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LEADAIR 12
LEADAIR 12
Page 0
User Manual
Index
1.0 Introduction
1.1 Compressor Connectivity
1.2 Pressure Detection and Control Health and Safety
Refer to LEADAIR Safety Manual
2.0 Features and Functions
2.1 Pressure Control
2.2 Tolerance
2.3 Damping
2.4 System Volume
2.5 Sequence Control Strategies
2.6 Priority Settings
2.7 Prefill
2.8 Pressure Schedule
2.9 Insufficient Capacity Alarm
2.10 Restricted Capacity Alarm
4.0 Operation
4.1 User Interface
4.2 Unit Status
4.3 Compressor Status Indicators
4.4 System Alarms
4.5 Unit Functions
4.6 User Menu
4.7 Information Displays
4.8 Manual Sequence Rotation
4.9 Compressor Identification
4.10 Stop
4.11 Start
4.12 Power Failure Auto-Restart
4.13 Failure Mode
4.14 Reset
4.15 Compressor Fault Indications
4.16 Fault Codes
Note
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LEADAIR LEADAIR 12
7 8 9 10 11 12
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User Manual
a
PH a
PH
PT
PT
PL
b PL
b
c
PH
PT
PL
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LEADAIR LEADAIR 12
Tolerance is a pressure band above and below In situations where the loading of an additional
the set pressure control levels that compressor, at the PL pressure set point, is
accommodates for an exceptional instance of inadequate to match a significant and/or
abrupt and/or significant increase, or abrupt increase in air demand the additional
decrease, in demand without compromise to reaction of the LEADAIR 12, while pressure
optimal energy efficient control. deviates into the ‘tolerance’ limit, is
dynamically calculated. The time before an
additional compressor is loaded, to increase
PH + TO
generation capacity further, will vary in
TO
accordance with the urgency of the situation.
PH
PT
The LEADAIR 12’s dynamic reaction algorithm
PL is pre-set by default to accommodate for the
TO majority of installation characteristics.
PL - TO
In some situations, of which the following are
examples, the rate of pressure change may be
Tolerance (TO) is expressed as a pressure
aggressive and disproportionate:
defining the width of the tolerance ‘band’.
a) Inadequate system volume
For example; a tolerance setting of 3psi
(0.2bar) means the LEADAIR 12 will b) Excessive air treatment equipment
pressure differential
implement appropriate optimal energy efficient
c) Inadequately sized pipe work
response(s) during a deviation of pressure
d) Delayed compressor response
3psi below the set PL pressure level. If
pressure ever deviates beyond the ‘tolerance’
In such instances the LEADAIR 12 may over-
limit the LEADAIR 12 will proportionally
react and attempt to load an additional
increment an emergency response,
compressor that may not be necessary once
abandoning optimum energy efficiency, until
the initial compressor is running, loaded, and
pressure is returned to normal levels.
able to contribute adequate additional
generation capacity. If an increase in the
If system volume is inadequate, and/or
‘tolerance’ band is insufficient, the LEADAIR
demand fluctuations are significantly large, it
12’s dynamic reaction response can be
is advisable to increase the ‘Tolerance’ band to
influenced by increasing the ‘Damping’ factor
maintain optimum energy efficiency, and
(DA) reducing tendency to over-react.
reduce over-reaction, during such transition
periods.
The ‘Damping’ factor is adjustable and scaled
from 0.1 to 10 with a default factor of 1. A
If system volume is generous, rate of pressure
factor of 0.1 equates to 10 times faster than
change is slow and demand fluctuations are
default and a factor of 10 equates to 10 times
insignificant and gradual, the ‘Tolerance’ band
slower than default.
can be reduced to improve pressure control
without compromise to optimum energy
efficiency.
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User Manual
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LEADAIR LEADAIR 12
Rotation: Control:
Each time the rotation interval elapses, or the Compressors are utilised, in response to
rotation time is reached, the sequence order changing demand, using a ‘FILO’ (First In,
of compressors is reviewed and re-arranged Last Out) strategy. The ‘duty’ compressor (A)
dependant on the running hours recorded for is utilised first followed by (B) if demand is
each compressor. The compressor with the greater than the output capacity of (A). As
least recorded running hours is assigned as demand increases (C) is utilised followed by
the ‘duty’ compressor, the compressor with the (D) if demand increases further. As demand
greatest recorded running hours is assigned reduces (D) is the first compressor to be
as the ‘last standby’ compressor. For systems unloaded, followed by (C) and then (B) if
with more than two compressors, the demand continuous to reduce. The last
remaining compressor(s) are assigned in compressor to be unloaded, if demand
accordance with there recorded running hours reduces significantly, is (A). The compressor
in the same way. assigned as (A) in the sequence is the first to
be loaded and the last to be unloaded.
Example: The compressors in a four-
compressor system have the following
recorded running hours at the ‘Rotation’ time. Timer Rotation Mode
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User Manual
The ‘duty’ compressor (A) is utilised first Energy Control mode incorporates adaptive
followed by (B) if demand is greater than the strategies and dynamic responses that
output capacity of (A). As demand increases continuously modify basic principles. With
(C) is utilised followed by (D) if demand ‘built-in’ knowledge of individual compressor
increases further. capabilities the management unit adapts to
accommodate system characteristics under
As demand reduces (D) is the first compressor varying demand situations.
to be unloaded, followed by (C) and then (B) if
demand continues to reduce. Tables:
100%
The ‘maximum’ pressure fault level and the
rotation interval, or rotation time, are set
80% independently in a configuration menu and are
unchanging regardless of Table selected.
2
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LEADAIR LEADAIR 12
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User Manual
1 2 3 4 1 2 3 4
1 2 2 2 1 2 2 3
#1 A B C D #1 A B C D
#2 A C D B #2 A C B D
#3 A D B C #3 A B C D
#4 A B C D #4 A C B D
Example 2: Example 4:
For a four-compressor system, that includes a Compressors can be separated in to rotation
compressor (for example compressor 4) that groups. In this example compressors 1 and 2,
is less efficient, or otherwise less desirable to of a four-compressor system, have been set
operate for other reasons, it may be as a high priority group and compressors 3
convenient to ensure the compressor is only and 4 as a lower priority group. Compressors
utilised as an emergency backup. To achieve 1 and 2 will always be utilised first in any
this assign compressor number 4 with a lower sequence arrangement and will be rotated at
priority. each ‘Rotation’ event. Compressors 3 and 4
will always be utilised as lower priority in any
Compressors 1 to 3 = priority 1
sequence arrangement and will be rotated at
Compressor 4 = priority 2
each ‘Rotation’ event.
1 2 3 4
1 2 3 4
1 1 1 2
1 1 2 2
#1 A B C D
#1 A B C D
#2 B C A D
#2 B A D C
#3 C A B D
#3 A B C D
#4 A B C D
#4 B A D C
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LEADAIR LEADAIR 12
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User Manual
2.9 Insufficient Capacity Alarm c) inhibited from use in the long term
maintenance menu.
CAP
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LEADAIR LEADAIR 12
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User Manual
Page 0 Page 1
Page 2
Item 1 Value
Item 2 Value Page 3 Item 1 Value
Item 3 Value Item 2 Value
Page 4
Item 4 Value Item 3 Value
Item 5 Value Page 5 Item 4 Value
Item 6 Value Item 5 Value
Page 0 Page 1
Page 2
Item 1 Value
Item 2 Value Page 3
Item 1 Value
Item 3 Value Item 2 Value
Page 4
Item 4 Value Item 3 Value
Item 5 Value Page 5 Item 4 Value
Item 6 Value Item 5 Value
Page 13
LEADAIR LEADAIR 12
LEADAIR 12 first.
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User Manual
3.1 Menus
Pressure Schedule
USER Level Menus (0011) P01
1 01 Schedule Setting #1
TABLE #1 to 28 Schedule Setting #28
T01
Compressor Maintenance
4 C02
TABLE #4
T04 01 Compressor #1 Maintenance
to 12 Compressor #12 Maintenance
PH High Pressure Set Point
PL Low Pressure Set Point
Pm Minimum Pressure Alarm
SQ Sequence Algorithm Fault Log
01 Compressor #1 Priority E01
to 12 Compressor #12 Priority
01 Fault Log #1 (most recent)
to 15 Fault Log #15
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LEADAIR LEADAIR 12
T01 P01
16 12 1 28 28 - . --:-- ---
01 PH 7.0 bar 01 01 - . --:-- ---
02 PL 6.8 bar 02 02 - . --:-- ---
03 Pm 0 bar 03 03 - . --:-- ---
04 SQ TR ( ) 04 04 - . --:-- ---
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User Manual
Page 17
LEADAIR LEADAIR 12
E01
15 -: --- . --
01 E : ERR . 01
02 -:--- . --
03 -:--- . --
04 -:--- . --
E01 – 01 to 15
E01 01.01
E: ERR.01
16/05/2006 14:25
1
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User Manual
7.0
BAR Alarm (Warning)
c Shutdown (Trip)
d 1 Indicators
e
17:30 #1 Off
On
a) System Pressure Value
Intermittant:
b) System Pressure Units
c) Unit Status
d) Unit Active Functions
e) User Menu Item 1sec
Keypad:
Slow Flash:
d a
e 1sec
b
Fast Flash:
f
g c
1sec
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LEADAIR LEADAIR 12
a
b CAP
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User Manual
Status Symbol:
Standby
Running, Offload
Running, Loaded
#
Removed From Service in Table
Priority Selection (# = Table Number)
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LEADAIR LEADAIR 12
#4 18:00
Shows the next Pressure Schedule event. 18 / 05 / 2006
1: The Current Active Table ABC D
2: Day (#1=Monday, #7=Sunday)
3: Time (24hr system)
4: Table
Items 2 and 3 show the day and time that Day of the week (#4: Thursday), the
the unit will change to use the ‘Table’ shown in time of day (18:00) and the date (18/05/2006)
item 4. of the next automated sequence rotation
event.
Compressor Status:
P00 The active ‘mode’ of operation
V-485 3
“ABCD” The current active rotation sequence
assignment.
100 % 4
1 1 1
20 % 5 4.8 Manual Sequence Rotation:
2
30% 6 The sequence assignment can be manually
rotated at any time. When viewing the
‘Sequence Rotation’ information screen press
1: Compressor Number Enter:
2: Priority Setting
3: Compressor/Connection Type
4: Maximum Capacity % Setting
5: Minimum Capacity % Setting The manual rotation symbols will
6: Minimum Efficiency % Setting appear and flash. Press Enter again to
execute a manual rotation or Escape to
Item values 5 and 6 are only shown if abandon the manual rotation.
compressor type is V-485 (variable
capacity/speed). Automated sequence rotation is not disrupted
by a manual rotation; the next scheduled
automated sequence rotation event will still
occur.
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User Manual
Prefill
1 2 3 4 5 6
CAP
7 8 9 10 11 12
Start Function
Page 23
LEADAIR LEADAIR 12
Page 24
User Manual
Page 25
LEADAIR LEADAIR 12
Page 26
User Manual
7 i-PCB 8
20mm
IEC 5mm
27mm 286mm
Dimensions 340mm x 241mm x 152mm
13.40” x 9.45” x 6.0” 27mm
Weight 7.5kg (16.5lb)
Mounting wall, 4 x screw fixings
Enclosure IP54, NEMA 12
Supply 230Vac +/- 10%
115Vac +/- 10%
188mm
Power 100VA
Temperature 0°C to 46°C (32°F to 115°F)
Humidity 95% RH, non-condensing
8mm Ø
Page 27
LEADAIR LEADAIR 12
T1-46-311-R6-DiC-CB
Terminal PCB
33 34 35 36
X06
+VDC C03
C01
X08
Ai1 C04 C03
4
A-GND
Ai2 C06 C05
3
Ao +VDC C07
31 32
C06 SEQ C08
X07
Ai3 C08
2
C07 C07
X09
GND
1
C08
27 28 29 30
C+ C019
C09
C010
C09
X06
1 C020
XPM485
C010
2
X08
C021
3 C022
SEQ
C011
X04
4 C023
L2 L1
A C012
25 26
5 C04
X05
C024
B C013
6 C025
C03
C019
C014
7
RS485#2
C026
+
-
19 20 21 22 23 24
C015 10k
8 C027
R-SEQ
C016 C024
24Vac
GND
C034 150k
C017 C06
X04
C018 150k
C011
R5 C019 C012
24Vac
C012
X02
C020
SEQ
C021
C031/1
R6 C022
Multi485
C031/2
C023
X07
C024
10k
13 14 15 16 17 18
C013 C025 C023
L2 L1
C09 R1
GND
C026 C027
C014
X03
C010
R2 C027
RS485#1
C015
X03
C028 C018
R3
C016 C029
C030
C017
24Vac
R4 C033
X01
7 8 9 10 11 12
C018 10k
C034
C022
2
1
0VDC
C026 X02
C031
C016
X02
XPM-TAC24
C032
1
0Vac - earthed
24Vac
N
E
E
L
1 2
X01
10k
6
X03
C021
1 2 3 4 5
0Vac C025
X01
C029
C028
24Vac
C015
X01
XPM-PSU24
L N E 24Vac
2 1
230Vac 10%
115Vac 10% X02 X03
24VDC 24VDC
1 2 1 2
1 L1
X01
iX 2 L2 1 2
3
X03
A 1 L1
X02
B 2 L2
XPM485 3 XPM-LED
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User Manual
SX
Terminal PCB
33 34 35 36
240V 'CE' / 115V ' UL' @ 5A maximum.
X08
Auxiliary Output ‘AO’
31 32
X07
Auxiliary Input ‘AI’
100m (330ft) max
L2 L2
27 28 29 30
L1
X06
Multi485 L1
L2
L1
100m (330ft) max -
25 26
- Ai1 System
X05
Pressure
+
+ +
+20VDC 6 4-20mA
19 20 21 22 23 24
Di5 Ready/Run
i-PCB 4
5
Ai2 Alarm/Serv. 4
X04
- GND 3
100m (330ft) max
R5 LOAD 2
R1 SEQ 1
4
I-PCB 6-core
+20VDC
13 14 15 16 17 18
6
+
Di4 Ready/Run
i-PCB 3
Di8 Alarm/Serv. 4
X03
- GND 3
100m (330ft) max
R4 LOAD 2
R1 SEQ 1
3
I-PCB 6-core
+20VDC 6
+
7 8 9 10 11 12
Di3 Ready/Run
i-PCB 2
Di7 Alarm/Serv. 4
X02
- GND 3
100m (330ft) max
R3 LOAD 2
R1 SEQ 1
2
I-PCB 6-core
+20VDC 6
+
6
Di2 Ready/Run
i-PCB 1
5
2 3 4 5
Di6 Alarm/Serv. 4
X01
- GND 3
100m (330ft) max
R2 LOAD 2
R1 SEQ 1
1
1
I-PCB 6-core
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LEADAIR LEADAIR 12
XPM-TAC24
BLUE BLACK
BROWN ORANGE
RED WHITE
GREEN VIOLET
1 2 3 4 X04
T3.15A T1.6A T1.6A T1.0A 1 2 3 4
115V
115V +-10%
IEC T1.0A FH1
5x20mm
1 2 3 4
X03 X02
2 1 2 X01
N L E E
24Vac/2 24Vac/1
earthed isolated NL E
Page 30