Almig Air Control B Service Manual

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AC B
AIRCONTROL B
Base
Software version: V1.30

Dated: 16.04.2014
Document dated 16.04.2014
Item number: 003630 (Standard)
Note:
All information provided corresponds with the current state of development (dated 16.04. 2014)
Changes may occur at any time without notice. This document supersedes all previous versions.
___________________________________________ ALMIG COMPRESSORS
Table of content
1 General............................................................................................................................................ 3
1.1 Safety messages ...................................................................................................................... 3
2 Control function and connection (hardware) .................................................................................... 4
2.1 Overview ................................................................................................................................... 4
2.2 AirControl B terminal assignment................................................................................................. 6
3 Operation of the AirControl B .......................................................................................................... 9
3.1 Assignment of keys ...................................................................................................................... 9
3.2 Basic display representation on the LCD of the operating/display unit ................................... 10
3.3 Code input .............................................................................................................................. 11
3.4 Menu system - Parameter inputs............................................................................................ 13
3.5 Menu item ............................................................................................................................... 16
3.5.1 Operating mode .................................................................................................................... 16
3.5.2 Automatic restart after power failure ..................................................................................... 16
3.5.3 Additional heater, fan, dryer (standard compressor!) ..................................................... 17
3.5.4 On-site operation, remote operation, feedback "LLC OK"......................................................... 18
3.5.5 Operating parameter ............................................................................................................ 19
3.5.6 LLC operation ....................................................................................................................... 20
3.5.7 Fault memory ....................................................................................................................... 21
3.5.8 Editing of target values for the maintenance intervals .......................................................... 22
3.5.9 Idle run, shutdown times, delay star/triangle......................................................................... 23
3.5.10 Setting the system type, pressure range and delivery amount............................................ 23
3.5.11 Setting the pulse/pause times for the condensate valve ..................................................... 24
3.5.12 Setting the control parameter of the frequency converter ................................................... 24
3.5.13 Dryer control ....................................................................................................................... 25
3.5.14 Default settings of the system data ................................................................................... 26
3.5.15 Toggle the units for the pressure display ............................................................................ 26
3.5.16 Toggle unit for temperature display.................................................................................... 26
3.5.17 Correction value for pressure measurement ...................................................................... 27
3.5.18 Setting the system address ............................................................................................... 28
3.5.19 Selection of the used FU type ............................................................................................. 28
3.5.20 Test of the digital inputs/outputs ........................................................................................ 29
3.5.21 Monitoring dew point .......................................................................................................... 29
3.5.22 Correction value for temperature measurement ............................................................... 30
3.5.23 Activate additional MK200 modules .................................................................................. 30
3.6 Processing of faults/warnings ................................................................................................. 31
3.6.1 Faults ................................................................................................................................... 31
3.6.2............................................................................................................................................... 32
Warning/maintenance ................................................................................................................... 32
4 Information about the program ...................................................................................................... 34
4.1 Operational states .................................................................................................................. 34
4.2 Operating modes .................................................................................................................... 35
4.3 Switch-on process .................................................................................................................. 35
4.4 Switch-off process .................................................................................................................. 35
4.5 Safety pressure ("P_ZUL") ........................................................................................... 36
4.6 "Additional heater" / "Fan" / "Dryer" function .......................................................................... 36
4.7 Maintenance intervals............................................................................................................. 38
4.8 Sequence during "Automatic restart", shutdown time ............................................................ 38
4.9 Settings for the frequency converter (FC): ............................................................................. 38
5 Transfer new program in the control ............................................................................................. 39
6 Document version ......................................................................................................................... 40
AirControl B V1.30 Page 2

1 General
PRIOR TO COMMISSIONING OF THE CONTROL, READ THE FOLLOWING OPERATING

INSTRUCTIONS!
1.1 Safety messages
1. Commissioning, parametrisation and maintenance of the control may only be

performed by trained qualified personnel.
2. Ambient conditions for storing: Ambient temperature
range (storage) -25..+75°C
humidity (storage) max. 90%; no condensation
3. Ambient condition during operation: Ambient
temperature range (operation) -5..+55°C
humidity (operation) max. 90%; no condensation
4. ALMiG reserves the right of changes, additions or improvements on this product
(hardware and software). Hence, no obligation to update any already delivered
devices.

2 Control function and connection (hardware)
2.1 Overview
Fig. 1: Key pad and display of the AirControl B.
The control consists of the following function blocks:

a) Microprocessing logic (with EEPROM memory for data security) for all control, monitoring
and display functions
b) Keypad with 6 keys for switching the compressor on and off, as well as for input of target
and limit values
c) Customised, coloured LCD display to show the current actual/target values and the
operational state, as well as faults/warning
d) Analogous processing of network pressure, compressor temperature and oil temperature

e) Digital inputs/outputs to control the compressor
f) RS-485 connection to control the frequency converter (Flex design)
Micro-processing logic
- 16-bit CISC Micro controller with Watchdog
- 256 KByte Flash EPROM,
- 20 KByte RAM,
- 8 KByte EEPROM (for data security),

Display and keyboard

The control is equipped with a customized keypad (see illustration 1) with 6 buttons (with pressure
points) and two integrated LEDs (green, red). THE display has the following data
(see illustration 2):
- LCD customised, multi-colour with about 76mm * 43mm display surface

- 7-Segm.A => 3 digit 7 segment display
- 7-Segm.B => 3 digit 7 segment display
- 7-Segm.C => 8 digit 7 segment display
- Units: %, °C, °F, K, bar, psi, MPa, min, m³/h, s, h
- Additional symbols (in part in colour) for: Faults, warnings, frequency converter, motor,
solenoid valve, heating, ventilation, remote (remote operation), restart, automatic
(operating types)
Inputs and outputs

3x Analogue inputs - galvanically separated, sensor voltage 24 VDC
- 1 Input 4-20mA (network pressure)

- 2 Inputs for temperature sensors (PT1000)
8x Digital inputs galvanically separated, sensor voltage 12 VDC and 24 VDC;
- 7 Normal inputs
- 1 Input for PTC temperature sensors 7
Digital outputs:
- 6 Relay outputs, closer with resp. connection, 250 VAC 6A,
- 1 Relay output, two-way contact, 250Vac, 6A;
Interfaces
- RS-485 interface (standard)
- RS-485 interface (control FU / optional)
- MK200 Bus module (optional)

- Analogue piggyback board (optional)

2.2 AirControl B terminal assignment
Pin Designation Function Plug/pitch

1 PE Functional earth (EMC) Phoenix
4 0V AC MINI-COMBICO
Supply for control N pitch 3.81 mm,
5 18V AC 24V AC
3-pole
Common connection for Phoenix

6 Relay output A 1 – A 6 COM
terminal 7 to 12 COMBICON
7 Relay output A 1 Mains contactor MSTBA itch
5.0 mm
With converter: * message
8 Relay output A 2 "Ready" 7-pole
otherwise: * Star contactor
With converter: * message

9 Relay output A 3 "Operation"otherwise: * Delta
contactor
10 Relay output A 4 Solenoid valve (with varistor)

"Combi with Dryer": *
11 Relay output A 5 Dryerotherwise:
* Fan
"Combi with Dryer": *

Condensate valve (with varistor)
12 Relay output A 6 otherwise: * Heater / Dryer (with
varistor)
13 Relay output A 7 Opener Phoenix

14 Relay output A 7 Common COMBICON
Collective fault MSTBA itch
15 Relay output A 7 Closer 5.0 mm
3-pole
16 PE Screen connection Phoenix
MINI-COMBICO
Ground for analogous
17 GND N pitch 3.81 mm,
inputs AE 2 and AE 3
6-pole
PT1000 (compressor
18 Analogue input AE 3
temperature)
PT1000 (oil temperature or

19 Analogue input AE 2
dewpoint temperature)
20 Analogue input AE 1 4 – 20 mA (network pressure)

21 24V DC limit switch voltage for AE 1
22 Dig. Input E 8 LLC: Load/idle run Phoenix

23 Dig. input E 7 Remote In/Out or LLC Ok MINI-COMBICO
N pitch 3.81 mm,
24 Dig. input E 6 Emergency off
10-pole
25 Dig. input E 5 Diff. pressure oil precipitator
26 Dig. input E 4 Direction of rotation fault
27 Dig. input E 3 Overpressure

28 Dig. input E 2 Overcurrent
29 Dig. Input E 1 (PTC) Motor temperature
Limit switch voltage 12V DC
30 12V DC
(PTC)
31 24V DC Limit switch voltage 24V DC
32 GND Phoenix
33 RS-485 B(-) MINI-COMBICO
RS-485 Standard N pitch 3.81 mm,
34 RS-485 A(+)
4-pole
35 Not in use
36 SIG-B Phoenix direct plug

37 SIG-A ZEC1.5/5-ST-5.0
Interface for MK200 5-pole
38 GNDX
Bus module
39 0V AC Bus module supply
40 18V AC Bus module supply
44 GND Phoenix
45 RS-485 B(-) MINI-COMBICO
RS-485 FU N pitch 3.81 mm,
46 RS-485 A(+)
4-pole
47 Not in use
Important:Ensure the "A2, A3, A5, A6" relay outputs are assigned correctly !!!


3 Operation of the AirControl B
3.1 Assignment of keys

There are six keys/buttons available with different functions:
▲▼ : Editing target values/limit values/codes

ENTER : Apply the edited value in the current variable
INFO : In the basic display: Display of the most important settings: by
pressing several times the info button scrolling is done through the following
parameter lists.
Display of the bottom

Parameter
row
1 ##.# Einschaltdruck (Switch-on pressure)
2 ##.# Ausschaltdruck (Switch-off pressure)
3 ##.# Sicherheitsdruck (Safety pressure)
4 ##.# Mindestdruck / GLW (Minimum pressure/LLC)
Min. Verdichtertemperatur
5 5.0
(Min. compressor temperature)
Max. Verdichtertemperatur
6 110
(Max. compressor temperature)
7 ##### Betriebsstunden (Hours of operation)
8 ##### Laststunden (Load hours)
9 ##### Restzeit Luftfilter (Remaining time air filter)
10 ##### Restzeit Öl/Ölfilter (Remaining time oil/oil filter)
Restzeit Ölabscheider
11 #####
(Remaining time oil precipitator)
Restzeit Schmierung
12 #####
(Remaining time lubrication)
Restzeit Kompressor
13 #####
(Remaining time compressor)
Restzeit Trockner (Remaining time dryer)
14 #####
(only VARIO compressor!)
O (1) If compressor is ON: Switching the compressor off

After occurring fault: Confirming the fault message
(= RESET button)
(2) Button pressed for more than 3 seconds: Initiated code input
(only possible if system is OFF);

I : Switching the compressor on;

<red LED> : Flashes during warnings/maintenance; continuous light during faults;
<green LED> : Operating mode display (lights up, if the compressor is switched on/ flashes,
if the compressor is expected to start at any time.
3.2 Basic display representation on the LCD of the

operating/display unit
Example 2: All segments of the customised LCD.
Top:
- 7 Segment display ( "7-Segm.A" )
- Symbols for MPa, psi, bar
- 7 Segment display ( "7-Segm.B" )
- Symbols for %, °C, °F, K,
- Digits 1 to 7
Centre:
- Tool = Fault
- Symbols for warnings/maintenance, frequency converter, motor, solenoid valve, heating,
ventilation, restart, automatic, remote - in part coloured!
Bottom:
- 7 Segment display ( "7-Segm.C" )
- Symbols for h, min, s, m³/h, %

Basic display
Example 3: Basic display while compressor is in operation (load run: motor in

operation, control valve open).
In the basic display, the following data can be displayed:

7-Segm.A: Current network pressure (in the example 7.2 bar)
7-Segm.B: Current compressor temperature (in the example 60°C)
Via the ▼ button the current temperature of the second temperature sensor can be
displayed (oil temperature or dewpoint temperature). After the value, 'T2' appears is
and is used to identify.
7-Segm.C: During fault/warning Number of current fault or warning and corresponding

fault/warning text (abbreviation, 5 characters). On activated automatic restart
after power failure, the expired delay time is shown here. A just expired
shutdown or stopping time will also appear here.
3.3 Code input

In order to be able to change parameters, a code must be entered. This code (customer
code, service code and factory code) determines which values can be edited.
Entering a code is only possible when the compressor is switched off.
The input mask for the code appears once the Off button (O) was pressed for about
three seconds (see illustration 3).
Example 4: Code input

Using the arrow keys the respective code can be entered. With the ENTER key, the
code is confirmed, using the 0 key the input is deleted and a switch to the basic display is
performed.
The following codes are available:
Code Authorisation Subsequent display

00001 Customer code Display of the first menu item of the customer menu
03846 Service code Display of the first menu item of the service menu
Display of the software version and random number for

09999 <Factory code> current factory code (day code) after its input: Display of the
first menu item of the factory menu
Variable factory codes

The factory code is variable after commissioning. To obtain the currently valid factory
code, the second parameter should be read in menu item (code level) 9999. It contains a
random number to generate a temporary valid factory code. The factory code allows
access to all menu items for 24 hours.
Example 5: Display after entering and confirming the customer code. Upper
row: Code 1 - below Menu item (code level) 2.

3.4 Menu system - Parameter inputs
All setting parameters can be changed by selecting the respective menu item (code level).
For this, the correct code must be entered (see section 3.3). Subsequently you can scroll with
the arrow keys in the menu items in the selected menu. With the Enter button, a menu item is
selected (see Figure 6).
Example 6: Operating mode: Menu item (code level) 2, first parameter
Each menu item may contain one or several parameters. This is indicated by green
numbers. Using the Enter key scrolling in the parameters is possible. If a value can be
edited then it flashes and can be changed using the arrow keys. Using the Enter key a new
value can be accepted and using the 0 key it can be deleted.
Using the 0 key the current menu item or the menu can be exited.
Note: The values, which are displayed in the basic display via the Info key cannot be
changed. They can be found in all menus (customer, service, factory) under menu item 11.
Menu item Descrip- With Access with code

(Code Content tion in out Custo
level) section ... code Service Plant
mer
0 Display: ALMIG, … (manufacturing) - - - -
Display
2 Betriebsart (Operating mode) 3.5.1
only
automatischer Wiederanlauf Display
3 3.5.2
(Automatic restart) only
Display
5 Heater / Fan / Dryer (standard) 3.5.3 - -
only
Display
8 Vorort/Fern (On-site/remote) 3.5.4
only
Operating parameter: Druckgrenzen
11 3.5.5 -
(Pressure limits)

18 Basic load cycle mode Fehler! Display only
Verweisq
21 Acknowledge approval of - -
maintenance intervals
30 Display fault memory Fehler!

Verweisq
40 Edit dryer maintenance interval Fehler! Display only -
("Combi with Dryer" only) Verweisq
uelle
41 Edit air filter maintenance interval Fehler! Display only -
Verweisq
42 Edit oil filter maintenance interval Fehler! Display only -
Verweisq
43 Edit oil separator maintenance Fehler! Display only -
interval Verweisq
uelle
44 Edit motor lubrication maintenance Fehler! Display only -
interval Verweisq
uelle
45 Edit compressor maintenance Fehler! Display only -
interval Verweisq
uelle
51 Edit idle mode/stop time, ramp-up Fehler! Display only - -
time Verweisq
uelle
60 Type selection (Start-up!): System Fehler! Display only - -
type, pressure range, delivery Verweisq
volume uelle
konnte
62 Select pressure range (e.g. after Fehler! Display only - -
software update!) Verweisq
uelle
65 Parameter for condensate valves Fehler! Display only -
(only for "Combi with Dryer“) Verweisq
ll Display only
69 Delivery volume (m³/h) (e.g. Fehler! - -
software update!) Verweisq
uelle
75 FC: Set regulating parameters Fehler! Display only - -
Verweisq
80 Selection: Without/with dryer (only Fehler! Display only - -
for "Combi with dryer“) Verweisq
uelle
88 Reset to factory settings Fehler! - - -
Verweisq
90 Pressure display in bar/MPa/psi Fehler! Display only
Verweisq
95 Temperature display in °C / °F/ K Fehler! Display only
Verweisq
105 Correction factor, pressure Fehler! Display only -
Correction factor, temperature(s) Verweisq
uelle
111 Start commissioning sequence(only Fehler! - - -
for frequency-regulated systems!) Verweisq
130 Delete fault memory Fehler! - -
Verweisq
uelle
9919 Edit operating/loaded hours - - -
9929 Edit operating/loaded hours (+/- Display only - -

1000)

9950 Edit RS485 address, mode, Baud Fehler! Display only -

rate, protocol, data format Verweisq
uelle
konnte
i ht Display only
9960 Select the type of the FC that is in Fehler! -
use Verweisq
uelle
9980 Call EA test Fehler! Display only -
Verweisq
9999 Display program version + display Fehler!
random number for plant code Verweisq
uelle

3.5 Menu item
3.5.1 Operating mode

The operating mode is set via menu item 2.
Menu item (code level) 2

Parameter no. Meaning Value range/default
0 = AUTOMATIC
1 Betriebsart (Operating mode)
1 = LOAD/IDLE RUN
If the "AUTOMATIC" operating mode is selected then this is displayed via the "Auto" symbol".
3.5.2 Automatic restart after power failure
The automatic restart after power failure is set via menu item 3. On the effects on the
process, see also section4.8 .

Automatischer Wiederanlauf nach

0 = Restart OFF
1 Spannungsausfall (Automatic
1 = Restart ON
restart after power failure)
If restart is activated then it is indicated by the "Restart" symbol.

3.5.3 Additional heater, fan, dryer (standard compressor!)
The parameters in menu option 5 differ according to compressor type.
Heater / fan / dryer
Menu option (code level) 5
Parameter No. Meaning Value range/ Default
1 "Heating" function 0 = Without heating1 = Additional

heating by comp. temp.2 = Additional
heating by oil temperature
2 Activation temperature for heating(ON, 2 to 77°C

when temperature ≤ ##°C)
3 Deactivation temperature for 5 to 80°C

heating(OFF, when temperature >
##°C)
4 "Recirculation" function 0 = recirculation OFF1 = recirculation

ON
5 "With fan" function 0 = without fan1 = with fan
6 Activation temperature for fan(ON, 10 to 90°C

when compressor temp. > ##°C)
7 Deactivation temperature for fan(OFF, 10 to 80°C

when compressor temp. < ##°C)
8 "With dryer" function 0 = without dryer1 = with dryer
9 Activation temperature for dryer(ON, 2 to 20°C

when dew point temp. > ##°C)
10 Deactivation temperature for 0 to 10°C

dryer(OFF, when dew point temp. ≤
##°C)
11 Min. deactivation time, dryer(before 30 to 180 s

being switched on again)
Note: If the "heating" is deactivated (Par. 1 = 0), the corresponding output is no longer
controlled.
In this case the two parameters for the activation/deactivation temperature(Par. 2+3) are also
hidden.If the "fan" is deactivated (Par. 5 = 0), the two parameters for the activation/deactivation
temperature (Par. 6+7) are hidden.If the "dryer" is deactivated (Par. 8 = 0), Parameters 9 + 10 +
11 are hidden (see also Point 4.6).

3.5.4 On-site operation, remote operation, feedback "LLC OK"

0 = on-site operation
Vorortbetrieb, Fernsteuerung (On-site
1 1 = remote operation
operation, remote operation)
2 = GLW-OK
Remote control
ON, if terminal 23+31 = closed [flange!] and on-site "keyed-in";
OFF, if terminal 23+31 = open or via 0 button;
If a switch to remote control occurred and the system is keyed-in, then it is indicated by the
flashing "Remote" symbol.
If the system is switched off via the 0 key, then the "Remote" symbol in the LCD is deleted!
LLC OK
LLC OK, if terminal23+31 = closed LLC fault, if
terminal23+31 = open

3.5.5 Operating parameter
The operating parameter can be opened without code input directly from the basic display by
pressing the info key (display only).
In menu item 11 and 9919 the parameter can be changed.
Menu item (code level) 11 and 9919

Can be edited
Value
Parameter no. Meaning under menu
range/default
item...
Depending on
1 Einschaltdruck (Switch-on pressure) 11
system type
Depending on
2 Ausschaltdruck (Switch-off pressure) 11
system type
3 Sicherheitsdruck (Safety pressure) Cannot be edited -
Mindestdruck / GLW
4 11
(Minimum pressure/LLC)
5 Min. Verd.Temp. (Min. compr. temp.) Cannot be edited 5°C -
6 Max. Verd.Temp. (Max. compr. temp) Cannot be edited 110°C -
7 Betriebsstunden (Hours of operation) Cannot be edited 9919
8 Laststunden (Load hours) Cannot be edited 9919

Restzeit Luftfilter
9 Cannot be edited -
(Remaining time air filter)
Restzeit Öl/Ölfilter
(Remaining time oil/oil filter)
Restzeit Ölabscheider
(Remaining time oil precipitator)
Restzeit Schmierung
(Remaining time lubrication)
Restzeit Kompressor
(Remaining time compressor)
Restzeit Trockner Dryer time
remaining (only if "With dryer")
By selecting a system type some parameters from a table are assigned. See also SectionFehler!
Verweisquelle konnte nicht gefunden werden..

3.5.6 LLC operation

0 = no LLC operation, meaning load/idle run

Via local pressure sensor
GLW-Betrieb (LLC operation)
1 1 =LLC operation
(system operates as LLC slave)
Load run, if terminal22+31 = closed,
idle, if terminal22+31 = open
CAUTION: If input e02.6 was defined via menu item (Code level) 0008 as feedback [LLC
OK] and this signal (e02.6=0) is missing, then the LLC operation is automatically switched
off and further processing is done with the local pressure sensor. (Until e02.6 = 1 again!)
If the LLC operation has been activated, then it is displayed by the static "Remote" symbol in the display.
During LLC operation the local pressure sensor is only used to monitor the safety pressure (P_ZUL).
During activated LLC operation the load/idle run prompt from the LLC Master can also occur via
the RS-485 interface. In this case, the respective digital input signals are ignored until a control
via the interface occurs. The control switches back to control via the digital inputs, if the data exchange
via the interface was interrupted for more than 2 seconds.
Should the network pressure drop under the "Mindestdruck (Minimum pressure)" threshold
during LLC operation then, a switch to the local pressure sensor occurs and the warning [7]
("Lower pressure threshold reached") appears. This warning must be confirmed using the 0 key prior
to the LLC Master switching back to the load prompt.

3.5.7 Fault memory
Display fault memory

Parameter no. Meaning Display/value range/default
1-20 Störspeicher anzeigen Position in the fault memory
(Display fault memory) number of the fault/warning
Operating hours when the
fault/warning occurred
If the "Warning triangle" symbol appears, then this entry is a

warning/maintenance.
If the "Tools" symbol appears, then this entry is

a fault.
With the arrow keys it is possible to scroll the 20 positions of the fault memory is possible.
Position 1 always contains the "newest" fault. The individual positions of the fault memory are also
saved in the EEPROM memory and is thereby also still available after a power failure. For a list of
possible messages see section 3.6.
Fig. 7: Fault memory position 1 (most current entry): Fault number 64

Fault occurred at 3 operating hours.
Fig. 8: Fault memory position 2: Fault number 22 Warning, occurred

at 1 operating hours.

Delete fault memory

1 Delete fault memory The fault memory is being deleted !
3.5.8 Editing of target values for the maintenance intervals

Trockner (Dryer) (Vario compressors
1 Range: 0-20000 h
only)

1 Luftfilter (Air filter) Range: 0-20000 h

1 Öl/Ölfilter (Oil/oil filter) Range: 0-20000 h
1 Ölabscheider (Oil participator) Range: 0-20000 h
1 Motorschmierung (Motor lubrication) Range: 0-20000 h

1 Kompressor (Compressor) Range: 0-20000 h
With the arrow keys the respective target value can be selected in 500 steps and
confirmed with the ENTER key (range: 0-20000 h)
If the target value is confirmed with the ENTER key, then the respective interval
(remaining time) is started anew with the target value.

3.5.9 Idle run, shutdown times, delay star/triangle

1 Leerlaufzeit (Idle time) Range: 10 - 1200s
2 Stillstandszeit (Shut-down time) Range: 0 - 60s
Hochlaufzeit (Start-up time)
3 Range: 3 - 30s
(delay star/triangle)
With the arrow keys the respective target value can be set and confirmed with the ENTER
key.
3.5.10 Setting the system type, pressure range and delivery

amount

Main type (group) Belt, Combi, Variable, Direct,
Gear, Flex
1
System type(default setting for e.g. "bE 11" (Belt 11)

2 system-specific parameters)
Pressure range (compressor's maximum Range: 7.0 to 15.0 bar

3 pressure)
Maximum delivery volume(compressor's Range: 0 to 9999 m³/h

4 max. delivery volume in m³/h)
Depending on the system type chosen here, the (setting) parameters "Hochlaufzeit
(Start-up time)", "Leerlaufzeit (Idle time)" and the "Wartungsintervalle (Maintenance
intervals)" are pre-assigned with the stored table values.
Pressure range: The "Ausschaltdruck (Switch-off pressure)" threshold is preassigned with

the value selected here, and the "Einschaltdruck (Switch-on pressure)" is preassigned
with the value"Switch-off pressure - 2 bar", The pressure ranges set here serve as upper limit
during editing of the "Einschaltdruck (Switch-on pressure)" and "Ausschaltdruck (Switch-off

pressure)" (also see section 3.5.5).
The pressure range (parameter 2) and the maximum delivery quantity (parameter 3) can
also be adjusted individually in menu items 62 and 69. For this the factory code must also
be entered.
3.5.11 Setting the pulse/pause times for the condensate valve

1 Impulszeit (Pulse time) Range: 1 – 99 s
2 Pausenzeit (Pause time) Range: 1 – 999 s
CAUTION: The condensate valve is always controlled (pulse/pause control) if the

compressor motor is also running (only for "combi with dryer").
3.5.12 Setting the control parameter of the frequency converter
1 Frequency converter (FC) present If 0 = without FC1 = with FC (AA

you switch from 0 (without FC) to a module)2 = with FC (MK200-2AA)3 =
value > 0 (with FC), you must then with FC (RS485/ModBus)
start the "start-up sequence"
(PointFehler! Verweisquelle konnte
nicht gefunden werden.).
2 Speed reduction from: Specify the Setting range: 5.0 to 13.0 bar
pressure above which the maximum Default setting: 5.0 bar
target value for the FC is limited.
3 Speed reduction to: Specify the Setting range: 5.0 to 13.0 bar
pressure above which the maximum Default setting: 13.0 bar
target value for the FC is not limited any
further.
4 Speed reduction by: Specify the Setting range: 0 to 100 % Default

maximum by which the max. target setting: 50 %
value is to be reduced.

Parameter No. Meaning Display/Value Range/Default
5 Percentage target value: Specify the Setting range: 0 to 100 % Default

target value within the current pressure setting: 50 %
tolerance range to which the FC is to be Example: 0 % : Target value =
set. switch-on pressure; 50 % : Target
value = (switch-on pressure +
shut-off pressure) / 2;100 % : Target
value = shut-off pressure;
6 Control factor: This is where you set the Range: 1 to 999 Default setting:
control factor (P part of the controller) 100
7 Reset time: Set the reset time (I part of Range: 0 to 9999 s Default setting:
the controller, for "0" => no I part) 10 s
8 Min. Control range. This is where you Range: 0 to 100 %

specify the minimum percentage value Default setting: 100%
for the speed, in the case of converters
(idle mode speed). The value specified
here must match the setting on the
frequency converter!
9 FC Max. Idle mode: This is where you Range: 0 to 100 %

specify the maximum percentage value Default setting: 75%
for the speed. This threshold applies
until the compressor reaches the
specified compressor temperature ("VT
min. idle mode) after being switched
from idle mode to loaded.
10 VT Min. Idle mode: Specify the Range: 0 to 100 %

temperature that must be reached, after Default setting: 60%
a switch from idle mode to loaded,
before the maximum speed is accepted
for the FC.
Caution: In systems with frequency converters (Par. 1 > 0), relay outputs "A2" and "A3" are
assigned differently (message "Ready" and "Operation")
3.5.13 Dryer control
Menu item (code level) 80 – only for VARIO compressors

0 = off
1 Dryer On/Off
1 = on

Trockner Ausschalttemperatur
2 Range 0...6°C
(Dryer switch-off temperature)
Trockner Diff.Temperatur
3 Range 2...10°C
(Dryer differential temperature)
Trockner minimale Ausschaltzeit

4 Range: 30 to 180s
(Dryer minimum switch-off time)
Offset, Taupunkttemperatur
5 Range: -10...+10°C
(Off-set dewpoint temperature)
If the dryer is activated, then it is indicated by the symbol: The dew point
temperature can be displayed when in the basic display the ▲ key is pressed is pressed (this is
also when the "T2" appears => 2.Temp.).
If the ▲ and ENTER key are pressed simultaneous, then the dryer can be switched on
or off manually. If the dryer is switched off, then the symbol flashes
3.5.14 Default settings of the system data
With menu item (code level) 88 all settable parameters are reset to their default value and a
change into the basic display occurs.
CAUTION! Previously data created manually might be overwritten!
3.5.15 Toggle the units for the pressure display

[0 = pressure display in [bar]

1 Einheit Druck (Pressure unit) 1 = pressure display in [MPa]
2 = pressure display in [psi]
3.5.16 Toggle unit for temperature display


0 = Temperature display in [°C]

1 Einheit Temperatur (Temperature unit) 1 = Temperature display in [°F]
2 = Temperature display in [K]
3.5.17 Correction value for pressure measurement

Korrekturwert Druckmessung
1 (Pressure measurement correction -0.5 to +0.5
value)
Via this value the slope of the pressure characteristic curve is changed, to compensate for
small variations on pressure sensors.
Current pressure value = measured value * P_MAX / (P_MAX - KORR.DRUCK) ]

Example: P_MAX = 10.0 bar
a) CORR>PRESSURE = +0.3 ……….P = P_meas * 10.0 / (10.0 - (+0.3)) = P_meas * 1.03
b) CORR>PRESSURE = -0.3 ………..P = P_meas * 10.0 / (10.0 - (-0.3)) = P_meas * 0.97

3.5.18 Setting the system address

Anlagenadresse 0 = RS485 connection is switched off
(System address) (PC [ Basic setting ]
1
connection/visualisati 1-16 = The system can be contacted via the
on/connection control) respective address.
0 = Data can be read and edited

via the interface. [ Basic setting ]
2 Modus (Mode)
1 = Only data can be read
via the interface.
0 = 4800 Baud [ default setting ]
3 Baudrate 1 = 9600 Baud
2 = 19200 Baud
0 = Standard [ default setting ]
4 Protokoll (Protocol)
1 = Modbus RTU
0 = 1 start bit, 8 data bit, 1 stop bit, no parity

[ Basic setting ]
Datenformat 1 = 1 start bit, 8 data bit, 2 stop bit, no parity
5
(Data format)
2 = 1 start bit, 8 data bit, 1 stop bit, straight parity
3 = 1 start bit, 8 data bit, 1 stop bit, uneven parity
Note: An additional address must be set for each connected system! The control must
be equipped with the respective interface module (RS-485).
It is important to ensure that any connected system is set to the same baud rate
(transmission speed), the same protocol and the data format!
3.5.19 Selection of the used FU type

0 = Yaskawa
1 = Emotron [ default setting ]
1 FU-Typ (FU type)
2 = Bosch-Rexroth
3 = ABB (ACS510)4 = Delta (C2000)

3.5.20 Test of the digital inputs/outputs

0 = Off
1-8 Eingang (Input) 1-8
1 = On
0 = switch off
9-15 Ausgang (Output) 1-7
1 = switch on
Using the arrow keys on output signals can switch on or off the effected output. With the
ENTER key a switch is done to the next input/output (here, the outputs are always
switched off first). After the last step it is switched back to the basic display.
CAUTION: The compressor motor can start, if the individual outputs are activated
in test mode!
3.5.21 Monitoring dew point

1 Dew point temp. max. 0 - +50°C (0 = monitoring off! )
2 Dew point temp. min. -10 - +50°C
3 Message = Warning or Fault 0 = Warning; 1 = Fault
If this function is active (Par.1 > 0°C) the dew point temp. and the 2. temp. sensor will be
observed for the setting values and faults.
If the dew point temperature, during pressing the I-button, is over the barrier “dew
point max.” then the warning “dew point temp.” will be generated and the start-up
is blocked until the value is falling down under the barrier again.
If the compressor motor is running and the dew point temp. is sinking under the
barrier “dew point min.”, the warning/fault “dew point to low” will be generated.
If the compressor motor is running and the dew point temp. is rising over the
barrier “dew point max.”, then the warning/fault “dew point to high” will be
generated.

3.5.22 Correction value for temperature measurement
2 Correction value for compressor -10°C to +10°C (default: 0°C)

temperature
3 Correction value for oil temperature (or -10°C to +10°C (default: 0°C)
correction value for dew point temp.)
4 Correction value for dew point -10°C to +10°C (default: 0°C)

temperature(if module "MK200-4AE4RA",
Addr. 7)
Use these values to specify an offset for each individual temperature measurement value.This will
compensate for minor deviations in the values recorded by the temperature sensors.
3.5.23 Activate additional MK200 modules
1 Profibus module present 0/1 = No/Yes (default: 0)
2 MK200-8E4RA (Addr. 2) present 0/1 = No/Yes (default: 0)
The control system must be equipped with a "bus module" before these modules can be connected!
If one of these modules is activated, but is not actually available, this warning message is
displayed"44 Module" (see: Point Fehler! Verweisquelle konnte nicht gefunden werden.).

3.6 Processing of faults/warnings
3.6.1 Faults
Fig. 9: Example Error/fault message example: Fault no. 65 - power failure.
The "Tool" symbol flashes and the fault number and text are displayed in the bottom
row in flashing red. The following fault messages are possible:
Number "Text" Meaning (fault)

61 EProM "EEPROM ?" (check all setting parameter)
63 PAr "Parameter falsch (Wrong parameter)" (check pressure target values!)
65 no AC "Spannungsausfall (Power failure)" (Only if not "Automatic restart"!)

"Kabeldef. V-Temperatur (Cable def. V Temperature)"
66 SE t
(monitoring: V temperature sensor)
"Kabeldef. Öltemperatur (Cable def. oil temperature)"
67 SE t2
(monitoring: oil temperature sensor)
68 SE P "Kabeldef. Druck (Cable def. pressure)" (monitoring: pressure sensor)
70 SE t3 "Cable defect dew point temperature" (if additional "MK200-4AE4R"
module!)
"NOT-AUS betätigt (EMERGENCY OFF triggered)"

71 EmErG
(contact open = fault)
72 rotAt "Drehrichtung (Direction of rotation)" (contact open = fault)
73 Mot t "Motortemperatur (Motor temperature)" (PTC)
74 hiCur "Überstrom (Overcurrent)" (contact open = fault)
75 hi Pr "Überdruck (Overcurrent)" (contact open = fault)
"V-Temperatur zu hoch V-temperature too high)"

77 hi t
(temperature >max. con. temperature)
"Netzdruck zu hoch (Network pressure too high)"
78 hi P
(pressure >safety pressure)

81 Fu "Störung Umrichter (Converter fault)" (FU defective or no response)

"Diff.Druck Ölabscheider (Diff. pressure oil precipitator)"
82 diF P
(contact open = fault)
89 Module "Fault on IO module" - The external "MK200-4AE4RA" module
(Addr. 7) reports a fault, or the module does not respond (although it
has been activated)!
The compressor switches off during occurrence of a fault. The red LED lights up until the
fault is acknowledged. Acknowledging with the 0 button is only possible, if the cause of the
fault has been remedied!
3.6.2 Warning/maintenance
The "Warning triangle" symbol flashes and the respective number and text is displayed in
the bottom row with 7 segment elements.
Fig. 10: Intake filter maintenance message.
Number "Text" Meaning (maintenance)

"Wartung Ansaugfilter (Maintenance intake filter)"
1 M Air
(remaining maintenance time < 100 h)
"Wartung Öl/Ölfilter (Maintenance oil/oil filter)"

2 M Oil
"Wartung Ölabscheider (Maintenance oil precipitator)"
3 M SEP
"Wartung Schmierung (Maintenance lubrication)"
4 M Mot
"Wartung Kompressor (Maintenance compressor)"
5 M Con
Dryer maintenance
6 M dry
(time remaining < 100 hours | only if "with dryer")
Number "Text" Meaning (warning)

"Verdichtertemperatur erhöht (Compressor temperature increased)"
21 hi t
(Temperature > max. comp.temp. - 5°C )
"Netzdruck erhöht (Network pressure increased)"
22 hi P
(Pressure > Safety pressure - 0.3 bar)

"Temperatur zu niedrig (Temperature too low)" VARIO:+1 °C ≤
23 Cold
Comp.Temp. ≤ +5°C Standard: Comp.temp or oil temperature < +1 °C
"Untere Druckschwelle erreicht (Lower pressure threshold reached)"
24 min P The system is running as a LLC slave and the "Mindestdruck (Minimum
pressure)" threshold was undercut
"Ölstand / Heizung (Oil heating/heating)" The "Heizung(Heating)"
25 OilHE
function is active and on input "E02.2" the signal is missing;
26 dEFEC “wrong calibration parameter” (sent it for repair / calibration)
"EA-Module warning" - An external "MK200" module reports a

fault, or does not respond (although it has been activated)!
* The flashing icons listed below tell you
44 Modul
which module is affected:
[ 1 ] => MK200-2AA (Addr. 1) [ 2 ] =>
MK200-8E4RA (Addr. 2) otherwise => MK200-Profibus (Addr.
31)
During a warning/maintenance the compressor is switched off. The red LED flashes until the
cause of the warning has been remedied or until the respective maintenance interval is
confirmed. Normally a fault/warning is immediately displayed. However, if the operator has
pressed the INFO button to select target or limit values, the fault / warning is only displayed
when switching back to the basic display.

4 Information about the program

This only applies to frequency-regulated systems:
If the "Start-up sequence" for the compressor motor has not been performed yet, you see -OFF-
on the display and you cannot start the compressor! To start this "Start-up sequence", use
code "111". When the "Start-up sequence" is running, the bottom 7-segment display shows
the current progress, the convertor's target value, and the time remaining for this step (for
example, "1 40: 15 s" ► Step = 1; Target value = 40%; Time remaining = 15 seconds).
4.1 Operational states

a) the compressor is switched off:
- The green LED is off
- The "Motor" and "Solenoid valve" symbol are off (LCD)
b) the compressor is switched on, but the current pressure is still above the
switch-on pressure (start-up safety).
- Green light flashes
- "Motor" and "Solenoid valve" symbol are off
c) The compressor was switched on but the compressor temperature (or the oil
temperature, while "with heating") is still below +1°C (Standard compressor) or
between +1°C and +5°C (VARIO compressor):
- Green light flashes

- "Motor" and "Solenoid valve" symbol are off
- Symbol for the temperature unit flashes (LCD: °C/°F/K)
d) The compressor is in operation, but the load valve is switched off, meaning the
compressor does not compress. ( Start-up phase or idle )
- The green LED is on
- The "Motor" symbol is on

- The "Load valve" symbol is off
e) The compressor is in operation, but the load valve is switched on, meaning the compressor is
compressing. (Load run)
- The green LED is on
- The green "Motor" symbol is on

- The green "Load valve" symbol is on

4.2 Operating modes
a) AUTOMATIC operation
After reaching the switch-off pressure, the system switches into IDLE (run-on) for the duration
of the idle time.
The decimal point left from the pressure display flashes if the idle run time is active.
After the "Idle run time" has elapsed, the compressor switches off. After switching off
the green LED => ready for restart flashes. The system restarts, as soon as the
pressure drops below the switch-on pressure.
b) LOAD/IDLE operation
The compressor switches between "Load" and "Idle" operation; meaning it operates
indefinitely.
4.3 Switch-on process
If the current network pressure is larger than the set switch-on pressure during the switch
on of the compressor, then the green LED (=operation ready) flashes. The compressor
will only operate and the operating mode display (green LED) is continuously lit after the
network pressure drops below the switch-on pressure. If the compressor temperature (or
oil temp. or if "with heating") is during the switch-on below +1°C (Standard compressor) or
between +1°C and +5°C (VARIO compressor), then the unit for the temperature (°C/°F/K)
flashes and the green LED also flashes. In addition, warning "4" is displayed. Should the
temperature rise to at least +1°C, then the compressor is started.
4.4 Switch-off process
If the compressor is switched off via the 0 key (or via remote OFF) then it always
changes initially to idle. THE decimal point in front of the pressure display flashes in
the display. The remaining time to switch off can be shown with the ▲ button. The
shutdown time is used as time. Only after expiry of this time the system switches off.
As long as the compressor is still in the "start-up" (meaning the star/triangle start up
is not completed), it is immediately (without delay) switched off.

4.5 Safety pressure ("P_ZUL")
The safety pressure is the set "Pressure range" + 0.8 bar. ("Pressure range")
Example: "Pressure range" = 10 bar => "P_zul" = 10.8 bar
A warning is provided, if the pressure rises above the "P_zul – 0.3 bar" threshold. The compressor
is switched off with a fault message, if the pressure rises over the "P_zul" threshold.
4.6 "Additional heater" / "Fan" / "Dryer" function

( Standard compressors ) [ see also: 3.2.3 ]
a) "Heater = 1" / compressor motor is OFF / main switch is ON If the compressor temperature
falls below the "Heating ON" threshold, the output for the "Additional heater" is switched on.
As soon as the compressor temperature rises above the "Heating OFF" threshold (again), the
output for the "Additional heater" is switched off again.
b) "Heater = 2" / compressor motor is OFF / main switch is ON If the oil temperature falls below
the "Heater ON" threshold, the output for the "Additional heater" is switched on. As soon
as the oil temperature rises above the "Heater OFF" threshold (again), the output for the
"Additional heater" is switched off again.
c) If the additional heater is deactivated (heater = 0), or if the compressor motor is running,
the output for the "Additional heater" is switched off!
d) "With fan"
If the compressor is activated, and the compressor temperature rises above the "Fan ON"
threshold, the output for the fan is switched on. If the compressor temperature falls below the
"Fan OFF" threshold, the output for the fan is switched off. If the "With fan" setting is active,
the 7-relay output also controls the condensate valve (only for "combi-compressors"!).
e) "With recirculation"
If the "Recirculation" function is active (see Point 3.5.3), and the system is keyed in, the
system starts when the compressor temperature falls below the +5°C threshold (the system
runs in idle mode). As soon as the compressor temperature rises above the +15°C threshold
again, the system is stopped again. Press the ENTER and ▼ keys (in the base screen
display!) at the same time to switch the activated "Recirculation" function on/off temporarily.
f) "With recirculation" and "With heater" and "System keyed in" In this case the "heater" is not
switched on until the temperature falls below the +1°C threshold.

g) "With dryer" (standard compressor!) If the dew point temperature rises above the threshold
[Dryer on], the "Dryer" output is switched on. As soon as the dew point temperature falls
below the threshold [Dryer off], the "Dryer" output is switched off again. * If the "Heater"
function is also activated, an additional "MK200-4AE4R" module (Addr. 7) is required to
record the dew point (Cl. 5+6) and to control the dryer (Cl. 12+13)! * If the "Heater"
function is deactivated, the 2nd temperature sensor (AE-2) and the "A6" output are used
here (each on "AirControl B").If the "Recirculation" function is activated, the icon is displayed.
This icon flashes if this function is temporarily switched off.
The compressor can usually only be started when the compressor temperature or the oil
temperature has at least reached the +1°C threshold.
If the output for additional heating, or the fan, is switched on, the corresponding icon appears on
the LCD display.
When the dryer is being controlled (standard compressor), you see a "4" on the display. If the "With
dryer" function is activated, you can then press the ▲ and ENTER keys at the same time to
switch the dryer on/off manually. If you use this method to switch off the dryer, the "4" flashes on
the display.

4.7 Maintenance intervals
(Actual values see: 3.1 / Target values see: 3.2.9)

a) Maintenance requirements
The corresponding intervals are counted down. Once one of these intervals is less than
100 hours, the corresponding message appears, and the red LED flashes (=>
Maintenance! ). To acknowledge this message, first, the menu item (code level) is
activated 21, and then the 0-key pressed. Thereby the relevant interval is reset to the
predetermined target value.
b) 1.Maintenance on "Öl/Ölfilter (Oil/oil filter)"

After the first (1.) maintenance the target value for the maintenance interval for
"Öl/Ölfilter (Oil/oil filter)" is automatically changed from 500 h to 2000 h!
4.8 Sequence during "Automatic restart", shutdown time
Has the "automatische Wiederanlauf nach Spannungsausfall (Automatic restart

after power failure)" been programmed, then after the power returns, the time
elapses that has been predetermined in the "Stillstandszeit (Shutdown time)"
parameter. While this time elapses, the "Restart" symbol flashes.
If the system was in operation prior to the power failure, then it will restart after this
time elapses, otherwise it will stay in STOP mode.
During active "Wiederanlauf (Restart)", the fault "Spannungsausfall (Power
failure)" is not issued after the power failure!
4.9 Settings for the frequency converter (FC):

Set the FC's interface parameters to the following values: [ Mode: Remote control and
target values specified via RS485 / ModBus ]
* RS485 address: 1;
* Baud rate: 9600 baud;
* Protocol: RTU ModBus© (ABB: EFB profile = "ABB DRV LIM")
* Data format: Yaskawa: 1 start bit, 8 data bits, 1 stop bit, equal parity;
Bosch Rexroth: 1 start bit, 8 data bits, 1 stop bit, no parity;
Rest: 1 start bit, 8 data bits, 2 stop bits, no parity;

5 Transfer new program in the control
1. Switch off the power supply to the control;

2. press ▲ and 0 simultaneous and switch on the power supply to the control again.
3. In the display the "FLASH: x.xx" appears.
4. Now it is possible to transfer the respective program (HEX file) to the control !
5. After the program has been successfully transferred to the control, the power
supply must be briefly switched on and switched off again.
Fault in the control program memory

If a fault has been detected in the program memory (Flash EPROM) after the mains power
is switched ON, then the following messages appears in the temperature display:
"noAPP",
"FLASH" => The program must be transferred in the control anew here!

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6HUYLFHPDQXDO

Software version: V1.30

AirControl B V1.30 Page 2

PRIOR TO COMMISSIONING OF THE CONTROL, READ THE FOLLOWING OPERATING

1.1 Safety messages

1. Commissioning, parametrisation and maintenance of the control may only be

AirControl B V1.30 Page 3

Fig. 1: Key pad and display of the AirControl B.

The control consists of the following function blocks:

d) Analogous processing of network pressure, compressor temperature and oil temperature

AirControl B V1.30 Page 4

Display and keyboard

- LCD customised, multi-colour with about 76mm * 43mm display surface

Inputs and outputs

- 1 Input 4-20mA (network pressure)

- MK200 Bus module (optional)

AirControl B V1.30 Page 5

2.2 AirControl B terminal assignment

Pin Designation Function Plug/pitch

Common connection for Phoenix

With converter: * message

10 Relay output A 4 Solenoid valve (with varistor)

"Combi with Dryer": *

13 Relay output A 7 Opener Phoenix

PT1000 (oil temperature or

20 Analogue input AE 1 4 – 20 mA (network pressure)

AirControl B V1.30 Page 6

21 24V DC limit switch voltage for AE 1

22 Dig. Input E 8 LLC: Load/idle run Phoenix

27 Dig. input E 3 Overpressure

36 SIG-B Phoenix direct plug

40 18V AC Bus module supply

AirControl B V1.30 Page 7

AirControl B V1.30 Page 8

3 Operation of the AirControl B

3.1 Assignment of keys

▲▼ : Editing target values/limit values/codes

Display of the bottom

O (1) If compressor is ON: Switching the compressor off

AirControl B V1.30 Page 9

I : Switching the compressor on;

3.2 Basic display representation on the LCD of the

Example 2: All segments of the customised LCD.

AirControl B V1.30 Page 10

Example 3: Basic display while compressor is in operation (load run: motor in

In the basic display, the following data can be displayed:

7-Segm.C: During fault/warning Number of current fault or warning and corresponding

3.3 Code input

Example 4: Code input

AirControl B V1.30 Page 11

The following codes are available:

Code Authorisation Subsequent display

Display of the software version and random number for

Variable factory codes

AirControl B V1.30 Page 12

3.4 Menu system - Parameter inputs

Example 6: Operating mode: Menu item (code level) 2, first parameter

Menu item Descrip- With Access with code

AirControl B V1.30 Page 13

18 Basic load cycle mode Fehler! Display only