Air Control 3 Dynamic: Manual

Air Control 3 Dynamic
Manual
Version: 2.03
as of: 20.10.2008
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Content
General Information ............................................................................................. 3

1 Hardware ............................................................................................................ 4
1.1 Microprocessorlogic......................................................................................................... 4
1.2 Key Pad ............................................................................................................................ 4
1.3 Display ............................................................................................................................. 4
1.4 Analogue Inputs ............................................................................................................... 4
1.5 Digital Inputs.................................................................................................................... 4
1.6 Digital Outputs ................................................................................................................. 5
1.7 Interface (Optional) .......................................................................................................... 5
1.8 Power Supply, Connectors, Housing................................................................................ 5
1.9 Terminal connections ....................................................................................................... 5
2 Basic Screen ....................................................................................................... 8
2.1 Analogue Values (ENTER).............................................................................................. 9
2.2 Usage (F1 Usage) ........................................................................................................... 10
2.3 LLC – State (F2 LLC).................................................................................................... 11
2.4 Service (F3 Service) ....................................................................................................... 12
2.5 Type plate ...................................................................................................................... 12
2.6 Line Pressure Diagram (F1 Pressure)............................................................................. 13
2.7 Diagram temperature before second stage (F2 Temp) ................................................... 14
2.8 Diagram bearing temperature A-side (F1 B.Temp.A)) .................................................. 15
2.9 Diagram bearing temperature B-side (F2 B.Temp.B).................................................... 16
2.10 Diagram delivery quantity (day) (F3 Air qu.d.) ........................................................... 17
2.11 Delivery quantity – weekly profile (F4 Luftm.Wo.).................................................... 18
3 Menu System.................................................................................................... 19
3.1 Menu limit values........................................................................................................... 21
3.1.1 Menu pressure limits ............................................................................................. 22
3.1.2 Menu temperature limits ....................................................................................... 22
3.1.3 Menu vibration limits............................................................................................. 24
3.2 Menu run parameters...................................................................................................... 25
3.3 Menu maintenance schedule ......................................................................................... 27
3.4 Menu timer ..................................................................................................................... 29
3.4.1 Switching times compressor .................................................................................. 29
3.4.2 Switching times LLC ............................................................................................. 30
3.4.3 Switching times channel x ..................................................................................... 31
3.5 Menu fault log ................................................................................................................ 32
3.6 Menu display parameters ............................................................................................... 33
Air Control 3 Dynamic V 2.03 page 1 of 53 as of: 20.10.2008

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3.6.1 Menu Diagrams...................................................................................................... 34
3.6.2 Menu Text ............................................................................................................. 36
3.7 Configuration menu....................................................................................................... 37
3.7.1 Menu measurement points ..................................................................................... 38
3.7.2 Menu current parameter......................................................................................... 39
3.7.3 Menu control parameter......................................................................................... 40
3.7.4 Menu Communication ........................................................................................... 41
3.8 Menu Lead Lag Control ................................................................................................. 43
3.8.1 Menu Priorities ...................................................................................................... 44
3.9 Menu Diagnostics........................................................................................................... 45
4 Program operation ........................................................................................... 46
4.1 Operation states .............................................................................................................. 46
4.2 Maintenance intervals .................................................................................................... 47
4.3 Default settings for all parameters ................................................................................ 47
5 Messages .......................................................................................................... 48
5.1 Faults .............................................................................................................................. 48
5.2 Warnings / Maintenance messages ................................................................................ 49
5.3 Error in the control’s program store .............................................................................. 50
6 Annex ............................................................................................................... 51
6.1 Codes.............................................................................................................................. 51
6.2 Software history ............................................................................................................. 51
6.3 Downloading new software onto the control ................................................................. 52

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General Information
The control contains the following functional blocks:

- Microprocessorlogic used for all control, monitoring and display purposes (includes
EEPROM for data storing)
- Key pad with 10 keys used to switch on/off the compressor as well as for data input
- Customer specific LC-Display for displaying current values of variables, operation mode
and pending messages
- Analogue logic for measuring and processing values of line pressure, end temperature
and oil temperature
- Digital inputs and outputs use to control the compressor;

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1 Hardware
1.1 Microprocessorlogic
- 16 Bit microcontroller including watchdog

- Powerfail recognition (down time > 30 ms)
- 512 KByte Flash-EPROM
- 512 Byte EEPROM (data storage)
- 128 Kbyte RAM
1.2 Key Pad
- Key pad with haptic feedback

- 10 keys
- customer specific design
1.3 Display
- Graphical - LCD with 240 x 128 pixel

- LED background lighting
- 2 LEDs (green, red)
1.4 Analogue Inputs
- galvanically isolated
- voltage 18 VDC
- 1 input 4-20mA (corresponding to 0-16 bar / apparent ohmic resistance 200 Ohm,
resolution 10 bit)
- 2 inputs for KTY temperature sensors (measurement current 1mA, resolution 10 bit)
1.5 Digital Inputs
- galvanically isolated
- voltage 12 VDC and 24 VDC
- 6 standard digital inputs 24 VDC, 10mA
- 2 inputs for PTC-temperature sensors 12 VDC (optionally usable as standard digital
inputs)

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1.6 Digital Outputs
- 5 Relay outputs, NO with one common contact, 250 VAC 6A,

thereof: one output with varistor for use with magnetic valve connection
load capacity of the common connector: 250 VAC 6A
- Relay output, changeover, 250VAC, 6A;
1.7 Interface (Optional)
- RS-232 or RS-485 interface
1.8 Power Supply, Connectors, Housing
Power supply 10 VAC (5 VA) and 18 VAC (5 VA), +/- 10%, 50/60 Hz
- Connection via Phoenix connectors (type MSTBVA for relay outputs,
type Mini-Combicon for all other connections);
- Compact housing with front plate 240mm*120mm, depth 35mm
- instrument panel mounted with four threaded bolts (3mm)
1.9 Terminal connections
Pin 1 protective earth connector for electronic

Pin 2 0 V (10 VAC)
Pin 3 10 V (10 VAC)
Pin 4 0 V (18 VAC)
Pin 5 18 V (18 VAC)
Pin 6 common for Pin 7-12

Pin 7 Relay output 1, net (A01.0)
Pin 8 Relay output 2, star (A01.1)
Pin 9 Relay output 3, triangle contactor (A01.2)
Pin 10 Relay output 4, magnetic valve (with varistor) (A01.3)
Pin 11 Relay output 5, heater/ fan (A01.4)
Pin 12 ( free )
Pin 13 Relais 7, NC / general fault (A01.5)

Pin 14 Relais 7, Common
Pin 15 Relais 7, NO
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Pin 16 shielding connection
Pin 17 analogue inputs, ground (AI00 – AI02)
Pin 18 KTY-1, signal (final temp.) (AI02)

Pin 19 KTY-2, signal (oil temp.) (AI01)
Pin 20 4-20mA-input signal (line pressure) (AI00)
Pin 21 4-20mA-input, voltage 18 VDC
Pin 22 Dig. Input 8, LLC: on-/off-load (I02.7)

Pin 23 Dig. Input 7, Remot on/off or LLC OK (I02.6)
Pin 24 Dig. Input 6, Fault emergency stop (I02.5)
Pin 25 Dig. Input 5, Fault Diff. Press. separator (I02.4)
Pin 26 Dig. Input 4, Fault rotation direction (I02.3)
Pin 27 Dig. Input 3, Fault over pressure (I02.2)
Pin 28 Dig. Input 2, Fault over current (I02.1)
Pin 29 Dig. Input 1, (PTC) Fault motor temperature (I02.0)
Pin 30 voltage 12 VDC (PTC)
Pin 31 voltage 24 VDC
Pin 32 Ground RS-485 / RS-232  Option:

Pin 33 RXD RS-485 / RS-232  interface
Pin 34 TXD RS-485 / RS-232 
Pin 35 power RS-485 / RS-232 
Pin 36 Sig. B 
Pin 37 Sig. A  Option:
Pin 38 GNDx  connection for
Pin 39 18 Vac  MK200-modules
Pin 40 18 Vac 
Please note:
Before using an interface module (RS232 or RS485) set the two dip-switches near Pin
35 (on the backside) to “off”!

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Air Control 3 Dynamic V 2.03 Seite 7 von Stand: 20.10.2008

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2 Basic Screen
After connecting the control with the power supply the following start up screen will appear:
After about four seconds it will automatically switch over to the basic screen:
The basic screen shows current status information, line pressure date and time. At the bottom
of the screen the current setting of the soft keys (function keys) F1 to F4 is displayed. As
there are more than four functions available in the basic screen, the setting for the soft keys
can be changed using the keys and from the key pad.
Press the corresponding function key to reach the information you are looking for.
In order to see the current analogue values press the ENTER key.

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2.1 Analogue Values (ENTER)
Press ENTER to view current analogue values.

Depending on the configuration of the machine up to nine current analogue values will be
displayed on this screen (see also configuration menu).
The possible values including
Line pressure bearing temperature A temperature before 2nd stage
Oil pressure 2 bearing temperature B/ oil pressure 3 oil temperature
Motor current vibration temperature after aftercooler
In order to get back to the basic screen press F4.

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2.2 Usage (F1 Usage)
This bar graph shows current operation hours, load hours, off load hours and stop hours.
The first bar graph shows the operation hours and will always fill the complete width of the
screen. All following bar graphs will use the same scaling.
The second bar graph starts off at the left side and shows the current load hours. Bar graph
number 3 shows off load hours and starts at the end of the load hours. That way the relation
between on and off load hours can easily be seen.
The last bar graph shows the stop hours. Should the number of stop hours exceed the
operation hours this graph will be cut short.
Below the bar graphs the so far produced air quantity is displayed. This value will be
calculated using load hours and the maximum delivery quantity as set in the configuration
menu.

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2.3 LLC – State (F2 LLC)
This screen is only available if LLC is set to YES in the LLC menu.
The diagram shows the states of up to five compressors of the LLC (with one auxiliary LLC
module).
Lead Lag Control

Load
Off-Load
Ready
Fault
“Fault” and “off load” for the compressors #2-#5 can only be displayed if the corresponding
feedbacks (fault and motor running) are connected to the auxiliary module. Otherwise only
“ready” and “load” will be displayed.
If the LLC includes more than five (up to nine) compressors (two auxiliary modules) the
diagram will look as follows
Load Lead Lag Control
Off-Load
Ready
Fault

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2.4 Service (F3 Service)
On this page the current state of the maintenance intervals is displayed.
Whereas:
1 – Maintenance interval air filter
2 – Maintenance interval oil filter
3 – Maintenance interval oil separator
4 – Maintenance interval motor
5 – Maintenance interval compressor
Each bar’s length corresponds to the length of the corresponding maintenance interval. The
filling shows the amount of time left until the next maintenance.
Scaling depends on the longest maintenance interval.
If the time until the next maintenance is less than 100 hours the bar will start flashing.
2.5 Type plate
This page shows machine specific data
All texts can be set in corresponding menu.

The installation date will be set after the first operation that exceeds 10 hours.

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2.6 Line Pressure Diagram (F1 Pressure)
This screen shows the line pressure diagram.
To change the scaling choose the value you would like to change using the up and down keys
and . Press ENTER to switch to edit mode. The cursor will start blinking and the
softkeys F1 to F4 will get the following functionalities:
Use the up and down keys - and - in order to change the current value. Move the cursor
using the function keys F1 and F2.
F3 leaves the edit mode without keeping any changes. Use ENTER to take over the new
value.
Please note that it is not possible to change the time limits of the x-axis if the diagram is in
automatic mode (X-AUTO on) as it will always show the most recent values of the line
pressure.
After leaving the edit mode the line graph adjusts to the new scaling and the functions of the
softkeys F1 to F4 switch back to their original functionalities.
F1 X-Auto automatic scaling of the x-axis

F2 X/Y-Init reset scaling to the values as set in “display parameters->diagrams”
F3 Delete delete ALL stored values (please note: this refers to ALL diagrams!)
F4 Back switch back to the basic screen

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2.7 Diagram temperature before second stage (F2 Temp)
This diagram shows the temperature before the second stage
To change the scaling please choose the value you would like to change using the up and
down keys and . Press ENTER to switch to edit mode. The cursor will start blinking and
the softkeys F1 to F4 will get the following functionalities:
F3 leaves the edit mode and ignores all changes. Use ENTER to take over the new value.
pressure.


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2.8 Diagram bearing temperature A-side (F1 B.Temp.A))
This diagram shows the bearing temperature (A-side)
pressure.


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2.9 Diagram bearing temperature B-side (F2 B.Temp.B)
This diagram shows the bearing temperature (B-side).
pressure.


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2.10 Diagram delivery quantity (day) (F3 Air qu.d.)
This diagram shows the delivery quantity.
pressure.


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2.11 Delivery quantity – weekly profile (F4 Luftm.Wo.)
This diagram shows the total daily delivery quantity for a time span of one week.
pressure.
After leaving the edit mode the line graph adjusts to the new scaling.
F4 leads back to the basic screen.

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3 Menu System
In order to reach the menu system, press the INFO button.
The code screen will appear:
Use the up and down keys to change the current digit (wherever thecursor is blinking). Move
the curser to left and right using the soft keys F1 and F2. Enter sets the code and switches to
the main menu or starts the action corresponding to the code (see Annex for a list of possible
codes).
Depending on the code level the parameters in the menus can be either “read only” or
changeable.
The main menu will be displayed:

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Within the menu system the operation works as follows:
Move the cursor up and down in order to choose the menu item. Press enter to activate the
current item. This results either in a change to the corresponding submenu or switches to edit
mode. If in edit mode the cursor will start blinking and the current value can be changed. The
softkeys will have the following functionalities:
The keys up and down ( , ) change the digit with the blinking cursor below. In order to
move the cursor, use F1 and F2.
F3 leaves the edit mode without storing the new values. The ENTER key stores the new value
and leaves the edit mode.If the new value is not within the allowed range the parameter is set
to its closest limit.
Changing a textvalue follows the same steps as above:

Switch to edit mode with the ENTER key; use the up and down keys to toggle through the
textvalues. Press ENTER again to store the new value or use F3 (Escape) to get leave the edit
mode without taking over the new value.
Editing text variables:

Again the ENTER key switches to edit mode. The cursor starts blinking below the current
letter. This letter can be changed using the up and down keys. Move to the next letter using F1
and F2. Press ENTER to store the new text or use F3 (Escape) to get leave the edit mode
without changing the text.

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3.1 Menu limit values
This menu contains the pressure and temperature limits.
Parameter Description/ value range/ default value Level

Start pressure Lower limit for the pressure control. C
Value range: 3.5 bar – stop pressure
Default: 8 bar
Stop pressure Upper limit for the pressure control C
Range: start pressure – maximum pressure (see
configuration menu)
Default: 10 bar

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3.1.1 Menu pressure limits
Parameter Description/ value range/ default value level

line pressure warning: Maximum pressure for warning line pressure C
Range:4.3 bar – 16.8 bar
Default: 10.0 bar
line pressure fault Maximum pressure for fault line pressure C
Default: 5.0 bar
system pressure warning Maximum pressure for warning system pressure C
Default: 0.0 bar
system pressure fault Maximum pressure for fault system pressure C
Default: 0.0 bar
oil pressure 2 warning Maximum oil pressure for warning C
Range: 0.0 bar – 6.0 bar
Default: 5.0 bar
oil pressure 2 fault Maximum oil pressure for fault C
Range0.0 bar – 6.0 bar
Default: 18.0 bar
oil pressure 3 warning Maximum oil pressure for warning C
Default: 4.5 bar
oil pressure 3 fault Maximum oil pressure for fault C
Default: 0.0 bar
Press F4 to get back to the limits menu.

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3.1.2 Menu temperature limits

Oil temperature warning Maximum oil temperature for warning C
Range: 0 – 100 °C
Default: 70°C
Oil temperature fault Maximum oil temperature for fault C
Range: 0 – 100 °C
Default:100 °C
Temp. b. 2nd stage warning Maximum temperature before 2nd stage for warning C
Range: 0 – 100 °C
Default: 0 °C
Temp. b. 2nd stage fault Maximum temperature before 2nd stage for Fault C
Range: 0 – 100 °C
Default: 0 °C
Temp. a. after cooler warning Maximum temperature after after cooler for warning C
Range: 0 – 100 °C
Default: 0 °C
Temp. a. after cooler fault Maximum temperature after after cooler fault C
Range: 0 – 100 °C
Default: 0 °C
Bearing temp. A-side warning Maximum bearing temperature warning (A-side) C
Range: 0 – 200 °C
Default: 0 °C
Bearing temp. A- side fault Maximum bearing temperature fault (A-side) C
Range: 0 – 200 °C
Default: 0 °C
Bearing temp. B- side warning Maximum bearing temperature warning (B-side) C
Range: 0 – 200 °C
Default: 0 °C
Bearing temp. B-side fault Maximum bearing temperature fault (B-side) C
Range: 0 – 200 °C
Default: 0 °C

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3.1.3 Menu vibration limits

Vibration warning Vibration for warning C
Range: 0 – 200 µm
Default:5 µm
Vibration fault Vibration for fault C
Range: 0 – 200 µm
Default: 2 µm

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3.2 Menu run parameters
This menu contains general operation parameters. Use the down key to scroll and reach the
parameters not visible on the page.

Star/delta time Duration of the star /delta phase. S
Range: 0 – 180 s
Default: 15 s
Acceleration time Time delay between feedback “engine speed ok” S
and on load operation.
Range: : 0 – 30 s
Default: 0 s
Exhaust valve delay Time delay between activation of inlet valve and S
exhaust valve
Range: 0 – 30 s
Default: 0 s
Exhaust impulse Duration of activation of the pulse output during S
exhaust.
Range: 0 – 30 s
Default: 0 s
Intake valve delay Time delay between outlet valve and suction S
controller
Range:0 – 30 s
Run on time Time delay between off-load operation and motor S
stop.
Range: 10 – 1200 s
Default: 600 s
Off time Delay between switch off oil pump and stop motor S
Range: 0 – 180 s
Default: 7 s
Automatic restart Start after power failure C
Range: NO / YES
Default: NO

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Run mode Choose run mode: C
Range: AUTOMATIC
LOAD-/NO LOAD
AUTOMATIC OPT.
Default: LOAD-/NO LOAD
Max. pressure loss Maximum allowed loss of pressure S
Range: 0.0 – 9.9 bar
Default: 2.0 bar
Max. no. of motorstarts Maximum number of motorstarts per hour S
Range: 1 – 55 /h
Default: 6 /h
Switching cycles monitored Monitoring of the number of motor starts active. S
Range: NO / YES
Default: NO
Press F4 to get back to the main menu.

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3.3 Menu maintenance schedule
This menu contains the maintenance intervals as well as the operation hours.
Parameter Description/ value range/ default value E

Maintenance air filter Maintenance interval air filter S
Range: 0 – 32000 h
Default: 2000 h
Maintenance oil filter Maintenance interval oil filter S
Range: 0 – 32000 h
Default: 500 h
Maintenance oil Maintenance interval oil S
Range: 0 – 32000 h
Default: 2000 h
Maintenance motor Maintenance interval motor S
Range: 0 – 32000 h
Default: 2000 h
Maintenance compressor Maintenance interval compressor S
Range: 0 – 32000 h
Default: 4000 h
Running hours Current operation hours (motor running) W
Range: 0 – 999999 h
Default: 0 h
Loaded hours Current hours on load operation W
Range: 0 – 999999 h
Default: 0 h
Ready hours Current ready hours (on/ motor stop) W
Range: 0 – 999999 h
Default: 0 h
Total delivery volume Total delivery volume as calculated using the set W
maximum delivery quantity and the current on load
operation hours.
Range: 0 – 999999999 m3
Default: 0 m3

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Please note: if the value of any maintenance interval is changed the corresponding
maintenance interval will automatically be reset (the time until the next scheduled
maintenance equals the new value of the maintenance interval)!
If at least the service code has been entered, the softkey F3 will also reset and restart the
currently selected maintenance interval.

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3.4 Menu timer

Date/time Set time and date for the realtime clock. K
Pleas note: The new setting will take effect as soon as
the seconds are set with the ENTER key.
3.4.1 Switching times compressor
This menu contains the switch on /off times of the compressor.
There are seven timer channels available (C1-C7). These channels are connected with a
logical OR; the compressor will run if at least one of the channels is active and valid.
In the figure above the compressor would be running from Monday to Thursday (6 am-8pm)
and Fridays from 6am to 4 pm. It would be off on weekends.
In order to let the compressor run continuously for one or several days the corresponding days
must be activated and the times must be set to 00:00.

Timer channels Switching the timer on/ off C
Range: OFF / ON
Default: OFF
C1 – C7 Timer: active days are displayed “black on white”. K
The new setting will take effect as soon as the minutes
are set with the ENTER key.
Press F4 to get back to the timer menu..

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3.4.2 Switching times LLC
This menu contains the running times of the lead lag control.
For LLC master only!
There are seven timer channels available (C1-C7). These channels are connected with a
logical OR; the LLC will be active if at least one of the channels is active and valid.
In order to keep the LLC active continuously for one or several days the corresponding days
must be activated and the times must be set to 00:00.

Timer channels Switching the timer on/ off C
Range: OFF / ON
Default: OFF
C1 – C7 Timer: active days are displayed “black on white”. C
The new setting will take effect as soon as the minutes
are set with the ENTER key.
Press F4 to get back to the timer menu.

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3.4.3 Switching times channel x
This menu contains the switching times for several sets of priorities for the LLC. Relevant for
LLC master only!
There are seven timer channels available (C1-C7). For each one the switch on and switch off
times as well as the priorities of all compressors can be set.
The search for an active channel starts with channel #1 and stops as soon as one is found. The
corresponding priorities will then replace the current priorities of the LLC. If no active
channel can be found the default values as set in the LLC menu are used.

Timer channel Switching on/off of the timer C
Range: OFF / ON
Default: OFF
CX Switching times: activated days are displayed “white C
(X => 1 – 7) on black”. New settings will take effect only after
entering the minutes of the switch off time using the
ENTER key.
Start pressure X LLC – start pressure valid at the time set in the same C
(X => 1 – 7) channel.
Stop pressure X LLC – stop pressure valid at the time set in the same C
(X => 1 – 7) channel.
Press F4 to get back to the timer menu.

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3.5 Menu fault log
This screen displays the 20 most current messages (maintenance. warnings and faults)
together with date and time of their occurrence.
Each new message is stored on top of the existing list. So the most recent message is always
at the top.
Each entry starts with position number of the message (01 – 20); follows either the warning
(maintenance/ warning) or the fault symbol. If this icon is flashing the message is still
pending. Next is date and time of the occurance of the message and the message text.
Up to ten entries can be displayed at once. In order to view more use the up and down keys to
scroll the page.
F3 deletes all entries if at least the service code has been entered.
F4 leads back to the main menu.

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3.6 Menu display parameters
The parameters in this menu all concern the appearance on the display.

Pressure dimension Setting of the unit used to display the line pressure. C
Range: BAR / MPA / PSI
Default: BAR
Temperature dimension Setting of the unit used to display the final- C
temperature
Range: °C / °F / K
Default: °C
Language Language used for the display. C
Range: DEUTSCH / ENGLISH / POLSKI
Default: DEUTSCH
Pressure offset Adjustment for the line pressure sensor. S
Range: -0.5 bar – 0.5 bar
Default: 0.0 bar

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3.6.1 Menu Diagrams
This menu contains all parameters necessary for the diagrams that can be reached from the
basic screen.

Saving interval Interval for the saving of line pressure values. C
temperature values and the current delivery quantity.
The control can store up to 8000 values for each
diagram. This setting therefore limits the history
displayed in the diagrams.
With an interval of 12sec 26.67h can be stored (12 *
8000 s = 96000 s = 26.67 h)
Range: 1 – 60 s
Default: 12 s
Number of points X-Auto Number of most recent values displayed if x-Auto is C
activated (see 2.6, 2.7 und 2.10 ).
E.g. in order to see the last hour and with a storing
interval of 12 seconds this parameter has to be set to
300.
(12 s * 300 = 3600 s = 1 h).
Range: 200 - 8000
Default: 300
Line pressure low Scaling of the line pressure diagram. Default value for C
the function X/Y init.
Range: 0.0 bar – “Line pressure high“
Default: 0.0 bar
Line pressure high Scaling of the line pressure diagram. Default value for C
Range: “Line pressure low“ – 16.0 bar
Default: 10.0 bar
Temperature low Scaling of the temperature diagram. Default value for C
Range: 0 °C – “Temperature high“
Default: 0 °C

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Temperature high Scaling of the temperature diagram. Default value for C
Range: “Temperature low “ – 120 °C
Default: 120 °C
Bearing temp. A-side low Scaling of the bearing temperature A-side diagram. C
Default value for the function X/Y init.
Range: 0 °C – “Bearingtemp. A-side high“
Default: 0 °C
Bearing temp. A-side high Scaling of the bearing temperature A-side diagram. C
Range: “Bearingtemp. A-side low“ – 250 °C
Default: 200 °C
Bearing temp. B-side low Scaling of the bearing temperature B-side diagram. C
Range: 0 °C – “Bearingtemp. B-side high“
Default: 0 °C
Bearing temp. B-side high Scaling of the bearing temperature B-side diagram. C
Range: “Bearingtemp. B-side low“ – 250 °C
Default: 200 °C
Delivery quantity day low Low for the current delivery quantity diagram (day) C
when running the X/Y-init function.
Range: 0 m3/h – “Delivery quantity day high“
Default: 0 m3/h
Delivery quantity day high High for the current delivery quantity diagram (day) C
Range: “Delivery quantity day low“ – 9999 m3/h
Default: 1000 m3/h
Delivery quantity week low Low for the current delivery quantity diagram (day) C
Range: 0 m3 – “Delivery quantity week high“
Default: 0 m3
Delivery quantity week high High for the current delivery quantity diagram (week) C
Range: ”Delivery quantity week low”–60000 m3
Default: 10000 m3
F4 leads back to the display parameter menu.

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3.6.2 Menu Text
This menu contains all freely definable texts for hotline and type plate.

Hotline Text to be displayed below messages in the basic S
screen (e.g. used for hotline no.)
Length: 31 Letters/numbers
Model Text displayed in the model field in the type plate. S
Factory-No. Text displayed in the factory-no. field in the type W
plate.
EDP-No. Text displayed in the EDP-no. field in the type plate. W
Consignment-No. Text displayed in the consignment-no. field in the type W
plate.
Schematic-No. Text displayed in the schematic-no. field in the type S
plate.

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3.7 Configuration menu
This menu contains several basic machine settings.

Maximal Air flow Maximum air flow of the compressor in m³/h C
Range: 0 – 3000 m³/h
Default: 1000 m³/h
Remote-Mode Switching between local operation, remote operation C
and operation via external LLC (using the ready
output).
Range: LOCAL / REMOTE / LLC-OK
Default: LOCAL
Lead Lag Control Operation with internal or external LLC S
Range: NO / YES
Default: NO
Powerfail Stop Stop compressor if power fails (low voltage). S
Range: NO / YES
Default: NO
Converter Operation with converter S
Range: NO / YES
Default: NO

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3.7.1 Menu measurement points

Temp. meas’mt a. after cooler Temperature measurement after after cooler exists. C
Range: NO / YES
Default: NO
Oil temperature measurement Oil temperature measurement exists C
Range: NO / YES
Default: NO
System pressure measurement System pressure measurement exists C
Range: NO / YES
Default: NO
Oil pressure 2 measurement Oil pressure 2 measurement exists C
Range: NO / YES
Default: NO
Oil pressure 3 measurement Oil pressure 3 measurement exists C
Range: NO / YES
Default: NO
Vibration measurement Vibration measurement exists C
Range: NO / YES
Default: NO
Bearing temp. measurement Bearing temperature measurement exists C
Range: NO / YES
Default: NO
Output signal Control signal at analogue output. C
Range: NO / YES
Default: NO
F4 leads back to the configuration menu.

__________________________________________________
3.7.2 Menu current parameter

Current sensor scaling Scaling for current input S
Range: 0 – 2000 A
Default: 0 A
Maximum current Maximum motor current S
Range: 0 – 999 A
Default: 0 A
Pump limit 1 pressure first surge point pressure S
Range: 0 –16.0 bar
Default: 0.0 bar
Pump limit 1 current first surge point current S
Range: 0 – 999 A
Default: 256 A
Pump limit 2 pressure Second surge point pressure S
Range: 0 –16.0 bar
Default: 0.0 bar
Pump limit 2 current Second surge point current S
Range: 0 – 999 A
Default: 0 A

__________________________________________________
3.7.3 Menu control parameter

Control type Control type S
Range: ON-/OFF-LOAD
AUTOMATIC
AUTO +DISCHARGE
Default: AUTOMATIC
Actuator Type of actuator S
Range: IGV / THR
Default: IGV
Minimum control range Minimum speed for converter machines (in %) (= off- S
load speed).
This parameter must be set to the same value as the
converter itself. Here it is used to calculate the current
air flow only.
Range: 0 – 100 %
Default 100 %
Desired value Position of the pressure set point within the current S
pressure range. If set to “0%” the desired value is the
same as the start pressure. if set to “100%” the desired
value is the same as the stop pressure.
Range: 0 – 100 %
Default: 50 %
Pressure control factor P-factor pressure control S
Range: 1 – 200 % / bar
Default: 100% / bar
Pressure reset time Reset time pressure control S
Range: 0 – 200 s
Default: 20 s
Surge control factor P-factor current control S
Range: 1 – 20 % / A
Default: 5% / A

__________________________________________________
Surge reset time Reset time current control S
Range: 0 – 20 s
Default: 5 s
Max. control factor P-factor current control S
Range: 1 – 20 % / A
Default: 5% / A
Max reset time Reset time current control S
Range: 0 – 20 s
Default: 5 s
Exhaustv. to over Exhaust valve closes at this limit if control type 2 is S
active (Auto + Discharge)
Range: 0 – 999 A
Default: 0 A
Exhaustv. To under Exhaust valve opens at this limit if control type 2 is S
active (Auto + Discharge)
Range: 0 – 999 A
Default: 0 A
3.7.4 Menu Communication
This menu contains all parameters for the serial communication.

RS485 address comp. RS485 address e.g. for teleservice S
Range: 0 - 27
Default: 0
RS485 address BLCO RS485 address of the internal LLC if the control is the S
LLC-master for LLC over RS485.
Range: 28 - 31
Default: 31

__________________________________________________
RS485 mode Mode for serial interface S
Available settings: READ
READ/WR. CUSTOM
READ/WR. SERVICE
READ/WR. FACTORY
Default: READ/WR. CUSTOM
RS485 baudrate Transmission rate of the serial interface. S
Available settings: 4800
9600
19200
Default: 4800
RS485 protocol Type of protocol for serial interface S
Available settings: STANDARD
MODBUS RTU
Default: STANDARD
Number of extension modules Number of 8E4AE modules for visualization. S
The current state of the modules’ inputs will only be
passed on to the visualization and will not be
considered in the control.
The modules’ addresses have to be consecutive
beginning with address 8.
Range: 0 – 24
Default: 0

__________________________________________________
3.8 Menu Lead Lag Control
This menu contains all parameters for the operation of the control as LLC master.

Lead lag control This parameter has to be set in order to activate the S
control as lead lag control master.
Range: NO
RS485 (RS485 network necessary)
Default: NO
Start pressure Lower pressure limit. C
Range: 0.0 bar – “stop pressure“
Default: 8.0 bar
Stop pressure Upper pressure limit C
Range: “stop pressure“–”Maximum
pressure“ (refer to section 3.7)
Default: 10.0 bar
Stop at If the master machine falls below this value slave C
compressors will be stopped.
If set to 0% the LLC control with power setpoint is
inactive and the control will use pressure limits only.
Range: 0 – 100 %
Default: 0 % (power control inactive)
Start at If the master machine exceeds this value slave C
compressors will be started.
Range: 0 – 100 %
Default: 100 %
Start delay Minimum delay between switching on two C
compressors.
Range: 5 – 600 s
Default: 5 s
Stop delay Minimum delay between switching off two C
compressors.
Range: 2 – 60 s
Default: 2 s

__________________________________________________
Changeover interval priority 1 Time before the LLC switches to the next compressor C
with priority 1.
Range: 1 – 168 h
Default: 24 h
with priority 2.
Range: 1 – 168 h
Default: 24 h
with priority 3.
Range: 1 – 168 h
Default: 24 h
3.8.1 Menu Priorities
This menu contains the default priorities of all compressors. These are valid only if no timer
channel is active.

Priority compressor X Setting of the priority for each compressor. K
( X => 1 – 9 ) Range: 0 – 3
0 -> not available
1 – 3 -> lowest – highest priority
Default: 0
F4 leads back to the lead lag control menu.

__________________________________________________
3.9 Menu Diagnostics
This menu contains the current states of the digital inputs and outputs.
With a codelevel service or higher the outputs can also be switched on and off. Choose the
output with F1 and F2 (only possible when all ouputs are “off”). Only one single output can
be active at any time.

__________________________________________________
4 Program operation
4.1 Operation states
a) compressor is off:
- green LED off
- the icons motor and inlet valve are off (not visisble in the basic screen)
b) compressor on, current pressure still higher than start pressure

- green LED flashing
- the icons motor and inlet valve are off (not visisble in the basic screen)
c) compressor on, end temperature below +1°C

- green LED flashing
- d he icons motor and inlet valve are off (not visisble in the basic screen)
d) compressor on, inlet valve closed, the compressor is not working (start up phase or off-
load)
- green LED on
- icon "motor" visible in the basic screen
- icon “inlet valve” not visible in the basic screen
- if the compressor is operating either in “automatic” or in “automatic + discharge” mode
and the run on time is active the latter will be displayed in the basic screen.
e) Compressor is operating inlet valve is open (on-load operation)

- Green LED is on
- The icons “motor” and “inlet valve” are visible

__________________________________________________
4.2 Maintenance intervals
(For current values see: 2.2 / for setting of intervals see:3.3)

The intervals are counted down. Whenever the time until the next meintenance falls below
100 hours, a maintenance message appears and the red LED starts blinking. In order to
acknowledge this message, change or reset the corresponding maintenance interval (see also
section 3.3).
4.3 Default settings for all parameters
Enter CODE 0088 => All changeable parameters are reset to their default values. Please
note: this also resets all changes that had been made before!

__________________________________________________
5 Messages
5.1 Faults
The fault icon is blinking and the corresponding error message is displayed together with the
text as set in “hotline” (see section 3.6.2). If more there are several messages pending. the
corresponding texts change every 3 seconds.
Fault Description / Solution
Fault: Parameter wrong At least one parameter is outside its valid range.
Fault: EEPROM?
Fault: Power low Power below the allowed minimum. (this message only
appears if monitoring activated – see section 3.7)
Fault: Power fail Power failure (only if automatic restart active!)
Fault: Adjustment wrong Analogue adjustment parameters are wrong. The control needs
to be sent back to the factory.
Fault: Emergency stop Digital input “emergency stop” open.
Fault: Rotation direction Digital input “rotation direction” open.
Fault: Motor temperature PTC input: motor temperature high
Fault: Oil level Input oil level monitoring open.
Fault: Water cooling Input water cooling open while the compressor is running.
Fault: Oil pump Input oil pump monitoring open.
Fault: Fan Input fan monitoring open.
Fault: Inverter Input inverter monitoring open (only if inverter active).
Fault: Line pressure high Line pressure exceeds the upper limit.
Fault: Oil pressure Input oil pressure monitoring open while compressor is
running and after the start up time of the oil pump.
Fault: Oil pressure 2 Current oil pressure 2 below the limit as set in the menu while
the compressor is running.
Fault: Oil pressure 3 Current oil pressure 3 below the limit as set in the menu while
the compressor is running.
Fault: Engine start No “engine speed ok” feedback from the inverter within the
start-up time.
Fault: Vibration Current vibration exceeds the allowed limit after start up..
nd
Fault: Temp. b. 2 stage Temperature before2nd stage exceeds the allowed limit.
Fault: Temp. a. aftercooler Temperature after after cooler exceeds the allowed limit.
Fault: System pressure System pressure exceeds the allowed limit.
Fault: Oil temperature Oiltemperature exceeds the allowed limit.
Fault: Engine current sensor Sensor monitoring of the motor current sensor reports fault.
Fault: Oil temperature sensor Sensor monitoring for oil temperature sensor reports fault.
Fault: Line pressure sensor Sensor monitoring for line pressure sensor reports fault.

__________________________________________________
Fault: System pressure sensor Sensor monitoring system pressure sensor reports fault.
Fault: Temp. b. 2nd stage Sensor monitoring for the temperature senor before the 2nd
sensor stage reports fault.
Fault: Temp. a. after cooler Sensor monitoring for the temperature sensor after after cooler
sensor reports fault.
Fault: Oil pressure 2 sensor Sensor monitoring for the sensor oil pressure-2 reports fault.
Fault: Oil pressure 3 sensor Sensor monitoring for the oil pressure-3 reports fault.
Fault: Vibration sensor Sensor monitoring for the vibration sensor reports fault.
Fault: intermediate cooler Input for the monitoring of the intermediate cooler open.
Fault: Power 115 V Input for the power monitoring 115 V open.
Fault: Bearingtemp. A sensor Sensor monitoring for the bearing temperature sensor
(A side).
Fault: Bearingtemp. B sensor Sensor monitoring for the bearing temperature sensor
(B side).
Fault: I/O Module (Addr.1) Complimentary I/O module with address 1 does not respond.
Fault: I/O Module (Addr.2) Complimentary I/O module with address 2 does not respond
Fault: Bearingtemp. A-side Bearing temperature (A-side) exceeds the allowed limit.
Fault: Bearingtemp. B-side Bearing temperature (B-side) exceeds the allowed limit.
Fault: Switching cycles Number of aloowed switching cycles per hour exceeded.
exceeded
If a fault message is pending the compressor is immediately shut down. The red LED is on
until the cause of the fault has been removed and the message has been acknowledged with
the O-key.
5.2 Warnings / Maintenance messages
The warning icon is blinking and the corresponding message is displayed together with the
text set in “hotline” (see section 3.6.2). If more there are several messages pending. the
corresponding texts change every 3 seconds.
Fault Beschreibung / Beseitigung

Warning: Battery Battery for real time clock and data storage in the RAM is
low. The control has to be sent to the factory.
Warning: Line pressure high Line pressure exceeds the warning limit.
Warning: System pressure System pressure exceeds the warning limit.

__________________________________________________
Warning: Oil pressure 2 Oil pressure 2 is below the warning limit while the
compressor is running.
Warning: Oil pressure 3 Oil pressure 3 is below the warning limit while the
compressor is running.
Warning: Vibration Vibration after start up phase exceeds the warning limit.
nd
Warning: Temp. b. 2 stage Temperature before 2nd stage exceeds the warning limit.
Warning: Temp.a. after cooler Temperature after cooler exceeds the warning limit.
Warning: Extension module An extension module used to transmit signals to the
visualization is not working properly.
Warning: Oil temperature Oil temperatur exceeds the warning limit.
Warning: Bekomat aftercooler Input for monitoring of the Bekomat after cooler open.
Warning: Oilpump Input for oil pump monitoring open.
Warning: Bearingtemp. A-side Bearing temperature (A-side) exceeds the warning limit.
Warning: Bearingtemp. B-side Bearing temperature (B-side) exceeds the warning limit.
Maintenance: Air filter Time until the next maintenance of the air filter is less than
100 h
Maintenance: Oil filter Time until the next maintenance of the oil filter is less than
100 h
Maintenance: Separator Time until the next maintenance of the separator is less than
100 h
Maintenance: Motor Time until the next maintenance of the motor is less than
100 h
Maintenance: Compressor Time until the next maintenance of the compressor is less than
100 h
If a warning or maintenance message is pending the compressor is not shut down but
continues to operate. The red LED starts blinking until the cause of the warning is fixed or the
corresponding maintenance interval has been reset.
5.3 Error in the control’s program store
If the control registers an error in the program store (in the flash EPROM. right after power
on) the display shows the following text:
“Download V...“
In this case the software has to be reloaded!

__________________________________________________
6 Annex
6.1 Codes
Code Function
0001 Customer code (parameters with a C in the third column)
5317 Service code (parameters with C or S in the third column)
1923 Factory/ Works code (parameters with C, S or W in the third
column)
9900 Reset operation hours and time until next maintenance.
0088 Reset all parameters. maintenance intervals and time until
next maintenance to their default values.
6.2 Software history
Date Version Programmer Description

06/01/07 1.00 B. L. First official delivery
06/11/07 1.01 B. L. - correction automatic restart
- DCLO recognition deactivated
- switching off of the display light after 5 minutes
- input ”inverter ready” is delayed by 10 seconds
- correction switch off inlet flap if the 0-key is pushed
in on load mode
- delay oil pressure – monitoring and start up by 5
seconds (automatic restart)
06/21/07 1.02 B.L. - Impuls delay on-load->off-load
- Schaltspielüberwachung
- fault power failure is stored in the error memory also
if automatic restart active
08/14/07 2.00 B.L. - new hardware V4
10/10/07 2.01 B.L. - 3 minutes delay time added after start of on load
operation for monitoring of Bekomat
10/20/08 2.03 B.L. − Polish added
− variable works code added; codelength extended to
5 digits (max: 19999)
− parameter “restart time oil pump” removed (using
oil pressure and oil temperature instead)
− “actuator” added to control parameters
− stop mode

__________________________________________________
6.3 Downloading new software onto the control
In order to set the control to programming mode follow these steps:

- switch off /remove power from the control
- Press and O simultaneously while switching the power back on.
- Thedisplay shows the text “Download V...“
- Now the new program (HEX file) can be loaded. The flash software has to be set to
19200 baud.
- After loading the software the power has to be switched off and on again to activate the
new software and to leave programming mode.

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Air Control 3 Dynamic

General Information ............................................................................................. 3

Air Control 3 Dynamic V 2.03 page 1 of 53 as of: 20.10.2008

Air Control 3 Dynamic V 2.03 page 2 of 53 as of: 20.10.2008

The control contains the following functional blocks:

Air Control 3 Dynamic V 2.03 page 3 of 53 as of: 20.10.2008

- 16 Bit microcontroller including watchdog

1.2 Key Pad

- Key pad with haptic feedback

- Graphical - LCD with 240 x 128 pixel

1.4 Analogue Inputs

1.5 Digital Inputs

Air Control 3 Dynamic V 2.03 page 4 of 53 as of: 20.10.2008

- 5 Relay outputs, NO with one common contact, 250 VAC 6A,

1.7 Interface (Optional)

- RS-232 or RS-485 interface

1.8 Power Supply, Connectors, Housing

1.9 Terminal connections

Pin 1 protective earth connector for electronic

Pin 6 common for Pin 7-12

Pin 13 Relais 7, NC / general fault (A01.5)

Pin 18 KTY-1, signal (final temp.) (AI02)

Pin 22 Dig. Input 8, LLC: on-/off-load (I02.7)

Pin 32 Ground RS-485 / RS-232  Option:

Air Control 3 Dynamic V 2.03 page 6 of 53 as of: 20.10.2008

Air Control 3 Dynamic V 2.03 Seite 7 von Stand: 20.10.2008

Air Control 3 Dynamic V 2.03 page 8 of 53 as of: 20.10.2008

Press ENTER to view current analogue values.

In order to get back to the basic screen press F4.

Air Control 3 Dynamic V 2.03 page 9 of 53 as of: 20.10.2008

In order to get back to the basic screen press F4.

Air Control 3 Dynamic V 2.03 page 10 of 53 as of: 20.10.2008

Lead Lag Control

Load Lead Lag Control

In order to get back to the basic screen press F4.

Air Control 3 Dynamic V 2.03 page 11 of 53 as of: 20.10.2008

On this page the current state of the maintenance intervals is displayed.

2 – Maintenance interval oil filter

3 – Maintenance interval oil separator

4 – Maintenance interval motor

5 – Maintenance interval compressor

In order to get back to the basic screen press F4.

2.5 Type plate

This page shows machine specific data

All texts can be set in corresponding menu.

Air Control 3 Dynamic V 2.03 page 12 of 53 as of: 20.10.2008

This screen shows the line pressure diagram.

F1 X-Auto automatic scaling of the x-axis

Air Control 3 Dynamic V 2.03 page 13 of 53 as of: 20.10.2008

This diagram shows the temperature before the second stage

F1 X-Auto automatic scaling of the x-axis

Air Control 3 Dynamic V 2.03 page 14 of 53 as of: 20.10.2008

2.8 Diagram bearing temperature A-side (F1 B.Temp.A))

This diagram shows the bearing temperature (A-side)

F1 X-Auto automatic scaling of the x-axis

Air Control 3 Dynamic V 2.03 page 15 of 53 as of: 20.10.2008

2.9 Diagram bearing temperature B-side (F2 B.Temp.B)