Controltronik

Engineer’s Manual

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 OPERATING INSTRUCTIONS FOR CONTROLTRONIK

CONTROL KEYS DISPLAY LED’s

K1 Scroll parameter display A1a Over temperature cut out

K2 Start button A1b Motor overload cut out

K3 Stop button A1c Sense of rotation

K4 Increase parameter A1d Oil filter warning

K5 Decrease parameter A1e Air filter warning

K6 Reset button A1f Separator warning

A1g Automatic restart after power loss

A1h Remote control operation

A1o Power on

ADDITIONAL FUNCTIONS

B Display panel

SB2 Emergency stop

SL Dryer on / off switch ( Genesis only )

DP Dewpoint indicator ( Genesis only )

The above display will give all operating, warning and fault information during operation.

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 CONTROL MENU’S

MENU 1 control menu

DANGER

Incorrect setting of the operating values can cause operational problems with the
compressor.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 01 ( menu 01 )

Max pressure value Up to Max pressure of model

K1 x 1, Min pressure value Normally 1 bar below max

K1 x 2, Bar or PSI Alternates display

K1 x 3, Celsius or Fahrenheit Alternates display

* K1 x 4, Condensate drain opening time Between 0.4 sec and 10 sec

* K1 x 5, Condensate drain duration between openings,

Between 10 sec and 1800 sec

K1 x 6, Run on timer setting 0 = continuous / 2 – 240 minutes

K1 x 7, Return to Max pressure.

* Applies to Genesis only, values shown but not functional on Smart range

MENU 2 reset maintenance

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 02 ( menu 02 )

The above procedure will re – set all service intervals that had reached zero hours.

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From Version E09 the following procedure should be used.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 02 ( menu 02 )

Use K4 to change the value to the default time (set in menu 12) then use K1 to scroll to the next
item to be re-set and repeat the above procedure, carry out this for each expired service item.

Return to the normal display with K6

Please note! The maintenance periods can now be re-set when the timer is within 100 hours of
zero.

MENU 3 auto restart

DANGER

During operation in auto restart mode the compressor can start up automatically at any
time !

Prior to accessing this menu, Menu 35 must be entered to unlock the access.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 03 ( menu 03 )then press buttons K2
and K3 together.

Display reads “ 0 “ Change with K4 from 10 – 240 sec

“0” = Auto re-start off.

10 – 240 = Duration of power loss sustained in seconds from which machine will re- start
automatically.
If chosen then LED A1g will illuminate.

MENU 5 Remote control

DANGER

During operation in Remote control mode the compressor can start up automatically at
any time !

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 05 ( menu 05 ) then press buttons K2
and K3 together.

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 Remote control of Motor or LoAd

K1 x 1, Remote control Local / Remote

K1 x 2, Air temp reading tON Enable or tOFF disable

K1 x 3, rs485 + number Select rs485 (not available yet)

MENU 10 Limit values

DANGER

Incorrect setting of the limit values can cause severe damage to the compressor and
could invalidate the warranty !

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 10 (menu 10) then press buttons K2
and K3 together.

TP 1 – 4 according to pressure of compressor TP 1 = 8Bar

TP 2 = 10Bar
TP 3 = 13Bar
TP 4 = 15 Bar
Should any adjustments of the Factory limit values be required then these must be adjusted
only in TP 0, first select the correct TP value 1 – 4 for the type of pressure, this will copy the set
values to TP 0, once copied enter TP 0 and adjust only the values to be changed, the
compressor should then be left operating in TP 0 with the new set values.

Possible settings in TP 0 are as follows:

K1 x 1, Max pressure 3 – 16 bar

K1 x 2, Centre temp for fan thermostat 0 – 110 deg C

K1 x 3, Delta T of fan switching 1 – 20 deg C

K1 x 4, Fan on time after power off 10 – 120 sec’s

K1 x 5, Max temp cut out 0 – 125 deg C

K1 x 6, Fan status / alarm

K1 x 7, Star / Delta time 0 – 15 seconds

K1 x 8, Soft stop timer 0 – 75 seconds

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K1 x 9, Blow down time 0 – 240 seconds

K1 x 10, Base time

K1 x 11, Total hours

K1 x 12, Load hours

K1 x 13, Return to max pressure.

Ensure all TP values are checked before putting machine back into service.

MENU 11 Digital inputs

DANGER

Adjustment of the digital inputs from their original settings could prevent the
compressor from starting !

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 11 ( menu 11) Then press buttons K2
and K3 together.

Factory default settings are as follows :

Input NR 2 = N/C

K1 x 1, Input NR 3 = N/C

K1 x 2, Input NR 4 = N/C

K1 x 3, Input NR 5 = N/O

K1 x 4, Input NR 6 = N/O

K1 x 5, Input NR 7 = N/O

K1 x 6, Input NR 8 = N/O

Input NR 1 can not be changed as this is always N/C and assigned to Emergency Stop.

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MENU 12 Maintenance Interval Defaults (NEW MENU FROM E09 ONLY)

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 05 ( menu 05 ) then press buttons K2
and K3 together.

The following maintenance intervals can be programmed in this menu, these values will take
effect after the factory stored value has elapsed, ie the value programmed for the Oil filter
change will take effect after the initial 100 hr interval programmed by the factory.

AFILT = 100 to 2000 Hours Increase with K4

K1 x 1, OFILT = 100 to 2000 Hours Increase with K4

K1 x 2, OSEP = 100 to 4000 Hours Increase with K4

K1 x 3, OILcH = 100 to 8000 Hours Increase with K4

When setting intervals ensure new value has stopped “flashing” before moving to next item to
ensure the new value is stored.

MENU 20 Test menu

Prior to accessing this menu, Menu 35 must be entered to unlock the access.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 20 ( menu 20 )then press buttons K2
and K3 together.

Display will test all LED’s and “8” will cycle through display.

K5 x 1, Inputs test 0 = OK, 1= not OK

All 8 inputs should be looked at ( only number 5 should read 1 )

K5 x 9, Output tests ( tUSC 1)

K5 x 10, Line contactor

K5 x 11, Star contactor

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MENU 20 Continued

K5 x 12, Delta contactor

K5 x 13, Load solenoid

K5 x 14, Fan

K5 x 15, Drain valve

K5 x 16, Rotation test ( press start to test )

Exit by pressing K3 and then K6.

MENU 35 ABAC Codes

DANGER

Use of the factory codes to change original settings could cause severe damage to the
compressor and may invalidate the warranty!

Access to this menu is by holding buttons K4 and K5 together until all display LED’s illuminate
and flash. Use button K4 to change display to 35 ( menu 35 ) then press buttons K2 and K3
together.
This will “ unlock “ the access to ABAC factory settings.

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FAULT DISPLAYS

All faults should be rectified and then cleared with the re-set button K6

Display reads --- Fault with Temperature transducer

Display reads ----- Fault with Pressure transducer

Display reads PCO Machine has gone over pressure(internal)

All LED’s flashing Emergency stop depressed

A1c illuminated Reverse direction of rotation

A1o off Fuse blown or power loss

A1a flashing (slow) Warning machine running over temperature

A1a flashing (fast) Machine cut out on over temperature

A1b illuminated Machine cut out on motor overload

A1d illuminated Change oil filter warning

A1e illuminated Change air filter warning

A1f illuminated Change separator warning

Display reads OILcH Oil change required

Display reads dP Air Air filter blocked

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OPERATION

During normal operation the compressor shows the operating status and the current receiver
pressure.

When first switching on the display will light and scroll through its start procedure. If A1c
illuminates then the power should be switched off at the supply and two incoming phases
should be reversed, once the power is restored press button K6 to re-set.

Press button K2 to start the compressor, the display will show A 0.0 or C 0.0 depending on
whether automatic or continuous run has been chosen ( see menu 1 ). When the intake valve
solenoid is energised to load the compressor an LED will illuminate next to the A or C, the 0.0
will rise with the pressure in the tank until the compressor off-loads at its maximum pressure
( see menu 1 ) If after 5 minutes there is no requirement for air then the compressor will shut
down in “ auto shutdown “ and will automatically re – start upon a requirement for air.

Whilst the power is on to the compressor button K1 can be used to scroll the following
information

K1 x 1, Discharge air / oil temperature (permanent display with twin display unit)

K1 x 2, Total run hours

K1 x 3, Loaded hours

K1 x 4, Hours left to service

K1 x 5, Back to pressure display

To stop the compressor press button K3 and the compressor will run for approximately 30
seconds depending on setting ( see menu 10 )
The emergency stop button SB2 will stop the compressor immediately.
The maintenance warning lights are pre – programmed and not adjustable, the following values
are programmed and after service should be re – set via menu 2.

ACTION 100 HRS 1000 HRS 2000 HRS 3000 HRS 4000 HRS
AIR FILTER # # # # #
OIL FILTER # # # # #
SEPARATOR # # # #
OIL CHANGE # # #

Air filter needs check only and verify at 100Hr

When oil change is required display will show OIL cH
Procedure is repeated with the exception of 100Hr service.
NOTE!
This applies to software up to E09, for later units use new Menu 12 to programme intervals and
modified re-set procedure as in Menu 2.

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