Installation instruction

This document covers the following subjects:

1.      General Information. 1

2.      Document Overview.. 1

3.      Document Information and History. 3

4.      Safety First 4

4.1.     Safety precautions during installation. 6

4.1.1.         General precautions. 6

4.1.2.         Precautions during installation. 6

4.1.3.         Precautions during operation. 6

5.      Introduction. 6

5.1.     Icons Clamp. 6

5.2.     Icons Clamp safety & environment 7

5.2.1.         General safety. 7

5.2.2.         Care and Maintenance. 7

5.2.3.         Environmental Compliance. 7

5.3.     Icons Clamp compliance (to be updated) 8

5.3.1.         European directive: 8

5.4.     List of supported machine types. 8

6.      Requirements. 9

6.1.     Icons Clamp hardware. 9

6.1.1.         Icons Clamp Kit (2901991024) 9

6.2.     Necessary tools & extra hardware. 10

6.2.1.         Tools. 10

7.      Installation procedure. 10

7.1.     Restrictions and remarks. 10

7.2.     Icons Clamp Configuration. 10

7.3.     Commission Icons Clamp. 13

7.4.     Determine where to install the Icons Clamp. 20

7.5.     After installation of the Icons Clamp. 21

8.      Service Procedure. 22

9.      Checking functionality. 26

10.    Default data upload. 26

10.1.   Transmitted MPL. 26

10.2.   List of measurement Points. 26

Appendix 1: HOW TO DOWNLOAD QR APP?. 26

4.1     Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be dis­claimed by the manufacturer.

4.1.1    General precautions

1. The operator must employ safe working practices and observe all related local work safety requirements and regulations.

2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply.

3. Installation, operation, maintenance and repair work must only be performed by authorised, trained, specialised personnel.

4. Before carrying out any maintenance, repair work, adjustment or any other non-routine checks, stop the device. In addition, the power isolating switch must be opened and locked.

4.1.2    Precautions during installation

1. Place the device where the ambient air is as cool and clean as possible.

2. During installation or any other intervention on one of the connected machines, the machine must be stopped, de-energized and the isolating switch opened and locked before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment.

3. The electrical connections must correspond to the local codes. The device must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the device.

4. For machines controlled by a central control system, a sign stating “This machine may start without warning” must be affixed near the instrument panel.

5. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return valves (check valves) must not be relied upon for isolating pressure systems.

6. Never remove or tamper with the safety devices.

4.1.3    Precautions during operation

checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.

2. Never operate the device in the presence of flammable or toxic fumes, vapours or particles.

3. Never operate the machine below or in excess of its limit ratings. 

4. Keep the door shut during operation.

5. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A) shall wear ear protectors.

6. Periodically check that: 

All fasteners are tight 

All electrical leads are secure and in good order

7. Never remove or tamper with the safety devices.

5.1    Icons Clamp 

The Icons Clamp is an electronic equipment and it is intended to be used to count the running hours of a machine. It comprises of two main components: a current sensor and an electronic control unit, which are embodied in a single housing.

The Icons Clamp uses cellular technology (LPWA), in order to send measured running hours to our back office.

Icons Clamp is manufactured by PSICONTROL NV., IEPER, Belgium. Technical assistance will be given by product owner which is Atlas Copco Airpower NV., Wilrijk, Belgium.

Icons Clamp is intended to be used in following environmental conditions:

• Indoor use only
• Altitude up to 2000m
• Temperature -20ºC to +65ºC
• Maximum relative humidity of 90%
• Overvoltage category II
• Pollution degree 2

  5.2 Icons Clamp safety & environment
  5.2.1 General safety

The Icons Clamp is designed and intended to be used in fixed and mobile applications. «Fixed» means that the device is physically secured at one location and is not able to be easily moved to another location. «Mobile» means that the device is designed to be used in other than fixed locations and generally in such a way that a separation distance of at least 20cm (8 inches) is normally maintained between the transmitter’s antenna and the body of the user or nearby persons. The
Icons Clamp is not designed for or intended to be used in portable applications (within 20cm of the body of the user) and such uses are strictly prohibited.

It is important to follow any special regulations regarding the use of radio equipment due in particular to the possibility of radio frequency, RF, interference. Please follow the safety advice given below carefully.

• Respect restrictions on the use of radio equipment in fuel depots, chemical plants or where blasting operations are in progress.
• There may be a hazard associated with the operation of your Icons Clamp close to in adequately protected personal medical devices such as hearing aids and pacemakers. Consult the manufacturers of the medical device to determine if it is adequately protected.
• Operation of your Icons Clamp close to other electronic equipment may also cause interference if the equipment is inadequately protected. Observe any warning signs and manufacturers recommendations.
• In any case of operation, the antenna must be located at least 20cm away from the human body.

If Icons Clamp is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

The current document must be printed and handed over to technicians for installation.

5.2.2    Care and Maintenance

Your Icons Clamp is the product of advanced engineering, design and craftsmanship and should be treated with care. The suggestion below will help you to enjoy this product for many years.

• Do not expose the Icons Clamp to any extreme environment where the temperature or humidity is high.
• Do not attempt to disassemble the Icons Clamp. There are no user serviceable parts inside.
• Do not expose the Icons Clamp to water, rain or spilt beverages, It is not waterproof.
• Do not attempt to clean Icons Clamp.
• Do not abuse your Icons Clamp by dropping, knocking, or violent shaking. Rough handling can damage it.
• Do not place the Icons Clamp alongside computer discs, credit or travel cards or other magnetic media. The information contained on discs or cards may be affected by the phone.
• Do not operate the Icons Clamp in areas where cellular modems are not advised without proper device certifications. These areas include environments where cellular radio can interfere such as explosive atmospheres, medical equipment, or any other equipment which may be susceptible to any form of radio interference. The modem can transmit signals that could interfere with this equipment.  

5.2.3    Environmental Compliance

• RoHS Directive Compliant

• Disposing of the Product

5.3    Icons Clamp compliance

5.3.1    European directive: 

The Icons Clamp solution is in compliance with the essential requirements and other relevant provisions of the:

• CE
  
  5.4    List of supported machine types

Icons Clamp supports following machine types:

• Fix speed compressors in 2-30 KW nominal power range which have an electrical cubicle (Running Hours and Loaded Hours)
• VSD compressors in 2-30 KW nominal power range which have an electrical cubicle (Running Hours)
• Piston, Dryer and vacuum pumps in 2-30 KW nominal power range which have an electrical cubicle (Running Hours)

6.1    Icons Clamp hardware

6.1.1    Icons Clamp Kit (2901991024)

  1x Icons Clamp

1x Void if broken label

 1x Quick Installation Guide

6.2    Necessary tools & extra hardware

6.2.1    Tools

• Insulated screwdriver for adjusting rotary switch; slotted screwdriver 3 mm

 Fig.1: an example for 3 mm screw driver (part number: 0462351021)           

7.1    Restrictions and remarks

1. The Icons Clamp contains a soldered sim chip which cannot be removed or replaced (no extra plastic sim required).
2. During installation or any other intervention on one of the connected machines, the machine must be stopped (Stop Button), de-energized and the isolating switch opened and locked before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice or signalisation shall be affixed to the start equipment.
3. The Icons Clamp must be installed on a single phase of power cord as shown in Fig.3. Also It is important that Icons Clamp must not be installed on ground cable (usually Yellow-Green in color).
4. For a full feature compressor put the Smart Clamp only over the power cable to the main motor; else the running hour counter might deviate while the cooling fan and dryer might consume power while compressor is stopped.

1. Make sure the Icons Clamp installation drawing is physically left behind inside the machine together with the logbook and the original service diagram.

   7.1.1.    Icons Clamp Configuration

On the body of Icons Clamp, there is a rotary switch which can be used to configure Icons Clamp based on the machine power. By default it is set to position 0.

This Rotary switch has 16 positions (0-F) that one of which will be set by using the 3 mm screwdriver. We must select the correct position based on table 1.

Position 0 is reserved for VSD machines, Pistons, Dryers and vacuum pumps. So no matter the machine power range for these machines the switch must be set to position 0 (THE ARROW SHOULD POINT TO “0”). By setting switch to position 0, the clamp will detect if the machine is running or stopped (if current > 2 Amps, machine is running otherwise it is stopped).

For example in the case of a compressor machine which has 2 KW nominal power and 400 Volts nominal voltage, we need to set the rotary switch to position 2 (THE ARROW SHOULD POINT TO “2”).

Position F is reserved for future use.

The configuration procedure is depicted in Fig.2.

Fig.2a: Check nominal power (KW) of the machine written on the machine’s plate

Fig.2b: Nominal power selector (Rotary Switch)

Fig.2c: Adjust rotary switch based on information presented in table 1 (note the arrow direction)

• Scan QR with your mobile QR reader app:

• The commissioning page opens in your browser

2. If you are not logged in already, you will be asked to sign in to your ICONS account first:

3. You will be asked to enter your password. Enter your password and sign in. Note: For internal employees, it is windows password for single sign in:

4. Click yes on next screen:

5. Fill in the commissioning form:

1. Insert Machine serial number, if machine data available in SAP the rest of form will be automatically filled
   1. Insert a name for the machine
   2. Insert machine model (e.g. GA11)
   3. Choose Machine type from dropdown list (e.g. compressor)
   4. “Serviced by” can be selected from the dropdown or by typing the company/organization name
   5. Customer can be selected from existing list. Or new customer can be added by clicking on + button. Same for Site
   6. Insert the current running hours of machine (e.g. 22000)
   7. Pick the service interval from dropdown menu (e.g. 2000)
   8. Select the proper service plan (e.g. AAAA)

6. After filling all information, click “Register”:

7. You will get the message at the bottom of the screen indicating “Machine Correctly registered”. And also make sure the clamp is configured correctly:

8. Confirm the setting by clicking on the “Confirm” button:

9. In your browser, you can go to https://portal.connectivityicons.com, to see the commissioned machine:

7.4    Determine where to install the Icons Clamp

        Icons Clamp is only intended for machines having an electrical cubicle in which Icons clamp can fit (Icons clamp dimentions: 18 cm x 6 cm)

Icons Clamp must be installed on incoming power cord to the electrical cubicle such a way that only one of three wires passes through the current transformer as shown in Fig.3.

The Icons Clamp is omni-directional, meaning that it can be installed in all directions. The current flow arrow on it can be safely ignored.

Fig.3a: Open the current clamp

Fig.3b: Pass only one phase (one leg) of the electrical power cord through the clamp and close it

7.5    After installation of the Icons Clamp

After clamp installation the “void if broken” label should be applied as shown in Fig.4

                                                      Fig.4: “void if broken” label applied

To acknowledge that the machine has been serviced follow the below steps:

1. Scan the QR code printed on bottom of clamp back label using a QR reader application (explained in appendix 1) on your mobile phone:

• Locate the QR code on back of clamp:

• Scan QR with your mobile QR reader app:

• The service page opens in your browser

2. If you are not logged in already, you will be asked to sign in to your ICONS account first:

3. You will be asked to enter your password. Enter your password and sign in. Note: For internal employees, it is windows password for single sign in:

4. Click yes on the next screen:

5. Click on the “service” button as shown below:

6. Check if the clamp has been configured correctly, and click on “confirm” button:

7. Now the machine service is complete:

There is no way foreseen to check the functionality of device in the field.

However, in your browser, you can go to https://portal.connectivityicons.com, to check if machine has been commissioned correctly.

10.1     Transmitted MPL

The Icons Clamp will transmit every 3 days*: running hours and loaded hours of machine to Icons Portal.

       Please note that 3 days means that the machine will be continuously running for 72 hours. So If the machine only runs e.g. 8 hours per day, the data will be sent after 9 days.

* First data communication can take a shorter or longer period depending on machine power and usage.

10.2    List of measurement Points

In the Atlas Copco app store (INTUO Company Portal), there is a QR code reader app available. 

While in the Company Portal “Apps” section, or on the Play store located on the Android Work Profile, search for 'QR' without the quotes, and you will see the 'Kaspersky QR Scanner' (iOS) and 'QR Code Reader and Scanner' (ANDROID) also by Kaspersky Lab.

Step 1: Open “Comp Portal” app from your work phone

Step 2: After opening the “Comp Portal” app, Type “QR Code” in the search box. You will see some list of app. Look for “Kaspersky QR Scanner” (iOS) or “QR Code Reader and Scanner” (Android).

Step 3: Click on the App and install. After some time you will have app installed in your phone.