 G11 G15
FF S103 S128 S153 S178
MAX PRESSURE
BAR
FOR APH UNITS
7,4  9,1  10,8  12,6 
TABLE 4 PACK S107 S132 S157 S182
G7 G11 G15
7,1 8,8  10,6  12,3 
FF S103 S128 S153 S178
WARNING: DO NOT USE A DIFFERENT PRESSURE SETTING FROM THE DATAPLATE!
‒ IT’S A SAFETY RISK AND COMPRESSOR COULD BE DAMAGED
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ELEKTRONIKON BASIC ON G7-15

Agenda
 GENERAL INFO 12. Is it possible to set an digital input for different pressure band
on Elektronikon® basic?

 Q & A from the field – VIRTUAL ALGORITHM

13. Why does the unit start even if within the pressure band?
– GENERAL 14. Is it correct that the unit never stops?
1. What is the factory setting for nr of motor restart? 15. Is it possible to disable the virtual algorithm and just let the unit
2. How to connect this controller to an ES system? load/ unload on the pressure settings?
3. Would SMARTLINK kit be mounted? 16. Customer asked for explanation of virtual algorithm: unit is
4. Does ARAVF apply no matter how long the voltage failure? running continuously (loop)
5. Why is Pressure Dew Point value driven by KL contactor of
OIS?
– PROCEDURE
6. Is it possible change the starting mode of G7-11 units? 17. How to do WIZARD procedure?
7. Wrong program: is it possible that the program installed into 18. How to set SERVICE WARNING (and counter back to zero)?
controller is DOL (Direct Online)? 19. How to re-set service counter @ 0hrs?
8. Is it possible remove the pressure anticipation function? 20. How to turn ON the ARAVF function?
9. Is there DSS timer in the new Elektronikon® basic like we 21. How to edit the delay before startup?
have in the MK5 modules? Or is it fix unload time? 22. How to change service interval? Is there any saved data in
10. Which is the minimum pressure band allowed? these new controllers(as far as trips)?
11. Why display shows “OFF”? 23. How to connect exactly the remote start / stop function?
24. How to un-block the menu of Elektronikon® basic?
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Q&A FROM THE FIELD – GENERAL

1. What is the factory setting for nr of motor restart?
– Can it be set to a lower number? Is password needed?
– 10# is the factory set up: it can be decreased (i.e. 6#) but NOT increased
 MENU->ProG->PASS2 (9888)->Ctrl->nHCA (for other info please check question #9)

2. How to connect this controller to an ES system?

– ES system is not compatible with Elektronikon® basic

3. Would Smartlink kit be mounted? What can be retrieved on the web portal?
– Smartlink is not compatible with Elektronikon® basic but only with Mk5

4. Does ARAVF apply no matter how long the voltage failure?

– i.e. if the failure lasts for 5 hours, will the unit still restart?
– Elektronikon® basic has no RTC (real time clock): so no matter how long voltage failure takes → it will
always restart
– In case of sensor error (bad connection/contact → ERR message appears on screen), the unit will stop
and error will disappear as soon as contact is ok again
 Unit will not start automatically even with ARAVF activated
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Q&A FROM THE FIELD – GENERAL

5. Why is Pressure Dew Point value driven by KL contactor of OIS?
– Customer has a problem with PDP: G7 FF works with many starts/stops
 PDP is bad for first period every time the compressor restarts)
– Dryer is powered in the same way on G7-15 and GX7-11 (previous design)
 When KL closed, dryer is ON
 Otherwise if OIS motor is OFF, dryer is OFF
– It can be explained by energy saving as well
 Moreover this is small FAD: so the time your dryer is reaching good PDP at startup is quite short
– We kindly recommend extra focus on how many start/stop customer set up in order to optimize PDP

6. Is it possible change the starting mode of G7-11?

– US customer is asking if we have an option to make this machine Y/D start or soft start.
– This range was not designed for SOFT START
– G7-11 are DOL (only for API/APO versions – 60Hz) but there is no option to change it as WYE/DELTA
 Only G15 is WYE/DELTA
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Q&A FROM THE FIELD – GENERAL

7. Wrong program: is it possible that the program installed into
controller is DOL (Direct Online)?
– Unit switched ON: the element outlet temperature is triggered/open. We
tried to reset but cannot reset: actual temperature is 34°C and the
contacts (temp sensor) is closed but still unable to reset element outlet
temperature triggered
– We installed spare controller: the element outlet now is not
triggered/open BUT we have encountered problem again: the unit is
WYE DELTA starter but upon switch on or starting the compressor only
main contactor is energized. But when our FSE tests it manually without
controller, the WYE/DELTA is working.
– You need to reprogram the controller because the parameters do not fit
with your unit WYE/DELTA
 MENU->ProG->PASS3 (4321)->Wiz->[Reset? YES]
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Q&A FROM THE FIELD – GENERAL

8. Is it possible remove the pressure anticipation function?
– See also question #12: pressure anticipation is active only if the unit is stopped
 This is to avoid that pressure decreases too much due to start up time (WYE DELTA transition)
– Pressure anticipation value is 0,2bar / 3psi
 This function is not active if unit is running in unload. It is not possible to deactivate it

9. Is there DSS timer in the new Elektronikon® basic like we have in the MK5 modules? Or fix
unload time (if yes, what is that time?)? What are the max starts/hour?
– There is no DSS function but here we have a virtual algorithm
– Min unload time is fixed and cannot be changed: 30 seconds
– Factory setup of motor start/stop is 10#/hr: you can decrease (i.e 6#) but not increase
 If nHCA = 0 (no restart per hour), unit is always in UNLOAD mode and never stops

10. Which is the minimum pressure band allowed?

– The Minimum delta LOAD/UNLOAD is always 0,5bar / 7psi: the factory setup of pressure band
depends on unit
 If customer needs to increase, first do it on UNLOAD PRESSURE and only then on LOAD PRESSURE
 If customer needs to decrease, first do it on LOAD PRESSURE and only then on UNLOAD PRESSURE
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Q&A FROM THE FIELD – GENERAL

11. Why display shows “OFF”?
– If display shows “OFF”, it means you select ES99 emulator mode
– Pressure switch is not present; you have temperature sensor: so you can never go unload
 You can solve thru WIZARD menu

12. Is it possible to set an digital input for different pressure band on Elektronikon® basic?
– Customer requests a contact for secondary pressure band settings activation: when this contact off,
compressor works as normal pressure band
– Unfortunately this is not possible
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Q&A FROM THE FIELD – VIRTUAL ALGORITHM

13. Why does the unit start even if within the pressure band?
– i.e. pressure band [10.8, 12.5] bar: unit starts even before reaching lowest pressure
– The unit is unloading at adjusted 12,5 bar every time
– BUT it is loading on different pressures (10,8/11/11,8/12,1bar)
– The load pressure is not fixed but it changes according to the different air delivered by
compressor
 This algorithm guarantees longer motor lifetime: it starts running before the "cut in pressure" and so it avoids
motor restart with high stress
– There is a parameter Px that is equal to 2/3 the value of pressure band
– At the end of each cycle the algorithm check if pressure is < or > Px within the pressure band
‒ if BELOW, it means we have air consumption and compressor moves to LOAD + UNLOAD for 30s (if no air consumption, compressor stops)
‒ if OVER, it means no air consumption and compressor stops
‒ if unit never stops, I think there is small air leak
 The unloading time is calculated according to the virtual algorithm and you can NOT adjust it in order to reduce it:
see question #8
– It considers the air consumption due to the application of the compressor
– If you reduce too much the unlading time, you will increase the hourly activation of the compressor: it could damage the motor
and the dryer (if installed)
 The algorithm adapts the unloading time to the proper time for the air consumption
– It's not as the ES99 that you can set the dip switch to change the unload
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Q&A FROM THE FIELD – VIRTUAL ALGORITHM

14. Is it correct that the unit never stops?
– During night OR weekend (even if no air consumption), the compressor is loading for short time
– The compressor has 4 status modes:
 START UP/ON
 LOAD
 UNLOAD
 OFF
 Virtual temp algorithm is the way we define UNLOAD timing before switching OFF in accordance with
the VIRTUAL temperature of motor (1), working time (2), duty cycle of motor (3) and nr of start/stop (4)
– If motor not too hot, unit moves OFF
– If motor too hot, it will be kept ON to cool temp down @ UNLOAD mode for compressor
– If unit never stops, first check air leakage in your air network.

15. Is it possible to disable the virtual algorithm and just let the unit load/ unload on the
pressure settings? Virtual algorithm creates too long idle time.
– You can NOT disable virtual algorithm related to idle time
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Q&A FROM THE FIELD – VIRTUAL ALGORITHM

16. Customer asked for explanation of virtual algorithm: unit is running continuously (loop)
 i.e. Setting: Pmax = 10bar; Pmin = 8,5bar. ∆P = 1.5; 1/3 ∆P = 0.5

– If after 30s of unload, the pressure is P = 9,4bar

 P = 9,4bar < P max-1/3 ∆P = P min + Px = P min + 2/3 ∆P = 9,5bar: the compressor runs LOADED and pressure
band is 9,4-10bar
– This means that there is air request at customer site
 Too small or no air receiver: we made a test  unit with 80 liters receiver at different air requests
– Unit is in "small loop" just when air demand is very low
 Too small pressure band
 Not right compressor size
– This function is related to LOAD/UNLOAD and not to START/STOP
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Q&A FROM THE FIELD – PROCEDURE

17. How to do WIZARD procedure?
– Go to menu/ProG/PASS/4321/Wiz/rESE/Yes
 Select the correct program by using buttons 4 and 8 (use button 7 to confirm program)
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Q&A FROM THE FIELD – PROCEDURE

18. How to set SERVICE WARNING (and counter back to zero)?
– MENU->ProG->PASS1 (9989)->tiMr->SrV.d

19. How to re-set service counter @ 0hrs?

– MENU->dAtA->d. 6->Press ENTER BUTTON for 5 seconds (up to PASS1 – 9989 blinking)->Select
YES>Press ENTER

20. How to turn on the ARAVF function?

– First the declaration of responsibility must be signed by customer/end user for safety reason
– Then you activate it through:
 MENU->ProG->PASS2 (9888)->Ctrl->Ar.Af->YES
– When ARAFV is active, you find icon on display

21. How to edit the delay before startup?

– You can change from 15sec to 120sec
 MENU->ProG->PASS2 (9888)->Ctrl->Ar.d
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Q&A FROM THE FIELD – PROCEDURE

22. How to change service interval? Is there any saved

data in these new controllers(as far as trips)?

– First this is NOT an error/alarm BUT a warning

– Here the procedure to change service interval
 MENU->ProG->PASS1 (9989)->tiMr->SrVd
– If you need to modify service timer
 MENU->dAtA->d. 6->Press ENTER BUTTON for 5 secs (up
to PASS1 – 9989 blinking)->Select YES>Press ENTER

– There is no saved data/error log on this controller

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Q&A FROM THE FIELD – PROCEDURE

23. How to connect exactly the remote start / stop function?
– What is the exact connection location?
– Is it possible for the costumer to see error and pressure signals on its
own control surface?
– You find all instructions on service diagram
 There is no free contact: so you can not remote alarm or pressure signal

24. How can I un-block the menu of Elektronikon® basic?

– Customer cannot modify the parameter of Elektronikon® basic: it
seems blocked
 To UNLOCK controller menu: it is necessary to push buttons 4 and 8
together for 5 seconds
 To LOCK it: again push buttons 4 and 8 together for 5 seconds
– If Elektronikon® basic menu is locked, it is possible view only
pressure and temperature values
 45

COMMITTED TO
SUSTAINABLE PRODUCTIVITY.