23 0 5MB
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
Last updated: 08/02/2019
Page: 3 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 4 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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.
Last updated: 08/02/2019
Page: 5 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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),
Last updated: 08/02/2019
Page: 6 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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)
Last updated: 08/02/2019
Page: 7 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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,
Page: 8 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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!
Last updated: 08/02/2019
Page: 9 / 73
ALMiG AirControl B
Last updated: 08/02/2019
V 1.80
04/10/2018
Page: 10 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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.
Last updated: 08/02/2019
Page: 11 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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, %
Last updated: 08/02/2019
Page: 12 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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).
Last updated: 08/02/2019
Page: 13 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Page: 14 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 15 / 73
ALMiG AirControl B Menu item
V 1.80
04/10/2018
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
Page: 16 / 73
ALMiG AirControl B Menu item
V 1.80
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!
Last updated: 08/02/2019
Page: 17 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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.
Last updated: 08/02/2019
Page: 18 / 73
ALMiG AirControl B
3.5.3
V 1.80
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
Last updated: 08/02/2019
Page: 19 / 73
ALMiG AirControl B
Note:
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 20 / 73
ALMiG AirControl B
3.5.5
V 1.80
04/10/2018
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.
Last updated: 08/02/2019
Page: 21 / 73
ALMiG AirControl B
3.5.6
V 1.80
04/10/2018
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
Page: 26 / 73
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%
Page: 27 / 73
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
Page: 28 / 73
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
Page: 30 / 73
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 ]
Page: 31 / 73
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
Page: 32 / 73
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
Page: 33 / 73
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
Page: 35 / 73
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
Page: 37 / 73
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
Page: 39 / 73
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
Page: 40 / 73
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
Page: 41 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 42 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 43 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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.
Last updated: 08/02/2019
Page: 44 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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: ---
Last updated: 08/02/2019
Page: 45 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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 ---
Last updated: 08/02/2019
Page: 46 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Page: 47 / 73
ALMiG AirControl B
V 1.80
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]
Page: 48 / 73
ALMiG AirControl B
V 1.80
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
Last updated: 08/02/2019
0 = Automatic mode Page: 49 / 73
ALMiG AirControl B Register
Address
V 1.80 Contents
04/10/2018
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]
Last updated: 08/02/2019
Page: 50 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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.
Page: 51 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Page: 52 / 73
ALMiG AirControl B
6.2.1
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 53 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Page: 54 / 73
ALMiG AirControl B
V 1.80
04/10/2018
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
Page: 55 / 73
ALMiG AirControl B
6.3.1
V 1.80
04/10/2018
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
Last updated: 08/02/2019
Page: 56 / 73
ALMiG AirControl B
V 1.80
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
04/10/2018
Page: 57 / 73
ALMiG AirControl B
6.3.2
V 1.80
04/10/2018
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
Page: 58 / 73
ALMiG AirControl B
V 1.80
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
Page: 59 / 73
ALMiG AirControl B
Byte
Contents
D14 D15
Fault 3 messages
V 1.80
04/10/2018
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
Page: 60 / 73
ALMiG AirControl B
6.3.3
V 1.80
04/10/2018
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]
Page: 61 / 73
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
V 1.80
04/10/2018
Data / comment Int16 [h]
UInt16 [h]
Int16 [h]
UInt16 [h]
Int16 [h]
UInt16
Int16
UInt16
Int16
UInt16
Int16
UInt16 [h]
Int16 [h]
Page: 62 / 73
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
Page: 63 / 73
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
Page: 64 / 73
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
Page: 65 / 73
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
Page: 66 / 73
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
Page: 67 / 73
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
Page: 68 / 73
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
Page: 69 / 73
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
Page: 70 / 73
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
Page: 71 / 73
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