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Service manual AC B V1.80

Software version: V 1.80 Software date:

04/10/2018

Document date

08/02/2019

Item number:

536.20410 536.20411

AirControl Base AirControl Base, RS485

Note: All information provided is up to date with the current development level (date 04/10/2018). Changes may be made at any time without prior notice. We accept no liability for printing mistakes. This document replaces all older versions.

ALMiG Kompressoren GmbH Adolf-Ehmann-Strasse 2 73257 Köngen Germany www.almig.de

ALMiG AirControl B

V 1.80

04/10/2018

Contents 1 General information.......................................................................................5 1.1 Safety notices..................................................................................................5

2 Control system function and connection (hardware)................................6 2.1 Overview.......................................................................................................... 6 2.2 Terminal assignment for AirControl B...........................................................8

3 Operation of AirControl B...........................................................................11 1

3.1 Assignment of keys.......................................................................................11 3.2 Default screen display, view on the LCD operating/display unit...............12 3.3 Code input......................................................................................................13 3.4 Menu system – parameter entries................................................................15 3.5 Menu items.....................................................................................................18 3.5.1 Operating mode...................................................................................................18 3.5.2 Automatic restart after power outage................................................................18 3.5.3 Additional heater, fan, dryer (standard compressor!)......................................19 3.5.4 Local operation, remote control, feedback "Basic load cycle OK".................20 3.5.5 Operating parameters.........................................................................................21 3.5.6 Basic load cycle operation.................................................................................22 3.5.7 Fault memory....................................................................................................... 23 3.5.8 Editing nominal values for maintenance intervals...........................................24 3.5.9 Idling time, stationary time, star/delta delay.....................................................25 3.5.10 Setting system type, pressure range and delivery volume............................25 3.5.11 Setting pulse/pause time for condensate valve..............................................26 3.5.12 Setting frequency converter control parameters............................................26 3.5.13 Dryer activation (only "Combi with dryer").....................................................29 3.5.14 Default setting of the system data...................................................................29 3.5.15 Changing unit for pressure display.................................................................30 3.5.16 Changing unit for temperature display:...........................................................30 3.5.17 Correction value for pressure measurement..................................................30 3.5.18 Setting RS485 parameter..................................................................................31 3.5.19 Selection of FC type used.................................................................................31 3.5.20 Testing the digital inputs/outputs....................................................................32 3.5.21 Monitoring: Dew point / bearing / winding temp.............................................32 3.5.22 Correction value for temperaturemeasurement..............................................34 3.5.23 Activating additional MK200 modules.............................................................34 3.5.24 Changing service code.....................................................................................35 3.5.25 Add. counters for oper.hrs./hrs. under load, load cycles, motor starts........35 6

3.6 Processing of faults/warnings......................................................................36 3.6.1 Faults.................................................................................................................... 36 3.6.2 Warning / maintenance.......................................................................................38

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4 Information about the program..................................................................40 4.1 Operating states............................................................................................40 4.2 Operating modes...........................................................................................41 4.3 Switching on..................................................................................................41 4.4 Switching off..................................................................................................41 4.5 Safety pressure ("P_PERM")........................................................................42 4.6 "Additional heater" / "Fan" / "Dryer" function.............................................42 4.7 Maintenance intervals...................................................................................44 4.8 Procedure for "Automatic restart", stationary time....................................44 4.9 Settings for the frequency converter (FC):..................................................44

5 Modbus RTU communication.....................................................................45 5

5.1 Addresses for the command 03_hex / "Read data register"......................45 5.2 Addresses for the command 10_hex / "Write data register"......................51

6 Standard protocol / Profibus DP................................................................52 6.1 Standard protocol..........................................................................................52 6.2 Profibus II (Profibus DP)...............................................................................52 6.2.1 Data allocation for Profibus output data ..........................................................53 6.2.2 Data allocation of Profibus input data ..............................................................53

6.3 Overview of commands................................................................................55 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

Command 1 – Status query................................................................................56 Command 2 – Fault query...................................................................................58 Command 3 – Read operating data....................................................................61 Command 10 – Switch off...................................................................................63 Command 11 – Switch on...................................................................................63 Command 12 – Idling/loaded and speed specification.....................................64 Command 18 – Acknowledge messages...........................................................64 Command 40 – Read system pass.....................................................................65

7 Transferring new program to control........................................................66 8 Document version........................................................................................67

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1 General information BEFORE PUTTING THE CONTROL SYSTEM INTO OPERATION, PLEASE READ THE FOLLOWING OPERATING INSTRUCTIONS CAREFULLY!

1.1 . Safety notices a. Only trained specialist staff are permitted to bring the control system into operation, undertake parameter settings, and perform maintenance work. b. Ambient conditions for storage: Ambient temperature range (storage) -25 to +75°C humidity (storage) max. 90%; non-condensing c. Ambient conditions during operation: Ambient temperature range (operation) -5 to +55°C Humidity (operation) max. 90%; non-condensing d. ALMiG retains the right to make changes, additions or improvements to this product (hardware and software). This does not imply any duty to update any devices already supplied.

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2 Control system function and connection (hardware)

2.1 . Overview

Figure 1: Keypad and display of the AirControl B

The control system consists of the following function blocks: a) Microprocessor logic (with EEPROM memory for backing up data) for all control, monitoring and display functions b) Keypad with 6 keys for switching the compressor on and off, and for entering nominal and limit values c) Customised colour LCD for depicting the current actual/nominal values and operating status as well as faults/warnings d) Analogue processing of mains pressure, compressor temperature and oil temperature e) Digital inputs/outputs for controlling a compressor f)

RS485 integration for controlling a frequency converter (Flex version)

Microprocessor logic 

16-bit CISC micro controller with watchdog



256 KByte Flash EPROM,



20 KByte RAM,



8 KByte EEPROM (for data backups),

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Display and keyboard The control system is equipped with a customised membrane keyboard (see also Figure 1) with 6 keys (with pressure point) and two integrated LEDs (green, red). The display presents the following data (see also Figure 2): 

Customised LCD, polychromatic, display area approx. 76mm x 43mm



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 (some in colour) for: fault, warning, frequency converter, motor, solenoid valve, heater, fan, remote (remote control), restart, automatic (operating mode), …

Inputs and outputs 3x analogue inputs – electrically separated, transmitter voltage 24 V DC 

1 input 4-20mA (mains pressure)



2 inputs for temperature sensor (PT1000)

8x digital inputs – electrically separated; transmitter voltages 12 VDC and 24 VDC; 

7 normal inputs



1 input for PTC temperature sensor

7 digital outputs: 

6 relay outputs, NO contact with shared connection, 250 VAC 6A



1 relay output, changer, 250 VAC, 6A Interfaces



RS-485 interface (standard)



RS-485 interface (FC control / optional)



MK200 bus module (optional)



Analogue piggyback board (optional)

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2.2 . Terminal assignment for AirControl B Pin

Designation

Function

Conn. plug / grid

1

PE

Functional earth (EMC)

Phoenix

4

0V AC

Control supply system

MINI-COMBICON

5

18V AC .. 24V AC

6

Relay output A 1 – A 6 COM

Grid 3.81 mm, 3-pin Shared connection for terminals 7 to 12

Phoenix COMBICON

7

Relay output A 1

Line contactor

MSTBA

8

Relay output A 2

With converter: * Message "Ready" otherwise: * Star contactor

Grid 5.0 mm

9

Relay output A 3

With converter: * Message "Operation" otherwise: * Delta contactor

10

Relay output A 4

Solenoid valve (with varistor)

11

Relay output A 5

"Combi with dryer": * Dryer otherwise: * Fan

12

Relay output A 6

"Combi with dryer": * Condensate valve (with varistor) otherwise: * Heater / dryer (with varistor)

13

Relay output A 7 Normally closed contact

Collective fault

7-pin

Phoenix COMBICON

14

Relay output A 7 Common

MSTBA

15

Relay output A 7 Normally open contact

Grid 5.0 mm 3-pin

16

PE

Screen connection

Phoenix

17

GND

Ground for analogue inputs AE 2 and AE 3

MINI-COMBICON 6-pin

18

Analogue input AE 3

PT1000 (compressor temperature)

19

Analogue input AE 2

PT1000 (oil temperature or dew point temperature)

20

Analogue input AE 1

4 – 20 mA (mains pressure)

21

24V DC

Transmitter voltage for AE 1

Last updated: 08/02/2019

Grid 3.81 mm,

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Pin

Designation

Function

Conn. plug / grid

22

Dig. input E 8

Basic load cycle: loaded / idling

Phoenix

23

Dig. input E 7

Remote On/Off or basic load cycle OK

MINI-COMBICON 10-pin

24

Dig. input E 6

Emergency stop

25

Dig. input E 5

Diff. pressure oil separator

26

Dig. input E 4

Direction of rotation fault

27

Dig. input E 3

Overpressure / oil level of heater

28

Dig. input E 2

Overcurrent

29

Dig. input E 1 (PTC)

Motor temperature

30

12V DC

Transmitter voltage 12V DC (PTC)

31

24V DC

Transmitter voltage 24V DC

32

GND

RS485 standard

33

RS-485 B (-)

34

RS-485 A (+)

35

Not used

36

SIG-B

37

SIG-A

38

GNDX

39

0V AC supply bus module

40

18V AC supply bus module

44

GND

45

RS-485 B (-)

46

RS-485 A (+)

47

Not used

Important:

Grid 3.81 mm,

Phoenix MINI-COMBICON Grid 3.81 mm, 4-pin

Interface for MK200 bus modules

Phoenix Direct plug ZEC1.5/5-ST-5.0 5-pin

RS485 FC

Phoenix MINI-COMBICON Grid 3.81 mm, 4-pin

Ensure the "A2, A3, A5, A6" relay outputs are assigned correctly!

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ALMiG AirControl B

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3 Operation of AirControl B 3.1 . Assignment of keys There are six keys with different functions available: ▲▼

: Editing of nominal / limit values / code

ENTER

: Transfer of the edited value into the current variable

INFO

: In the default screen display: Display of the most important settings: Pressing the info key repeatedly scrolls through the following list of parameters.

Display, bottom line

O

Parameter

1.

##.#

Switch-on pressure

2.

##.#

Switch-off pressure

3.

##.#

Safety pressure

4.

##.#

Minimum pressure / basic load cycle

5.

5.0

Min. compressor temperature

6.

110

Max. compressor temperature

7. ######

Operating hours

8. ######

Hours under load

9. #####

Air filter time remaining

10. #####

Oil/oil filter time remaining

11. #####

Oil separator time remaining

12. #####

Lubrication rime remaining

13. #####

Compressor time remaining

14. #####

Annual maintenance time remaining

15. #####

Dryer time remaining (only if "With dryer")

(1)

(2)

If compressor ON:

Switch off the compressor

After occurrence of fault:

Acknowledge the fault message (= RESET key)

Key depressed for longer than 3 seconds: Initiate code input (only possible if system OFF);

I

: Switch on compressor;

: flashes during warning/maint., lights up continuously during fault;

: operating display (lights up when the compressor is switched on / flashes whenever the compressor may start.

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3.2 . Default screen display, view on the LCD operating/display unit

Figure 2: All segments of the customised LCD.

Top:    

7-segment display ( "7-segm.A" ) Symbols for psi, MPa, bar 7 segment display ( "7-segm.B" ) Symbols for %, °F,°C, K,

Middle:  Symbols for fault, warning/maintenance, frequency converter, motor, solenoid valve, heater, fan, data query (RS485), automatic, remote control, restart, – in colour in some cases!  Figures "1" to "7" Bottom:  7-segment display ( "7-segm.C" )  Symbols for min, m³/h, s, h, %

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Default screen display

Figure 3: Default screen display when compressor is running (load: motor running, regulating valve open).

The following data can be displayed in the default screen display: 7-segm.A: current mains pressure (in example 7.2 bar) 7-segm.B: current compressor temperature (60°C in the example) If the ▲ button is pressed, all temperatures of the temperature sensors in place are displayed in sequence (switching after 2-3s in each case): "t. 1" = compressor temperature "t. 2" = oil or dew point temperature "t. 3/4/5" = winding temperature 1/2/3 (only if present!) "t. 6/7" = bearing temperature A/B (only if present!) The identifier "T2" is displayed here after the temperature. 7-segm.C: during fault/warning: Number of the current fault or warning and corresponding fault/warning text (abbreviation, 5 characters) With automatic restart activated after power outage the delay so far is displayed here. A stationary / overrun time currently in progress is displayed here also.

3.3 . Code input A code must be entered before parameters can be changed. This code (customer, service, factory code) determines which values can be edited. Codes can only be input if the compressor is switched off! The input screen for the code appears when the Off button (O) has pressed for at least 3 seconds (see Figure 4).

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Figure 4: Code input. The corresponding code can now be entered using the arrow keys. Use the ENTER key to accept the code or the 0 key to reject the entry again and return to the default screen display. The following codes are available: Code

Authorisation

Following display

00001

Customer code

Displays first menu item of customer menu

03846

Service code

Displays first menu item of the service menu The "Service code" can be set at will (see Item 3.5.24).

01923

Factory code

Same as "daily code" with full access. Only for commissioning. Is replaced by dynamic daily code after installation.

09999

Displays software version and random number for current factory code (daily code) – once entered: Displays first menu item of factory menu

Variable factory code The factory code is variable once commissioning has taken place. To obtain the factory code currently valid, the second parameter must be read from the menu item (code level) 9999. It contains a random number to generate a temporary factory code. This factory code then provides access to all menu items for 24h.

Figure 5:

Display following input and confirmation of the customer code. Top line: Code 1 – bottom: Menu item (code level) 2. Last updated: 08/02/2019

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3.4 . Menu system – parameter entries All setting parameters can be changed by selecting the corresponding menu item (code level). The right code has to be entered first (see Section 3.3). Afterwards, it is possible to scroll through the menu items of the selected menu using the arrow keys. Menu items are selected using the Enter key (Figure 6).

Figure 6:

Operating mode: Menu item (code level) 2,

first parameter Each menu item may contain one or more parameters. These are indicated by green digits. The Enter key is used to scroll through the parameters. If a value can be edited, it will flash and can then be changed using the arrow keys. The new value is adopted by pressing the Enter key and is rejected using the 0 key. The respective menu item or menu can be exited using the 0 key. Note: The values that are displayed on the default screen display using the Info key cannot be changed there. They can be found in all menus (customer, service, factory) under menu item 11. Menu item

Contents

(code level)

Description in Section

Without code

Access with code Custo Service Factor mer y

✔

-

-

-

3.5.1

Display only

✔

✔

✔

Automatic restart

3.5.2

Display only

✔

✔

✔

5

Heater / Fan / Dryer (standard)

3.5.3

Display only

-

-

✔

6

Monitoring: Dew point temperature (option: bearing temp., winding temp.)

3.5.21

Display only

✔

✔

✔

8

Local / remote

3.5.4

Display only

✔

✔

✔

11

Operating parameters: pressure tolerances

3.5.5

-

✔

✔

✔

0

Display: ALMIG, … (production)

-

2

Operating mode

3

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Contents

Description in Section

Without code

18

Basic load cycle operation

3.5.6

Display only

✔

✔

✔

21

Release: acknowledge maintenance intervals

-

-

✔

✔

30

Display fault memory

3.5.7

✔

✔

✔

✔

40

Edit: dryer maintenance interval ("Combi with dryer" only)

3.5.8

Display only

-

✔

✔

41

Edit air filter maintenance interval

3.5.8

Display only

-

✔

✔

42

Edit: oil filter maintenance interval

3.5.8

Display only

-

✔

✔

43

Edit: oil separator maintenance interval

3.5.8

Display only

-

✔

✔

44

Edit: Motor lubrication maintenance interval

3.5.8

Display only

-

✔

✔

45

Edit: compressor maintenance interval

3.5.8

Display only

-

✔

✔

51

Edit: idling/stationary time, ramp-up time

3.5.9

Display only

-

-

✔

55

Operating hours, hours under load, load cycles, motor starts (internal!)

3.5.25

Display only

-

-

-

60

Type selection (commissioning!): System type, pressure range, delivery volume

3.5.10

Display only

-

-

✔

62

Select pressure range (e.g. after software update!)

3.5.10

Display only

-

-

✔

65

Parameter for condensate valves (only for "Combi with dryer")

3.5.11

Display only

-

✔

✔

69

Delivery volume (m³/min) (e.g. after software update!)

3.5.10

Display only

-

-

✔

75

FC: set control parameters

3.5.12

Display only

-

-

✔

80

Selection: without/with dryer (only for "Combi with dryer")

3.5.13

Display only

-

-

✔

88

Reset to default setting

3.5.14

-

-

-

✔

90

Pressure display in bar/MPa/psi

3.5.15

Display only

✔

✔

✔

95

Temperature display in°C / °F / K

3.5.16

Display only

✔

✔

✔

105

Correction factor, pressure Correction factor, temperature(s)

3.5.17 3.5.22

Display only

-

✔

✔

111

Initiate commissioning sequence (only FLEX systems!)

4

✔

-

-

-

(code level)

Last updated: 08/02/2019

Access with code

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Contents

(code level)

Description in Section

04/10/2018 Without code

Access with code

201

OEM Almig

✔

-

-

-

213

OEM FS-Curtis

✔

-

-

-

255

Activate additional MK200 modules

3.5.23

✔

-

-

-

3846

Change "Service code"

3.5.24

-

-

-

✔

9900

Approve cancellation of operating hours / hours under load

-

-

-

✔

9919

Edit operating hours/ hours under load

-

-

-

✔

9929

Edit operating hours/ hours under load (+/- 1000h)

Display only

-

-

✔

9950

Edit RS485 address, mode, baud rate, protocol, data format

3.5.18

Display only

-

✔

✔

9960

Selection of FC type used

3.5.19

Display only

-

✔

✔

9980

Call up IO test

3.5.20

Display only

-

✔

✔

9999

Display program version + display random number for factory code

3.3

✔

✔

✔

CAUTION:

✔

Some of this codes are for ALMiG only and should not be given to customers!

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3.5 . Menu items 3.5.1

Operating mode

The operating mode is set through menu item 2.

Menu item (code level) 2 Parameter no. 1

Meaning

Value range / Default

Operating mode

0 = AUTOMATIC 1 = LOADED/IDLING

The "Autom." symbol is displayed if the "AUTOMATIC" operating mode has been selected.

3.5.2

Automatic restart after power outage

The automatic restart after power outage is set using menu item 3. Also refer to Section 4.8 for details of how this impacts on the procedure. Menu item (code level) 3 Parameter no. 1

Meaning

Value range / Default

Automatic restart after power outage

0 = Restart OFF 1 = Restart ON

The "Restart" symbol indicates that restart has been activated.

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Additional heater, fan, dryer

04/10/2018

(standard compressor!)

The parameters in menu item 5 differ according to compressor type (with "Combi with dryer" type only parameter 1 is available). Heater / fan / dryer Menu item (code level) 5 Parameter no. 1

Meaning

Value range / Default

"Heater" function

Standard compressor: 0 = without heater 1 = additional heater via comp. temp. 2 = additional heater by oil temp. "Combi with dryer": 0 = recirculation OFF >0 = recirculation ON

2

Heater switch-on temperature

2 – 15°C

3

Heater switch-off temperature

2 – 15°C

4

"Recirculation" function

0 = recirculation OFF 1 = recirculation ON

5

"With fan" function

0 = without fan 1 = with fan (digital) 2 = fan with frequency converter

6

Fan switch-on temperature

10 – 90°C

7

Fan switch-off temperature

10 – 80°C

8

Fan min. temperature (= min. speed, if with FC)

40 – 70°C

9

Fan max. temperature (= max. speed, if with FC)

70 – 95°C

10

"With dryer" function

0 = without dryer 1 = with dryer

11

Dryer switch-on temperature

2 – 20°C

12

Dryer switch-off temperature

0 – 10°C

13

Min. deactivation time, dryer (before being switched on again)

30 to 180 s

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Note:

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If the "Heater" is deactivated (par. 1 = 0), the corresponding output is no longer controlled. In this case the two parameters for the switch-on/off temperature (par. 2+3) are then also hidden. If the "Fan" is deactivated (par. 5 = 0), the parameters for the activation/ deactivation temperature (par. 6+7) and min./max. temp. (par. 8+9) are hidden. If "Fan with FC" (par. 5 = 2) is selected, parameters 6+7 are hidden. If "Fan digital" (par. 5 = 1) is selected, parameters 8+9 are hidden. If the "Dryer" is deactivated (par. 10 = 0), parameters 11+12+13 are hidden (see also Item 4.6).

3.5.4

Local operation, remote control, feedback "Basic load cycle OK"

Menu item (code level) 8 Parameter no.

Meaning

Value range / Default

1

Local operation, remote control

0 = local operation 1 = remote control 2 = basic load cycle OK

Remote control ON, if terminals 23+31 = closed [edge!] and "keyed in" locally; OFF if terminals 23+31 = open or using 0 key; If the system has been switched to remote control and the system has been keyed in, this will be indicated by the flashing "Remote" symbol. If the system is switched off using the 0 key, the "Remote" symbol is removed from the LCD! Basic load cycle OK Basic load cycle OK if terminal 23+31 = closed basic load cycle fault if terminal 23+31 = open

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Operating parameters

The operating parameters can be called up, without entering a code, directly from the default screen display by pressing the Info key (display only). Some of the parameters in menu items 11 and 9919 can then be changed.

Menu item (code level) 11 and 9919 Parameter no.

Meaning

Value range / Default

Can be edited from menu item...

1

Switch-on pressure

Depending on the system type

11

2

Switch-off pressure

Depending on the system type

11

3

Safety pressure

Cannot be edited

--

4

Minimum pressure / basic load cycle

5

Min. comp. temp.

Cannot be edited

--

6

Max comp. temp.

Cannot be edited

--

7

Operating hours

Cannot be edited

9919

8

Hours under load

Cannot be edited

9919

9

Air filter time remaining

Cannot be edited

--

10

Oil/oil filter time remaining

Cannot be edited

--

11

Oil separator time remaining

Cannot be edited

--

12

Lubrication rime remaining

Cannot be edited

--

13

Compressor time remaining

Cannot be edited

--

Cannot be edited

--

Cannot be edited

--

14 15

Annual maintenance time remaining Dryer time remaining (only if "With dryer")

11

Some parameters are preassigned from a table by selecting a system type. For more information, also refer to Section 3.5.10.

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Basic load cycle operation

Menu item (code level) 18 Parameter no. Meaning

Value range / Default

1

0 = No basic load cycle operation, i.e. loaded/idling via local pressure sensor 1 = basic load cycle operation, loaded if terminal 22+31 = closed idling if terminal 22+31 = open

Basic load cycle operation (system running as basic load cycle slave)

CAUTION: If input e02.6 has been defined as feedback [Basic load cycle OK] using the menu item (code level) 0008 and there is no signal (e02.6 = 0), basic load cycle operation is automatically switched off and the system continues to run with the local pressure sensor (until "e02.6 = 1" again). If basic load cycle operation has been activated, this is also indicated by the static "Remote" symbol in the display. With basic load cycle operation, the local pressure sensor is only used for monitoring the safety pressure (P_PERM). With basic load cycle operation activated, the loaded/idling request from the basic load cycle master can also be made via the RS485 interface. In this case, the corresponding digital input signals are ignored as long as control is performed via the interface. If the data exchange via the interface is interrupted for longer than 2 seconds, the control system switches back to control via the digital inputs. In basic load cycle operation, if the mains pressure falls below the "Minimum pressure" threshold, the system switches to the local pressure sensor and the warning [7] ("Minimum pressure threshold reached") appears. This warning must be acknowledged using the 0 key before switching back to the load request from the basic load cycle master.

Last updated: 08/02/2019

Page: 22 / 73

ALMiG AirControl B

3.5.7

V 1.80

04/10/2018

Fault memory

Display fault memory Menu item (code level) 30 Parameter no.

Meaning

Display / Value Range / Default

1 - 20

Display fault memory

- Item in the fault memory - Number of the fault/warning - Operating hours upon occurrence of the fault/warning

If the "Hazard triangle" symbol is shown, this entry constitutes a warning/maintenance. If the "Tool" symbol is show, this entry constitutes a fault. The arrow keys can be used to scroll through the 20 items of the fault memory. Item 1 is always the "most recent" fault. The individual items in the fault memory are stored in the EEPROM memory, and are therefore still available even after a power outage. See Section 3.6 for a list of potential messages.

Autom.

h

Figure 7:

Fault memory item 1 (most recent entry): Error number 65 fault, occurred at 3 operating hours.

Autom.

h

Figure 8:

Last updated: 08/02/2019

Fault memory item 2:Error number 22, warning, occurred at 1 operating hour.

Page: 23 / 73

ALMiG AirControl B

3.5.8

V 1.80

04/10/2018

Editing nominal values for maintenance intervals

Menu item (code level) 40 – only if "With dryer" Parameter no.

Meaning

Display / value range

1

Dryer

Range: 0 - 30000 h

Menu item (code level) 41 Parameter no.

Meaning

Display / value range

1

Air filter

Range: 0 - 30000 h

Menu item (code level) 42 Parameter no.

Meaning

Display / value range

1

Oil / oil filter

Range: 0 - 30000 h

Menu item (code level) 43 Parameter no.

Meaning

Display / value range

1

Oil separator

Range: 0 - 30000 h

Menu item (code level) 44 Parameter no.

Meaning

Display / value range

1

Motor lubrication

Range: 0 - 30000 h

Menu item (code level) 45 Parameter no.

Meaning

Display / value range

1

Compressor

Range: 0 - 30000 h

Menu item (code level) 46 Parameter no.

Meaning

Display / value range

1

Annual maintenance

Range: 8760 / 8784h

The corresponding nominal values can be selected in steps of 500 using the arrow keys and then accepted using the ENTER key. If a nominal value is accepted using the ENTER key, the corresponding interval (remaining time) will also be restarted with the nominal value.

Last updated: 08/02/2019

Page: 24 / 73

ALMiG AirControl B

3.5.9

V 1.80

04/10/2018

Idling time, stationary time, star/delta delay

Menu item (code level) 51 Parameter no. Meaning

Display / Value Range / Default

1

Idling time

Range: 10 – 1200s

2

Stationary time

Range: 0 – 60 s

3

Ramp-up time (delay star/delta)

Range: 3 - 30s

The corresponding nominal value can be set with the arrow keys and then accepted with the ENTER key.

3.5.10

Setting system type, pressure range and delivery volume

Menu item (code level) 60 Parameter no. Meaning

Display / Value Range / Default

1

System group

Belt, Combi, Variable, Direct, Gear, Flex, V-Drive, G-Drive

2

System type (default setting for system-specific par.)

e.g. "bE 11" (Belt 11)

3

Pressure range (compressor's maximum pressure)

Range: 7.0 – 15.0 bar

4

Maximum delivery volume (max. delivery vol. of compr. in m³/min)

Range: 0 – 99.99 m³/min

System type: Depending on the system type selected here, the system parameters are preassigned with saved table values. Pressure range: The pressure range set here also serves as the maximum limit when editing the "Switchon pressure" and "Switch-off pressure" parameters (see also Section 3.5.5). The pressure range (parameter 3) and the maximum delivery volume (parameter 4) can also be set separately in code levels 62 and 69. The factory code must also have been entered beforehand.

Last updated: 08/02/2019

Page: 25 / 73

ALMiG AirControl B

3.5.11

V 1.80

04/10/2018

Setting pulse/pause time for condensate valve

Menu item (code level) 65 – only for "Combi with dryer" type Parameter no.

Meaning

Display / Value Range / Default

1

Pulse time

Range: 1 – 99 s

2

Pause time

Range: 1 – 999 s

3

Control condensate valve, if: [0] = "compr. motor on" [1] = "dryer on"

Range: 0 / 1

The condensate valve is always controlled (pulse/pause control) if the condition defined in par. [3] is met.

3.5.12

Setting frequency converter control parameters

Menu item (code level) 75 Parameter no.

Meaning

Display / Value Range / Default

1

Frequency converter present

0 = without FC 1 = with FC (AA module) 2 = with FC (MK200-2AA) 3 = with FC (RS485/Modbus)

2

Speed reduction from: Here, it is possible Setting range: 5.0 to 13.0 bar to specify the pressure above which the Default setting: 5.0 bar maximum nominal value for the FC is limited.

3

Speed reduction to: Here, it is possible to specify the pressure above which the maximum nominal value for the FC is not to be further limited.

4

Speed reduction by: Here, it is possible to Setting range: 0 to 100 % specify the maximum amount by which Default setting: 50 % the max. nominal value is to be reduced.

Last updated: 08/02/2019

Setting range: 5.0 to 13.0 bar Default setting: 13.0 bar

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ALMiG AirControl B

V 1.80

04/10/2018

Menu item (code level) 75 Parameter no. Meaning

Display / Value Range / Default

5

Setting range: 0 to 100 % Default setting: 50 %

Percentage nominal value: Here, it is possible to specify the nominal value within the current pressure tolerance used for control purposes.

Example: 0 % : nom.value = switch-on press. ; 50 % : nom.value = (switch-on press. + switch-off press.) / 2; 100 % : nom.value = switch-off press.;

6

Control factor: This is where the contr. Range: 1 to 999 factor (P part of the controller) is set Default setting: 100

7

Reset time: This where the reset time Range: 0 to 9999 s (I part of the controller, is set; when "0" Default setting: 10 s => no I part)

8

Min.speed red.from: This is the pressure where a press.contr. linear adjustment of the min.speed starts. At this value the parameter “min. speed from” is used.

9

Min.speed red.to: This is the pressure Range: “Min.speed red.to” to 13,0 bar where a press.contrr. linear adjustDefault setting: depends on compr.type ment of the min.speed ends. At this value the parameter “min.speed to” is used

10

Min.speed from: This is the min.speed Range: 0 to “Min.speed to” of the compr. below the pressure Default setting: depends on “min.speed red.from”. compr.type

11

Min.speed to: This is the min.speed of the compr. above the pressure “min.speed red.to”.

Range: “Min.speed from” to 100 % Default setting: depends on compr.type

12

FC max idling: This is where the maximum percentage value for speed can be specified. This threshold applies until the compressor reaches the specified compressor temperature ("CT min. idling) after being switched from idling to loaded.

Range: 0 to 100 %

Last updated: 08/02/2019

Range: 5,0 to “Min.speed red.to” Default setting: depends on compr.type

Default setting: 75%

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ALMiG AirControl B

V 1.80

04/10/2018

Menu item (code level) 75 Parameter no. Meaning

Display / Value Range / Default

13

Range: 0 to 100 %

Caution:

CT min. idling: The temperature that must be reached after a switch from idling to loaded before the maximum speed for the FC is accepted is specified here.

Default setting: 60%

In the case of systems with frequency converter (par. 1 > 0), the relay outputs "A2" and "A3" are assigned differently (message "Ready" and "Operation")

Last updated: 08/02/2019

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ALMiG AirControl B

3.5.13

V 1.80

Dryer activation

04/10/2018

(only "Combi with dryer")

Menu item (code level) 80 – only for "Combi with dryer" type Parameter no.

Meaning

Display / Value Range / Default

1

Dryer on/off

0 = off; 1 = on

2

Dryer switch-off temperature

Range 0...6°C

3

Dryer diff. temperature

Range 2...10°C

4

Dryer minimum switch-off time

Range: 30 to 600 seconds

5

Offset, dew point temperature

Range: -10...+10°C

6

Switch-off delay

Range: 0…5 minutes

7

Dryer on with system off

0 = no; 1 = yes;

The dryer is switched on if the dew point temperature rises above the "Dryer switch-off temperature + dryer diff. temperature". The dryer is switched off again if the dew point temperature has fallen below the "Dryer switch-off temperature" threshold for at least the set time (par. 6 = switch-off delay). After the dryer is switched off, the "Dryer minimum switch-off time" must have expired before it can be switched on again. If parameter [7] is programmed to "1" (i.e. dryer on with system off), the dryer will be activated even if the system is switched off, otherwise the dryer is switched off along with the system. The dew point temperature can be displayed if the ▲ key is pressed in the default screen display (the "T2" symbol is then displayed at the same time => 2nd temp.). If the dryer is activated, this will be indicated by the "4" symbol. Pressing the ▲ and ENTER keys at the same time allows the dryer to be switched on/off manually. If the dryer has been switched off manually, the "4" symbol flashes

3.5.14

Default setting of the system data

Menu item (code level) 88 resets all adjustable parameters to their default values and returns the display to the default screen display. CAUTION: Any data set manually prior to this are overwritten!

Last updated: 08/02/2019

Page: 29 / 73

ALMiG AirControl B

3.5.15

V 1.80

04/10/2018

Changing unit for pressure display

Menu item (code level) 90 Parameter no.

Meaning

Display / Value Range / Default

1

Pressure unit

0 = Pressure display in [bar] 1 = Pressure display in [MPa] 2 = Pressure display in [psi]

3.5.16

Changing unit for temperature display:

Menu item (code level) 95 Parameter no.

Meaning

Display / Value Range / Default

1

Temperature unit

0 = Temperature display in [°C] 1 = Temperature display in [°F] 2 = Temperature display in [ K]

3.5.17

Correction value for pressure measurement

Menu item (code level) 105 Parameter no.

Meaning

Display / Value Range / Default

1

Pressure measurement correction value

-0.5 to +0.5

This value can be used to specify an offset for the pressure measurement value in order to compensate for minor deviations with the pressure sensors.

Last updated: 08/02/2019

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ALMiG AirControl B

3.5.18

V 1.80

04/10/2018

Setting RS485 parameter

Menu item (code level) 9950 Parameter no.

Meaning

Display / Value range / Default

1

System address 0= The RS485 connection is switched off (PC integration / [ Default setting ] Visualisation / 1-16 = The system can be contacted using the Global control system) corresponding address.

2

Mode

0 = Data can be read and amended via the interface. [ Default setting ] 1 = It is only possible to read the data via the interface.

3

Baud rate

0 = 4800 baud 1 = 9600 baud 2 = 19200 baud

[ Default setting ]

4

Protocol

0 = Standard 1 = Modbus-RTU

[Default setting ]

5

Data format

0 = 1 start bit, 8 data bit, 1 stop bit, no parity [ Default setting ] 1 = 1 start bit, 8 data bit, 2 stop bit, no parity 2 = 1 start bit, 8 data bit, 1 stop bit, even parity 3 = 1 start bit, 8 data bit, 1 stop bit, odd parity

Note: Note that a separate address must be set for each system connected. In addition, the corresponding interface module (RS485) must be present in the control system. Note that the same baud rate, the same protocol and the same data format must be set for each system connected!

3.5.19

Selection of FC type used

Menu item (code level) 9960 Parameter no.

Meaning

Display / Value Range / Default

1

FC type

0 = Yaskawa 1 = Emotron 2 = Bosch-Rexroth 3 = ABB (ACS510) 4 = Delta (C2000)

Last updated: 08/02/2019

[ Default setting ]

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ALMiG AirControl B

3.5.20

V 1.80

04/10/2018

Testing the digital inputs/outputs

Menu item (code level) 9980 Parameter no.

Meaning

Display / Value Range / Default

1-8

Input 1-8

0 = off 1 = on

9-15

Output 1–7

0 = switch off 1 = switch on

The arrow keys can be used to switch the relevant output ON or OFF for the output signals. The ENTER key moves you on to the next input/output (in this case, the outputs are always switched off beforehand). The last step is always followed by the default screen display. CAUTION: Activating individual outputs in test mode may cause the compressor motor to start up!

3.5.21

Monitoring: Dew point / bearing / winding temp.

Menu item (code level) 6 Parameter no.

Meaning

Value range / Default

1

Max. dew point temperature

0 - +50°C (0 = monitoring off!)

2

Min. dew point temperature

-10 – +50°C

3

Message = warning or fault

0 = warning; 1 = fault

4

With winding temp. monitoring

0 = No, 1 = Yes

5

Max. winding temperature

80 – 150°C

6

With bearing temp. monitoring

0 = No, 1 = Yes

7

Max. bearing temperature

80 – 150°C

If this function "Dew point temp. monitoring" is activated (par. 1 > 0°C), the dew point temperature is monitored for the set limit values and the corresponding temp. sensor is monitored for defects. When the I key is pressed, if the dew point temperature is above the "Dew point max" threshold, a "Dew point temperature" warning is generated.

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

If the compressor motor is running and the dew point temperature falls below the "Dew point min" threshold, a "Dew point too low" warning / fault is generated. If the compressor motor is running and the dew point temperature exceeds the "Dew point max" threshold, a "Dew point too high" warning / fault is generated. If the function "Winding temp. monitoring" is activated (par. 4 = 1), the temperatures for "Winding 1 / 2 / 3" are monitored for the set limit value. If a winding temperature exceeds the limit value (par. 5), a "Winding temp. 1 / 2 / 3 too high" fault is generated and the compressor is shut down. If a sensor defect is identified, a "Cable defect winding temp. 1/2/3" fault is generated and the compressor is shut down. For this option, an additional module "MK200-8E4AE" (addr. 8 / Pt100: -20°C .. +300°C) is required! If the function "Bearing temp. monitoring" is activated (par. 6 = 1), the temperatures for "Bearing A / B" are monitored for the set limit value. If a bearing temperature exceeds the limit value (par. 7), a "Bearing temp. A/B too high" fault is generated and the compressor is shut down. If a sensor defect is identified, a "Cable defect bearing temp. A/B" fault is generated and the compressor is shut down. For this option, an additional module "MK200-8E4AE" (addr. 9 / Pt100: -20°C .. +300°C) is required!

Last updated: 08/02/2019

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ALMiG AirControl B

3.5.22

V 1.80

04/10/2018

Correction value for temperaturemeasurement

Menu item (code level) 105 Parameter no. Meaning

Display / Value Range / Default

2

Correction value for compressor temperature

-10°C to +10°C (default: 0°C)

3

Correction value for oil temperature (or correction value for dew point temp.)

-10°C to +10°C (default: 0°C)

4

Correction value for dew point temp. (if module "MK200-4AE4RA", addr. 7)

-10°C to +10°C (default: 0°C)

These values can be used 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

Activating additional MK200 modules

Menu item (code level) 255 Parameter no. Meaning

Display / Value Range / Default

1

MK200 Profibus module present

0/1 = No/Yes

(default: 0)

2

MK200-8E4RA (addr. 2) present

0/1 = No/Yes

(default: 0)

In order to be able to connect these modules, the control system must be equipped with a "Bus module"! If one of these modules is activated, but is not actually available, the "44 Module" warning message is displayed (see: Item 3.6.2).

Last updated: 08/02/2019

Page: 34 / 73

ALMiG AirControl B

3.5.24

V 1.80

04/10/2018

Changing service code

Menu item (code level) 3846 Parameter no. Meaning

Display / Value Range / Default

1

1 - 9999

Change current service code

(default: 3846)

A new "Service code" can be defined here. CAUTION:

3.5.25

If a code is entered here that has already been used elsewhere, the old function will subsequently no longer be available!

Additional counters for operating hours/hours under load, load cycles, motor starts

Menu item (code level) 55 Parameter no.

Meaning

Display / Value Range / Default

1

Operating hours (cannot be edited, cannot be deleted)

0 – 999999 h

2

Hours under load (cannot be edited, cannot be deleted)

0 – 999999 h

3

Load cycles (cannot be edited, cannot be deleted)

0 – 999999

4

Motor starts (cannot be edited, cannot be deleted)

0 – 999999

This values are also recorded here but cannot be edited or deleted! They remain unchanged even after switching to "Default setting".

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

3.6 . Processing of faults/warnings 3.6.1

Faults

bar

°C Autom.

Figure 9: For example, error message: 65 – power outage. The "Tool" symbol flashes and the fault number and text are displayed in the bottom line, flashing in red. The following error messages are possible:

Number

"Text"

Meaning (fault)

61

EProM

"EEPROM defective?" (check all setting parameters)

63

PAr

"Parameter incorrect" (check nominal pressure values!)

65

no AC

"Power outage" (only if not "Automatic restart")

66

SE t

"C temperature cable defect" (monitoring: temperature sensor 1)

67

SE t2

"Oil temperature or dew point temperature cable defect" (monitoring: temperature sensor 2)

68

SE P

"Pressure cable defect" (monitoring: pressure sensor)

70

SE t3

"Dew point temperature cable defect" (if module "MK200-4AE4R" !)

71

EMErG

"EMERGENCY STOP activated" (contact open = fault)

72

rotAt

"Direction of rotation" (contact open = fault)

73

Mot t

"Motor temperature" ( PTC )

74

hiCur

"Overcurrent" (contact open = fault)

75

hi Pr

"Overpressure" => The "heater" function is deactivated, and there is no signal at the "E 3" input;

Last updated: 08/02/2019

Page: 36 / 73

ALMiG AirControl B Number

"Text"

V 1.80

04/10/2018

Meaning (fault)

77

hi t

"C temperature too high" (temperature > max. compr. temperature)

78

hi P

"Network pressure too high" (pressure > safety pressure)

81

Fu

"Compressor FC fault" (compr. FC malfunctioning or not responding)

82

diF P

"Diff.pressure oil separator" (contact open = fault)

83

Mod 8

The module "MK200-8E4AE" (addr. 8) is reporting a fault or it is not responding (with activated winding temp. monitoring)

84

Mod 9

The module "MK200-8E4AE" (addr. 9) is reporting a fault or it is not responding (with activated bearing temp. monitoring)

85

SE LA

Cable defect "Bearing temp. A" (sensor monitoring)

86

SE Lb

Cable defect "Bearing temp. B" (sensor monitoring)

87

hi LA

Bearing temp. A too high (temp. > max. bearing temperature)

88

hi Lb

Bearing temp. B too high (temp. > max. bearing temperature)

89

Module

"Fault on IO module" – the external module "MK200-4AE4RA" (addr. 7) is reporting a fault or the module is not responding (although it has been activated)!

90

dP Mi

Dew point temperature too low

91

dP MA

Dew point temperature too high

93

SE W1

Cable defect "Winding temp. 1" (sensor monitoring)

94

SE W2

Cable defect "Winding temp. 2" (sensor monitoring)

95

SE W3

Cable defect "Winding temp. 3" (sensor monitoring)

96

hi W1

Winding temp. 1 too high (temp. > max. winding temperature)

97

hi W2

Winding temp. 2 too high (temp. > max. winding temperature)

98

hi W3

Winding temp. 3 too high (temp. > max. winding temperature)

99

FAnFu

"Fault converter fault" (fan FC malfunctioning or not responding)

If one of these faults occurs, it results in the compressor shutting down. The red LED lights up until the fault has been acknowledged. Acknowledgement with the 0 key is only possible if the cause of the fault has been rectified in the meantime!

Last updated: 08/02/2019

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ALMiG AirControl B

3.6.2

V 1.80

04/10/2018

Warning / maintenance

The "Hazard triangle" symbol flashes and the corresponding number and text are displayed in the bottom line with 7 segment elements.

bar

°C Autom.

Figure 10: Intake filter warning message.

Number

"Text"

Meaning (maintenance)

1

M Air

"Intake filter maintenance"

(remaining maint. time < 100 hours)

2

M Oil

"Oil/oil filter maintenance"

(remaining maint. time < 100 hours)

3

M SEP

"Oil separator maintenance"

(remaining maint. time < 100 hours)

4

M Mot

"Lubrication maintenance"

(remaining maint. time < 100 hours)

5

M Con

"Compressor maintenance"

(remaining maint. time < 100 hours)

6

M dry

"Dryer maintenance" (time remaining < 100 hours | only if "With dryer")

8

M 365

"Annual maintenance"

21

hi t

"Compressor temperature increased" (temp. > max.compr.temp. - 5°C )

22

hi P

"Mains pressure increased" (pressure > safety pressure - 0.3 bar)

23

Cold

"Temperature too low" VARIO:+1°C ≤ compr. temperature ≤ +5°C Default: compr. temperature or oil temperature < +1°C

24

Min P

"Lower pressure threshold reached" The system is running as basic load cycle slave and has fallen below the "Minimum pressure" threshold

25

OilHE

"Heater oil level" => The "Heater" function is activated, and there is no signal at the "E 3" input;

26

dEFEC

"Calibration parameter incorrect" (send in for repairs/calibration)

35

dP tE

Dew point temperature (I-key and "Dew point temp. > max. dew point")

Last updated: 08/02/2019

(remaining maint. time < 100 hours)

Page: 38 / 73

ALMiG AirControl B

Number

"Text"

V 1.80

04/10/2018

Meaning (maintenance)

38

dP Mi

Dew point temperature too low

39

dP MA

Dew point temperature too high

44

Module "IO module warning" - An external "MK200" module is reporting a fault or the module is not responding (although it has been activated)! * The flashing icons (1 to 7) listed below tell you which module is affected: [ 1 ] => MK200-2AA (addr. 1) [ 2 ] => MK200-8E4RA (addr. 2) otherwise => MK200-Profibus (addr.31)

The compressor is not shut down in the event of a warning/maintenance signal. The red LED flashes until the cause of the warning has been rectified and/or the corresponding maintenance interval has been acknowledged. Normally a fault/warning is displayed instantly. If, however, the operator has pressed the INFO key in order to enter nominal or limit values, the fault/warning will not be displayed until the operator switches back to the default screen display.

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

4 Information about the program This only applies to the "FLEX" system type: If the "Commissioning sequence" for the compressor motor has not been performed yet, -OFF- appears on the display and the compressor cannot be started! To start this "Commissioning sequence", use code "111". While the "Commissioning sequence" is running, the bottom 7-segment display shows the current progress, the nominal value for the converter and the time remaining for this step (for example, "1 40: 15 s" ► Step = 1; Nominal value = 40%; Time remaining = 15 seconds).

4.1 . Operating states a) the compressor is switched off:  the green LED is off  the "Motor" and "Solenoid valve" symbols are off (LCD) b) the compressor is switched on but the current pressure is still above the switch-on pressure (start-up safeguard).  the green LED is flashing  the "Motor" and "Solenoid valve" symbols are off c) The compressor has been switched on but the compressor temperature (or oil temperature if "With heater") is still below +1°C:  the green LED is flashing  the "Motor" and "Solenoid valve" symbols are off  the symbol for the temperature unit is flashing (LCD: °C/°F/K) d) the compressor is running but the load valve is switched off, i.e. the compressor is not compressing. (Ramp-up phase or idling)  the green LED is on  the "Motor" symbol is on  the "Load valve" symbol is off e) the compressor is running and the load valve is switched on, i.e. the compressor is compressing. (loaded)  the green LED is on  the green "Motor" symbol is on  the green "Load valve" symbol is on

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

4.2 . Operating modes a) AUTOMATIC operation Once the switch-off pressure is reached, the system goes into IDLE MODE (overrun) for the duration of the "Idling time". To indicate that the idling time is active, the decimal point to the left of the pressure display flashes. The compressor shuts down after the "Idling time". Once shut down, the green LED flashes => Ready to start up again. As soon as the pressure again falls below the switch-on pressure, the system restarts. b) LOADED/IDLING mode The compressor switches between "Loaded" and "Idling" mode, i.e. it overruns for an unlimited time.

4.3 . Switching on If the "Dew point temp.monitoring" option (see: Item 3.5.19) is activated and if the dew point temperature is above the "Max. dew point" threshold, the "Dew point temperature" warning [35] appears. When switching on the compressor, if the current mains pressure is greater than the set switch-on pressure, the green LED flashes (= ready). Only when the mains pressure falls below the switch-on pressure does the compressor start up and the operating display (green LED) light up continuously. When the compressor temperature (or oil temp. if "With heater") is below +1°C when switching on, the unit for the temperature flashes (°C/°F/K) and the green LED flashes too. The warning [23] is also displayed here. If the temperature then rises to at least +1°C, the compressor is started.

4.4 . Switching off If the compressor is switched off using the 0 key (or remote OFF), it first switches to idling. In the display, the decimal point before the pressure display flashes. The remaining time until shut down can be displayed using the ▼ key. Here the stationary time is used as time. Only when this time has passed does the system shut down completely. As long as the compressor is in "Ramp-up" mode (i.e. star/delta ramp-up not yet completed) it will be shut down immediately (without delay).

Last updated: 08/02/2019

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4.5 . Safety pressure ("P_PERM") The safety pressure is the set "Pressure range" + 0.8 bar. ("Pressure range") Example: "Pressure range" = 10 bar => "P_perm" = 10.8 bar If the pressure rises above the threshold "P_perm – 0.3 bar", a warning will be reported. If the pressure rises above the threshold "P_perm", the compressor will be shut down with a fault message.

4.6 . "Additional heater" / "Fan" / "Dryer" function (Standard compressors // see also 3.5.3) a) "Heater = 1" / compressor motor is OFF / main switch is ON If the compressor temperature falls below the "Heater ON" threshold (or "Min. ompressor temp. - 1°C", if the control has not been keyed in), the output for the "Additional heater" is switched on. If the compressor temperature rises above the "Heater OFF" threshold (or "Min. compressor temp. + 2°C", of the control has not been keyed in), the output for the "Additional heater" is switched off. In the case of a warning "25" (heater oil level) or a fault "66" (compr. temperature sensor defect), the heater is switched off. a) "Heater = 2" / compressor motor is OFF / main switch is ON If the oil temperature falls below the "Heater ON" threshold (or min. compressor temp. - 1°C", if the control has not been keyed in), the output for the "Additional heater" is switched on. If the oil temperature rises above the "Heater OFF" threshold (or "Min. compressor temp. + 2°C", of the control has not been keyed in), the output for the "Additional heater" is switched off. In the case of a warning "25" (heater oil level) or a fault "67" (oil temperature sensor defect), the heater is switched off. c) If the additional heater unit is deactivated (heater = 0), or if the compressor motor is running, the output for the "Additional heater" is switched off! d) "With fan (digital)" If the compressor is keyed in 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

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e) "With fan (frequency converter)" If the compressor is keyed in and the compressor temperature rises above the "Fan MIN" threshold, the output for the fan is switched on. Depending on the current compr. temp. the fan is controlled using a converter in the range of 0% (CT ≤ fan MIN) up to 100% (CT ≥ fan MAX) of its max. speed. If the compressor temperature falls below the "Fan MIN" threshold, the output for the fan is switched off. f) "With recirculation" (now also valid for the "Combi with dryer" type) If the "Recirculation" function is activated (see Item 3.5.3) and the system has been keyed in, the system will start up if the compressor temperature falls below the threshold of +5°C (the system is idling). As soon as the compressor temperature rises above the threshold of +15°C again, the system is stopped again. Press the ENTER and ▼ keys (in the default screen display!) at the same time to switch the activated "Recirculation" function on/off temporarily. g) "With recirculation" and "With heater" and "System keyed in" In this case, the "Heater" is only switched on if the temperature falls below the threshold of +1°C. h) "With dryer" (standard compressor!) If the dew point temperature rises above the threshold [dryer on], the "Dryer" output is switched on. If the dew point temperature falls below the threshold [dryer off], the "Dryer" output is switched off. * If the "Heater" function is also activated, an additional “MK200-4AE4R" module (addr. 7) is required to read in the dew point temperature (terminals 5+6) and also to control the dryer (terminals 12+13)! Press the ▼ key in the default screen display to display this temperature! * If the "Heater" function is deactivated, the 2nd temperature sensor (AI-2) and the "A6" output are used here (each on "AirControl B"). If the "Recirculation" function is activated, the symbol is displayed; if the function is switched off temporarily this symbol flashes. 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 the additional heater or fan is switched on, the corresponding symbol appears on the LCD. If the dryer is activated, this will be indicated by the "4" symbol. 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 the dryer was switched off in this way, the "4" symbol flashes

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4.7 . Maintenance intervals (For actual values, see: 3.1 / For nominal values, see: 3.5.9 ) There is a countdown of the corresponding intervals. As soon as one of these intervals reaches less than 100 hours, the corresponding message appears and the red LED flashes ( => Maintenance !). To acknowledge this message, first activate menu item (code level) 21 and then press the 0 key. This resets the interval in question to the preset nominal value. If a (new) nominal value is accepted using the ENTER key, the corresponding maintenance interval is likewise started anew with this nominal value.

4.8 . Procedure for "Automatic restart", stationary time If the "Automatic restart after power outage" has been programmed, then after the power returns, the time that has been set in the parameter "Stationary time" elapses. The "Restart" symbol flashes during this time. If the system was in operation before the power outage, it restarts after this time, otherwise it remains in STOP mode. If "Restart" is activated, the "Power outage" fault is not reported when the power returns!

4.9 . Settings for the frequency converter (FC): Set the FC's interface parameters to the following values: [ Mode: Remote control and nominal values specified via RS485 / ModBus ] * RS485 address: * Baud rate: * Protocol:

1; 9600 baud; Modbus-RTU©

* 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; Others: 1 start bit, 8 data bits, 2 stop bits, no parity;

(ABB: EFB profiles = "ABB DRV LIM")

If the "Yaskawa" type is used as fan FC (see Item 3.5.3, Par. 5), then the following settings will be required here: * RS485 address: * Data format:

2; 1 start bit, 8 data bits, 1 stop bit, no parity;

In this case, if the "Emotron" type is used at the same time as FC for compressor motor, then its "ComFehlZeit" parameter (par. 2642) should be set to 2.0 sec.

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5 Modbus RTU communication To activate this operating mode, "Modbus RTU" must be selected as protocol for the interface (see Item 3.5.18 / Par. 4). Abbreviations used: Bit: UInt8: UInt16: UInt32:

Bit register (16 bit) 8 bit unsigned 16 bit unsigned 32 bit unsigned

Int8: Int16: Int32:

8 bit signed 16 bit signed 32 bit signed

5.1 . Addresses for the command 03_hex / "Read data registers" Register

Address

Contents

Data / comment

40001

0000h

Maintenance messages

Bit 0x0001: M001 Intake filter 0x0002: M002 Oil filter 0x0004: M003 Oil separator 0x0008: M004 Motor lubrication 0x0010: M005 Compressor 0x0020: M006 Dryer 0x0040: --0x0080: M008 Annual maintenance 0x0100: --0x0200: --0x0400: --0x0800: --0x1000: --0x2000: --0x4000: --0x8000: ---

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Register

Address

Contents

Data / comment

40002

0001h

Warning 1 messages

Bit 0x0001: W021 Compressor temp. increased 0x0002: W022 Mains pressure increased 0x0004: W023 Temperature low 0x0008: W024 Lower press. thresh. reached 0x0010: W025 Check oil level / heater 0x0020: W026 Calibration incorrect 0x0040: --0x0080: --0x0100: --0x0200: --0x0400: --0x0800: --0x1000: --0x2000: --0x4000: W035 Dew point temperature 0x8000: ---

40003

0002h

Warning 2 messages

Bit 0x0001: --0x0002: W038 Dew point temperature too low 0x0004: W038 Dew point temp. too high 0x0008: W040 Oil pressure too low 0x0010: W041 Oil temperature too high 0x0020: W042 Diff. pressure too high 0x0040: W043 Bekomat 0x0080: W044 Extension module 0x0100: W045 I/O module (addr.1) 0x0200: W046 I/O module (addr.2) 0x0400: --0x0800: --0x1000: --0x2000: W050 I/O module (addr.31) 0x4000: --0x8000: ---

40004

0003h

Warning 3 messages

- Free (with ACB not assigned)

40005

0004h

Warning 4 messages

- Free (with ACB not assigned)

40006

0005h

Fault 1 messages

Bit 0x0001 E061 EEPROM 0x0002 --0x0004 E063 Parameter incorrect 0x0008 --0x0010 E065 Power outage 0x0020 E066 Comp. temp. cable def. 0x0040 E067 Oil temp. cable def. 0x0080 E068 Pressure cable def. 0x0100 --0x0200 E070 Dew point cable def. 0x0400 E071 EMERGENCY STOP confirmed 0x0800 E072 Direction of rotation incorrect 0x1000 E073 Motor temperature 0x2000 E074 Overcurrent 0x4000 E075 Overpressure 0x8000 ---

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Register

Address

Contents

Data / comment

40007

0006h

Fault 2 messages

Bit 0x0001 E077 Compr. temp too high 0x0002 E078 Mains pressure too high 0x0004 --0x0008 --0x0010 E081 Converter fault 0x0020 E082 Diff. pressure oil separator 0x0040 E083 I/O module (addr.8) 0x0080 E084 I/O module (addr.9) 0x0100 E085 Bearing temp. cable def. A 0x0200 E086 Bearing temp. cable def. B 0x0400 E087 Bearing temp. A too high 0x0800 E088 Bearing temp. B too high 0x1000 E089 Extension module 0x2000 E090 Dew point temperature too low 0x4000 E091 Dew point temperature too high 0x8000 ---

40008

0007h

Fault 3 messages

Bit 0x0001 E093 Winding temp. cable def. 1 0x0002 E094 Winding temp. cable def. 2 0x0004 E095 Winding temp. cable def. 3 0x0008 E096 Winding temp. 1 too high 0x0010 E097 Winding temp. 2 too high 0x0020 E098 Winding temp. 3 too high 0x0040 E099 Fan converter fault 0x0080 --0x0100 --0x0200 E102 I/O module (addr.7) 0x0400 --0x0800 --0x1000 --0x2000 --0x4000 --0x8000 ---

40009 40020

0008h 0013h

Messages fault 4 - 15

40021

0014h

Reserved

40022

0015h

Reserved

40023

0016h

Compressor status

Last updated: 08/02/2019

- Free (with ACB not assigned)

Bit 0x0001: Operation 0x0002: Motor running 0x0004: Loaded 0x0008: Ramp-up / idling / overrun 0x0010: Automatic restart 0x0020: Maintenance message 0x0040: Warning message 0x0080: Fault message 0x0100: Ramp-up phase 0x0200: Overrun phase

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Register

Address

Contents

40024 40029

0017h 001Ch

Free

40030

001Eh

Speed Frequency converter

UInt16 [rpm]

40031

001Eh

Frequency converter percent display

UInt16 [%]

40032

001Fh

Delivery volume

UInt16 [0.1 m³/h]

40033

0020h

Mains pressure

UInt16 [0.001 bar]

40034

0021h

Compressor temperature

Int16 [0.1 °C]

40035

0022h

Oil temperature

Int16 [0.1 °C]

40036

0023h

Dew point temperature

Int16 [0.1 °C]

40037

0024h

Free

40038

0025h

Power consumption of compressor

40039 40050

0026h 0032h

Free

40051

0032h

Winding temp. 1

Int16 [0.1 °C]

40052

0033h

Winding temp. 2

Int16 [0.1 °C]

40053

0034h

Winding temp. 3

Int16 [0.1 °C]

40054

0035h

Bearing temperature A

Int16 [0.1 °C]

40055

0036h

Bearing temperature B

Int16 [0.1 °C]

40056

0037h

Free

40057 40058

0038h 0039h

Operating hours

UInt32 [h]

40059 40060

003Ah 003Bh

Hours under load

UInt32 [h]

40061 40065

003Ch 003Dh

Free

40066

0041h

Intake filter maintenance interval

UInt16 [h]

40067

0042h

Oil filter maintenance interval

UInt16 [h]

40068

0043h

Oil separator maintenance interval

UInt16 [h]

40069

0044h

Motor maintenance interval

UInt16 [h]

40070

0045h

Compressor maintenance interval

UInt16 [h]

Last updated: 08/02/2019

04/10/2018

Data / comment

UInt16 [0.01 kW]

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Register

Address

Contents

Data / comment

40071

0046h

Dryer maintenance interval

UInt16 [h]

40072 40075

0047h 004Ah

Free

40076

004Bh

Annual maintenance maintenance interval

40077 40081

004Ch 0050h

Free

40082

0051h

Time until next maint.: intake filter

Int16 [h]

40083

0052h

Time until next maintenance: oil filter

Int16 [h]

40084

0053h

Time until next maintenance: oil separator

Int16 [h]

40085

0054h

Time until next maintenance: motor

Int16 [h]

40086

0055h

Time until next maintenance: compressor

Int16 [h]

40087

0056h

Time until next maintenance: dryer

Int16 [h]

40088 40091

0057h 005Ah

Free

40092

005Bh

Time until next annual maintenance

40093 40100

005Ch 0063h

Free

40101

0064

Switch-on pressure

UInt16 [0.1 bar]

40102

0065h

Switch-off pressure

UInt16 [0.1 bar]

40103 40104

0066h 0067h

Free

40105

0068h

Minimum pressure

UInt16 [0.1 bar]

40106

0069h

Percentage target value

UInt16 [%]

40107 -

006Ah -

Free

40110

006Dh

40111

006Eh

Automatic restart

04/10/2018

UInt16 [h]

Int16 [h]

0 = No 1 = Yes

40112

006Fh

Operating mode

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Data / comment 1 = Loaded/idling

40113

0070h

Remote On / Off

0 = No 1 = Yes

40114

0071h

Remote loaded / idling

0 = No 1 = Yes

40115

0072h

Dew point monitoring

0 = Off, 1 = Warning, 2 = Fault

40116

0073h

Min. dew point

Int16 [°C]

40117

0074h

Max. dew point

Int16 [°C]

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5.2 . Addresses for the command 10_hex / "Write data registers" Register

Address

Contents

Data/comments

40001

0000h

Acknowledge messages

Writing "005a hex" resets pending and acknowledgeable messages. No other values are permitted

40002

0001h

Switch system On / Off

"0080 hex" value: Switch system Off "0081 hex" value: Switch system On No other values are permitted To be able to switch the system, these values must be keyed in locally and be correspondingly enabled for remote access in the menu.

40003

0002h

Remote loaded / idling

"0080 hex" value: No control via interface "0081 hex" value: No control via interface "0082 hex" value: No load request (idling / Off) "0083 hex" value: Load request No other values are permitted The system must be correspondingly enabled in the menu for external pressure control. In addition, this command must be repeated at least every 20s.

40004

0003h

External speed nominal value

Last updated: 08/02/2019

Value range 4000 – 20000 corresp. 0 – 100% This command must be repeated at least every 20 sec.

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6 Standard protocol / Profibus DP To activate this operating mode, "standard" must be selected as protocol for the interface (see Item 3.5.18 / Par. 4).

6.1 . Standard protocol A detailed technical description of the standard protocol including an exact structure of the send/receive telegram is available in a separate document.

6.2 . Profibus II (Profibus DP) A technical description of the Profibus module including the terminal assignment is available in a separate document.

Data set structure A max. of 104 bytes each can be transferred via the "Profibus II" module (Profibus DP - slave) to one or more connected control systems or called up from there. The Profibus module generates the corresponding command telegrams for the control system (=> "Standard protocol") from the output data received by the Profibus master. The reply telegrams from the control system are then re-converted accordingly and stored in the input data area for the Profibus master. In a special "status byte", the Profibus master is informed when the reply data are available and/or whether the slave acknowledged the command (if no reply data available). The byte sequence is "Big Endian", i.e. with values that require 2 or more bytes, the more significant byte always comes first (Hi, Lo). Abbreviations used: UInt8: UInt16: UInt32:

8 bit unsigned 16 bit unsigned 32 bit unsigned

Last updated: 08/02/2019

Int8: 8 bit signed Int16: 16 bit signed Int32: 32 bit signed

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Data allocation for Profibus output data (send data from the Profibus master)

Byte

Contents

Data / comment

1

RS485 address of the control system to be addressed

This corresponds to the respective RS485 address set

2

Command number

A list and description of the individual command numbers can be found under the Overview of commands (Item 6.3).

A new command is only accepted if this byte had previously been "0"! 3

Number of send bytes (0 - 101)

With commands purely for calling up data "0", otherwise number of the data bytes to be sent to the control system. The value can be found in the description of the individual commands (number of data bytes under command telegram)

4– 104

Send data

The data described under the Overview of commands (command telegram) (D0 – D100), if available, are transferred here. Only the first data bytes, stated under "Number of send bytes", are taken into consideration.

6.2.2

Data allocation of Profibus input data (receive data for the Profibus master)

Byte

Contents

Data / comment

1

RS485 address of the control system replying

Normally the address from the output data

2

Command number or error identifier

Normally command number from the output data. In the case of error 7FHEX. In this case, the error code is in byte 4

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Byte

Contents

Data / comment

3

Status byte

00 HEX [

0]: Module is waiting for a command from the Profibus master

F0 HEX [240]: Command was sent to the corresp. control system FF HEX [255]: Module has received the reply data from the control system and/or the control system has acknowledged the command. 4– 104

Receive data

The data described under the "Overview of commands" (reply telegram) (D0 – D100), if available, are transferred here. In the case of error (Byte 2 = 7F HEX), the error code appears in byte 4: 1 = Forbidden data 2 = Unknown command 3 = Checksum incorrect 4 = Profibus module / telegram length incorrect 5 = (currently not used) 6 = Control system / number of send bytes incorrect 7 = Timeout / control system is not responding

Example: The example used here is a status query from the "AirControl B" (command 1). In this example, the "AirControl B" is set to the RS485 address "2". a) Profibus output data (send data from the Profibus master) 1. byte

RS485 address of the desired control system

2

2. byte

Command (e.g. status query) * A new command is only recognised if this byte has previously been "0"!

1

3. byte

Number of send bytes

0

------ from this point, the send data would arrive at the control system unless 3.byte is "0" b) Profibus input data (receive data for the Profibus master) 1. byte RS485 address of the control system replying 2. byte Command or error message [127 with control system error message! ] 3. byte Status byte / Profibus module:

2 1 255

------- from this point onwards, the reply data from the control system is received ---------4. byte D0 (status 1 more significant byte) 0 5. byte D1 (status 1 less significant byte) 0 … 42. byte 43. byte

… D38 \ reserved D39 /

Last updated: 08/02/2019

32768

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6.3 . Overview of commands

The individual control system commands for the standard protocol are listed and explained below. For each telegram, the transmitted data bytes (useful data) and their significance are explained. The interface description only applies to the standard software of the "AirControl B" and not to “special versions”.

Overview of commands: Command 1

Status query

Command 2

Fault query

Command 3

Read operating data

Command 10

Switch off

Command 11

Switch on

Command 12

Idling/loaded and speed specification

Command 18

Acknowledge messages

Command 40

Read system pass

Last updated: 08/02/2019

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Command 1 – Status query

Command telegram: 0 data bytes

Reply telegram 40 data bytes

Byte

Contents

Data / comment

D0 D1

Status 1

Bit mask 0x0001: Operation / keyed in 0x0002: Motor running 0x0004: Loaded / load valve open 0x0008: Idling (motor running, load valve closed but no ramp-up) 0x0010: Not assigned 0x0020: Maintenance message active 0x0040: Warning message active 0x0080: Fault message active

D2 D3

Status 2

Not assigned

D4

Frequency converter percent display (variable)

UInt8 [%]

D5

Reserved

D6 D7

Delivery volume

UInt16 [m³/h]

D8 D9

Mains pressure

UInt16 [0.001 bar]

D10 D11

Compressor temperature

Int16 [0.1 C°]

D12 D13

Oil temperature

Int16 [0.1 C°]

D14 D15

Reserved

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Byte

Contents

Data / comment

D16 D17

Dew point temperature

Int16 [0.1 C°]

D18 D19

Power consumption of compressor

UInt16 [0.01 kW]

D20 D21

Reserved

D22 D23

Reserved

D24 D25

Reserved

D26 D27

Reserved

D28 D29

Winding temperature 1

Int16 [0.1 C°]

D30 D31

Winding temperature 2

Int16 [0.1 C°]

D32 D33

Winding temperature 3

Int16 [0.1 C°]

D34 D35

Bearing temperature A

Int16 [0.1 C°]

D36 D37

Bearing temperature B

Int16 [0.1 C°]

D38 D39

Reserved

Last updated: 08/02/2019

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Command 2 – Fault query

Command telegram: 0 data bytes

Reply telegram 40 data bytes

Byte

Contents

Data / comment

D0 D1

Maintenance messages

Bit 0: 1: 2: 3: 4: 5:

M001 Intake filter M002 Oil filter M003 Oil separator M004 Motor lubrication M005 Compressor M006: Dryer (option)

7: M008: Annual maintenance

D2 D3

Warning 1 messages

Bit 0: 1: 2: 3: 4: 5:

W021 Compressor temp. increased W022 Mains pressure increased W023 Temperature too low W024 Lower pressure threshold reached W025 Check oil level / heater W026 Calibration incorrect

14: W035 Dew point temperature high

D4 D5

Warning 2 messages

Bit 0: W037 Oil separator 1: W038 Dew point temperature too low 2: W039 Dew point temperature too high 7: W044 I/O module (general) 8: W045 I/O module (addr.1) 9: W046 I/O module (addr.2) 13: W050 Profibus module (addr.31)

Last updated: 08/02/2019

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Byte

Contents

Data / comment

D6 D7

Warning 3 messages

Not assigned

D8 D9

Warning 4 messages

Not assigned

D10 D11

Fault 1 messages

Bit 0: E061 EEPROM defective

04/10/2018

2: E063 Parameter incorrect 4: 5: 6: 7:

E065 Power outage E066 Comp. temp. cable def. E067 Oil temp. cable def. E068 Mains pressure cable def.

9: E070 Dew point temp. cable def. 10: E071 EMERGENCY STOP confirmed 11: E072 Direction of rotation incorrect 12: E073 Motor temperature 13: E074 Overcurrent 14: E075 Overpressure

D12 D13

Fault 2 messages

Bit 0: E077 C temp too high 1: E078 Mains pressure too high 4: E081 Converter fault 5: E082 Diff. pressure oil filter 6: E083 I/O module (address 8) 7: E084 I/O module (address 9) 8: E085 Bearing temp. cable def. A 9: E086 Bearing temp. cable def. B 10: E087 Bearing temp. A too high 11: E088 bearing temp. B too high 12: E090 I/O module (general) 13: E090 Dew point temperature too low 14: E091 Dew point temperature too high

Last updated: 08/02/2019

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ALMiG AirControl B

Byte

Contents

D14 D15

Fault 3 messages

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Data / comment Bit 0: 1: 2: 3: 4: 5: 6:

E093 Winding temp. 1 cable def. E094 Winding temp. 2 cable def. E095 Winding temp. 3 cable def. E096 Winding temp. 1 too high E097 Winding temp. 2 too high E098 Winding temp. 3 too high E099 Fan converter

9: E102 I/O module (address 7)

D16 D17

Fault 4 messages

Not assigned

D18 D19

Fault 5 messages

Not assigned

D20 D21

Fault 6 messages

Not assigned

D22 D23

Fault 7 messages

Not assigned

D24 D25

Fault 8 messages

Not assigned

D26 D27

Fault 9 messages

Not assigned

D28 D29

Fault 10 messages

Not assigned

D30 D31

Fault 11 messages

Not assigned

D32 D33

Free (messages)

Not assigned

D34 D35

Free (messages)

Not assigned

D36 D37

Free (messages)

Not assigned

D38 D39

Free (messages)

Not assigned

Last updated: 08/02/2019

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Command 3 – Read operating data

Command telegram: 0 data bytes

Reply telegram 52 data bytes

Byte

Contents

D0 D1 D2 D3

Operating hours

D4 D5 D6 D7

Hours under load

D8 D9 D10 D11

Reserved

D12 D13

Intake filter maintenance interval

D14 D15

Intake filter maintenance time remaining

D16 D17

Oil filter maintenance interval

D18 D19

Oil filter maintenance time remaining

D20 D21

Separator maintenance interval

UInt16 [h]

D22 D23

Separator maintenance time

Int16 [h]

D24 D25

Data / comment UInt32 [h]

UInt32 [h]

UInt32

UInt16 [h]

Int16 [h]

UInt16 [h]

Int16 [h]

remaining Motor maintenance interval

Last updated: 08/02/2019

UInt16 [h]

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ALMiG AirControl B

Byte

Contents

D26 D27

Motor maintenance time remaining

D28 D29

Compressor maintenance interval

D30 D31

Compressor maintenance time remaining

D32 D33

Dryer maintenance interval

D34 D35

Dryer maintenance time remaining

D36 D37

Reserved

D38 D39

Reserved

D40 D41

Reserved

D42 D43

Reserved

D44 D45

Reserved

D46 D47

Reserved

D48 D49

Annual maintenance interval

D50 D51

Annual maintenance time remaining

Last updated: 08/02/2019

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Data / comment Int16 [h]

UInt16 [h]

Int16 [h]

UInt16 [h]

Int16 [h]

UInt16

Int16

UInt16

Int16

UInt16

Int16

UInt16 [h]

Int16 [h]

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ALMiG AirControl B

6.3.4

V 1.80

04/10/2018

Command 10 – Switch off

This command works in a similar way to the "Remote On/Off" digital input. It is only active if the control system is configured accordingly. Command telegram: 0 data bytes The compressor is switched off!

Reply telegram 0 data bytes

6.3.5

Command 11 – Switch on

This command works in a similar way to the "Remote On/Off" digital input. It is only active if the control system is configured accordingly. In addition, the control system must have been keyed in through the keyboard beforehand. Command telegram: 0 data bytes The compressor is switched on!

Reply telegram 0 data bytes

Last updated: 08/02/2019

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ALMiG AirControl B

6.3.6

V 1.80

04/10/2018

Command 12 – Idling/loaded and speed specification

This command must be repeated at least every 20 seconds as the compressor will otherwise switch back to the internal pressure control. In addition, the "External pressure control" must be activated. Command telegram: 4 data bytes Byte

Contents

D0

Reserved (0)

D1

Idling / loaded

Data / comment UInt8 (0) Bit 0: Idling / loaded control deactivated 1: Reserved 2: No load request 3: Load request

D2 D3

Target value for speed

UInt16 4000 – 20000 correspond to min. – max. 0: Speed specification deactivated

Reply telegram 20 data bytes Byte

Contents

Data / comment

D0 D19

Reserved

Not relevant for loaded / idling and speed specification

6.3.7

Command 18 – Acknowledge messages

Command telegram: 0 data bytes Resettable faults, warnings and maintenance prompts are acknowledged!

Reply telegram 0 data bytes

Last updated: 08/02/2019

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ALMiG AirControl B

6.3.8

V 1.80

04/10/2018

Command 40 – Read system pass

Command telegram: 0 data bytes Reply telegram 87 data bytes

Byte

Contents

Data / comment

D0 :: D14

Model

15-character ASCII text

D15 :: D27

Factory no.

13-character ASCII text

D28 :: D42

DP no.

15-character ASCII text

D43 :: D57

Commission no.

15-character ASCII text

D58 :: D80

Circuit diagram no.

23-character ASCII text

D81 D82

Software version 1/100 version number (#.##)

D83 :: D86

Reserved

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

7 Transferring new program to control 1. Switch off supply voltage to the control system; 2. Press the ▲ and 0 keys at the same time and, while doing so, switch the control system's supply voltage back on. 3. "FLASH: x.xx" now appears in the display. 4. The program (HEX file) can now be transferred to the control system! 5. Once the program has been successfully transferred to the control system, the supply voltage has to be briefly switched off and on again.

Error in control system's program memory If an error is detected in the program memory (Flash-EPROM) after switching on the mains, the following message appears in the temperature display: "noAPP", "FLASH" => In such a case, the program must be transferred to the control system once again!

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

8 Document version Doc. version Softw. version

Author Content of changes

V 0.80 08/11/2011

V 0.80 08/11/2011

RB

Control of the AA module and the MK200 modules integrated; "Flex" system types added;

V 0.90 16/12/2011

V 0.90 16/12/2011

RB

It is now possible to also change the protocol and the data format for the RS485 interface.

V 0.92 01/08/2012

V 0.92 01/08/2012

RB

The range for fault, warning, maintenance numbers was changed: * 01-19 = Maintenance prompts; * 21-59 = Warnings; * 61-99 = Faults; The faults / warnings / maintenance prompts have been renumbered so they have identical number ranges for all 3 new control systems (AC-B, AC-P, AC-HE). The terminal designations have been modified. The "Autom.Opt." operating mode is no longer available! Warnings / maintenance prompts are now displayed in "magenta".

V 0.94 10/08/2012

V 0.94 10/08/2012

RB

Minor corrections in the description (images); The default value for the FC selected was changed (for the time being) from "Yaskawa" to "Emotron".

V 0.95 14/11/2012

V 0.95 14/11/2012

RB

"Bosch-Rexroth" can now be also selected as "FC type" (Item 3.5.20). "Calibration param. fault" (message 62) has now become "Calibration param. warning" (message 26). The "Dew point temperature monitoring" function has now also been added here (Item 3.5.22). To be able to differentiate between fault and warning with the "Emotron FC", the status of "Relay 1" (Emotron) is also read out here. If this relay is switched on, the FC reports a corresponding fault.

V 0.99 03/04/2013

V 0.99 03/04/2013

RB

Modifications for network control/web server; additional system types "Flex 3s/4s/6s/8s";

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

Doc. version Softw. version Author Content of changes V 1.00 04/06/2013

V 1.00 04/06/2013

RB

Change in control parameters (code 75) * The param. "Speed reduction by" is now entered in [%] instead of [mA].

V 1.00 11/06/2013

V 1.00-b2 11/06/2013

RB

Standard compressor: * Fan always via output "A5"; * Heater always via output "A6";

V 1.10 17/06/2013

V 1.10 17/06/2013

RB

The "VARIO" system types were removed. With the "COMBI" system type, heater and fan are now controlled in the same way as with the standard software. With system type "COM-T" (Combi with dryer), output "A5" is used to control the dryer and "A6" to control the condensate valve (as previously).

V 1.11 16/07/2013

V 1.11 16/07/2013

RB

In the case of systems "With frequ. Converter" (Item 3.5.13), the message "Ready" is output at output "A2" and the message "Operation" at output "A3".

V 1.12 21/08/2013

V 1.12 21/08/2013

RB

Control for "YASKAWA FC" adjusted.

V 1.13 12/09/2013

V 1.13 12/09/2013

RB

The default values for var. system types (flex) were updated. Offset for measured temperature measurement value (see Item. 3.5.23)

V 1.20 11/12/2013

V 1.20 11/12/2013

RB

The "Heater/fan" menu (see: Item 3.5.3) was rearranged and expanded to include the "Dryer" function (standard compr. / see also: Item 4.6). In the event of a "Module warning" (MK200 module) the corresponding module is now indicated by an additional flashing symbol (1 / 2 / 7). All frequency controlled systems must now run through the "Commissioning up sequence" before continuing (see: Item 3.4 and Item 4)!

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

Doc. version

Softw. version Author Content of changes

V 1.30 16/04/2014

V 1.30 16/04/2014

RB

Additional sub-menu for the integration (activation) of additional MK200 modules (see: Item 3.5.23). The module warning (MK200, addr. 7) has now become a module fault (only MK200-4AE4R!) The "Heater switch-off temp." parameter (previously code 15) had now been moved into the heater menu (code 5) (see: Item 3.5.3). The procedure for the "Additional heater" has been changed! The data set structure for calling up data via "Modbus RTU" was updated to the level of the "AC-P" (only for the data relevant for the "AC-B"!). Here, the commands "1/2/3" were additionally implemented for calling up data via "Profibus DP", (for details, see description for the "AC-HE"). Two additional FC types were implemented (ABB, DELTA // see: Item 3.5.19). The "Commissioning sequence" (FC) can now be started directly (without service code). Selection of the system type now consists of two steps, first the group and then the type (see Item 3.5.10)

V 1.31 15/05/2014

V 1.31 15/05/2014

RB

The "Utilisation" parameter (addr. 23 / 0-100%) has been added to the "Modbus data". The control of FC types "ABB" and "Delta" was corrected again. With regard to the selection "System type = Flex", the following presettings were modified: * Code 5 => No heater; * Pressure => 13 bar; The first maintenance for "Oil/oil filter" after 500 hours is now no longer required.

V 1.32 15/07/2014

V 1.32 15/07/2014

RB

The compressor data for system types "Variable", "Flex" and "Combi" were modified according to ALMiG specifications. The "Basic load cycle OK" function was changed back again (if "code 8 != 2" then "Basic load cycle OK" always "active" for internal purposes).

V 1.40 18/09/2014

V 1.40 18/09/2014

RB

Changes to the dryer activation with compressor type "Combi-T" (see Item 3.5.13)

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

Doc. version

Softw. version Author Content of changes

V 1.41 22/10/2014

V 1.41 22/10/2014

RB

Changes to activation of the condensate valves with the "Combi-T" type (Item 3.5.11). Par. 3 can now be used to select when the condensate valve is activated.

V 1.43 28/10/2014

V 1.43 28/10/2014

RB

The "Commissioning sequence" (FC) is now once again only performed with "FLEX systems" and no longer with all control compressors.

V 1.50 09/03/2015

V 1.50 09/03/2015

RB

The "Service code" can now be set at will (see Item 3.5.24).

V 1.51 07/05/2015

V 1.51 07/05/2015

RB

The delivery volume of the compressor is now stated in "m3/h" and no longer in "m3/h" (see Item 3.5.10, par. 4).

V 1.60 22/09/2016

V 1.60 22/09/2016

RB

There is now an additional maintenance interval "Annual maintenance" (24h x 365 = 8760h). A countdown to this interval commences as soon as the supply voltage is connected to the control (see Item 3.1, Par. 14). Once theinterval has expired (< 100h of time remaining), the warning [8] "M 365" appears (see Item. 3.6.2). The operating hours, hours under load, load cycles and motor starts are now additionally recorded by counters that cannot be modified (see Item 3.5.25). The fault memory can now no longer be deleted!

V 1.61 17/02/2017

V 1.61 17/02/2017

RB

Two new system groups have been added ("V-Drive" and "G-Drive"). If a nominal value of 0 hours is stored for a maintenance interval, this interval is deactivated (i.e. no message is sent out). Setting range for the maintenance intervals extended to 0 – 30000 (previously: 0 – 20000).

V 1.62 10/04/2017

V 1.62 10/04/2017

RB

Deactivation of a maintenance interval by entering "0 hours" has been removed again!

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

Doc. version

Softw. version Author Content of changes

V 1.63 22/06/2017

V 1.63 22/06/2017

RB

Now, with the "Combi with dryer" type, the function "Recirculation" can be switched on/off in parameter 1 at code level 0005: ( par. 1 = 0 : recirculation OFF par. 1 > 0 : recirculation ON )

V 1.70 29/09/2017

V 1.70 29/09/2017

RB

a) Extension of system types "G-Drive" and "V-Drive" (new: 38, 45, 56, 75); b) Option "Bearing temperature monitoring" (see Item 3.5.21) c) Option "Winding temperature monitoring" (see Item 3.5.21) d) Change in the optional temperature display (T2) in the default screen display (Item 3.2) e) Option "Fan control via FC" (see Item 3.5.3) "Yaskawa" type is always used here as frequency converter, which then always has to be programmed at address 2 (see Item 4.9).

V 1.71 16/10/2017

V 1.71 16/10/2017

RB

The temperature thresholds for the fan control are now split as follows: (see Item 3.5.3 / 4.6). a) Fan without FC "Fan ON" + "Fan OFF" b) Fan with FC "Fan MIN" + "Fan MAX"

V 1.72 07/02/2018

V 1.72 06/02/2018

RB

The "Additional heater" function was modified: a) If "Heater = 1" (i.e. with compressor temperature), then digital input "E3" (heater oil level) is also monitored here. b) The setting range for the thresholds "Heater on/off" is now limited to +2 to +15°C.

RB

The description for "Modbus RTU" (Item 5) and "Profibus DP" (Item 6) is now included in this description.

V 1.72a 26/03/2018

Last updated: 08/02/2019

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ALMiG AirControl B

V 1.80

04/10/2018

Doc. version

Softw. version Author Content of changes

V 1.72b 06/08/2018

V 1.72 06/02/2018

RB

Codes for changing OEM-type included (see item 3.4 / code overview)

V 1.80 08/10/2018

V 1.80 04/10/2018

RB

Pressure dependent min. speed included (see item 3.5.12 / set freq.conv. control par.)

Last updated: 08/02/2019

Page: 72 / 73

ALMiG Kompressoren GmbH Adolf-Ehmann-Straße 2 73257 Köngen Phone +49 7024 9614 0 Email [email protected] Internet www.almig.de