ProTech V Series User Guide

ProTech V Series User Guide
Table of Contents
CHAPTER 1……………………………………………………………….....- 7-
About This Manual ............................................................................. - 8 -
Introduction ........................................................................................ - 9 -
SAFETY PRECAUTIONS ...................................................................................................................... - 10 -
SAFETY LABELS ............................................................................................................................... - 11 -
LIMITED WARRANTY .......................................................................................................................... - 12 -
LIMITATION ON LIABILITY ................................................................................................................... - 12 -
UNAUTHORIZED REPAIR .................................................................................................................... - 12 -
Installation ........................................................................................ - 13 -
GENERAL CONSIDERATIONS .............................................................................................................. - 13 -
ENCLOSURE CONSIDERATIONS .......................................................................................................... - 14 -
ENVIRONMENTAL CONSIDERATIONS ................................................................................................... - 15 -
POWER REQUIREMENTS, GROUNDING AND WIRING ............................................................................ - 15 -
ANALOG INPUT WIRING ..................................................................................................................... - 16 -
TEMPERATURE INPUT WIRING............................................................................................................ - 16 -
DIGITAL INPUT WIRING ...................................................................................................................... - 17 -
CURRENT TRANSFORMER WIRING ..................................................................................................... - 17 -
ANALOG OUTPUT WIRING ................................................................................................................. - 18 -
DIGITAL OUTPUT WIRING .................................................................................................................. - 18 -
MOTOR CONTROL OUTPUT WIRING.................................................................................................... - 18 -
COMMUNICATION WIRING .................................................................................................................. - 19 -
M AIN DRIVE MOTOR CONTROL .......................................................................................................... - 19 -
Specifications ................................................................................... - 21 -
USER INTERFACE MODULE (UIM) ...................................................................................................... - 21 -
M AIN LOGIC MODULE (MLM) ............................................................................................................ - 22 -
Troubleshooting ............................................................................... - 23 -
COMPRESSOR START FAILURE .......................................................................................................... - 24 -
SENSOR FAULT ............................................................................................................................ - 24 -
CONTROL PANEL INOPERATIVE ................................................................................................ - 25 -
DISPLAY CONTRAST POOR ........................................................................................................ - 25 -
MOTOR OVERLOAD ..................................................................................................................... - 25 -
ABNORMAL CONTROL PERFORMANCE ................................................................................... - 26 -
HIGH AIR PRESSURE ................................................................................................................... - 26 -
LOW AIR PRESSURE .................................................................................................................... - 26 -
Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

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HIGH AIR TEMPERATURE ............................................................................................................ - 27 -
SURGING OR HIGH SURGE COUNT ............................................................................................ - 27 -
INLET VALVE WILL NOT OPEN .................................................................................................... - 27 -
BLOW OFF VALVE WILL NOT CLOSE ......................................................................................... - 28 -
Parts and Service ............................................................................. - 29 -

PARTS ORDERING PROCEDURE ......................................................................................................... - 29 -
PARTS AVAILABILITY......................................................................................................................... - 30 -
RETURNING PARTS ........................................................................................................................... - 30 -
REPLACEMENT PARTS LIST ............................................................................................................... - 30 -
REPLACING CONTROLLER MODULES ................................................................................................. - 30 -
CHAPTER 2………………………………………………………………....-32-
Introduction ...................................................................................... - 33 -
ProTech Checks: Before Turning Power On .................................. - 34 -
ProTech Checks: Initial Application Of Power ............................... - 35 -
Initial Start of Compressor............................................................... - 39 -
Initial Control Loop Tuning Process ............................................... - 40 -
Surge Testing ................................................................................... - 42 -
Natural Surge test ......................................................................................................................... - 42 -
High Throttle Surge Test .............................................................................................................. - 44 -
Mid Throttle Surge Test ................................................................................................................ - 44 -
Low Throttle Surge Test ............................................................................................................... - 44 -
Enter Commissioning Settings ....................................................... - 45 -

Additional Performance Control Parameters ................................. - 46 -
Review All Control Parameters ....................................................... - 47 -
Review the Operator Settings and Setpoints ................................. - 47 -
Run the Compressor In the Automatic Control Mode.................... - 48 -
Tune the Blow Off and Inlet System Pressure Loops .................... - 48 -
Shutdown Compressor .................................................................... - 48 -
Reset the Operation History ............................................................ - 49 -
Save the Configuration To Laptop .................................................. - 49 -
Put In Access Codes and Send to ProTech .................................... - 49 -

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ProTech Startup Checklist………………………………………………- 50-
CHAPTER 3………………………………………………………………..- 52 -
About This Guide.............................................................................. - 53 -
The ProTech Control Panel.............................................................. - 54 -
The ProTech User Interface Module ................................................ - 55 -
INFORMATION KEYS .......................................................................................................................... - 56 -
View Pages .................................................................................................................................... - 56 -
Performance Control .............................................................................................................................. - 57 -
Monitor Points ........................................................................................................................................- 58 -
Control Points .........................................................................................................................................- 59 -
Protection (Running) .............................................................................................................................. - 59 -
Protection (Startup) ................................................................................................................................ - 60 -
Permissive Status...................................................................................................................................- 60 -
Information ..............................................................................................................................................- 61 -
Auxiliary Control.....................................................................................................................................- 61 -
History Pages ................................................................................................................................ - 62 -
Protection History ..................................................................................................................................- 62 -
Event History ..........................................................................................................................................- 63 -
Operation History ...................................................................................................................................- 63 -
Motor Trip History ..................................................................................................................................- 64 -
Surge Test Results .................................................................................................................................- 64 -
Performance Log ....................................................................................................................................- 65 -
Network Pages .............................................................................................................................. - 65 -
Compressor Network ............................................................................................................................. - 66 -
Modbus Interface ....................................................................................................................................- 67 -
FUNCTION KEYS ............................................................................................................................... - 68 -
Start ................................................................................................................................................ - 68 -
Stop ................................................................................................................................................ - 68 -
Auto ................................................................................................................................................ - 69 -
Unload ............................................................................................................................................ - 69 -
Set Points ...................................................................................................................................... - 69 -
Operator ..................................................................................................................................................- 70 -
Commissioning.......................................................................................................................................- 71 -
Tools ........................................................................................................................................................ - 71 -
Additional Set Point Menu Items ...........................................................................................................- 71 -
INPUT / NAVIGATION KEYS ................................................................................................................. - 72 -
Increase and Decrease……………………………………………………………….…………….- 72-
Enter and Back……………………………………………………………………………..………..- 72-

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Up and Down………………………………………………………………………………...…….....- 72-
ProTech Control Methods ................................................................ - 73 -

AUTO-OFFLINE CONTROL.................................................................................................................. - 74 -
Auto-Offline Control Set Points ............................................................................................ - 74 -
Auto-Offline Control Steps .................................................................................................... - 74 -
AUTO-STANDBY CONTROL ................................................................................................................ - 75 -
Auto-Standby Control Set Points ......................................................................................... - 75 -
Auto- Standby Control Steps ................................................................................................ - 75 -
AUTO-UNLOAD CONTROL .................................................................................................................. - 76 -
Auto-Unload Control Set Points ........................................................................................... - 76 -
Auto- Unload Control Steps .................................................................................................. - 76 -
CONSTANT FLOW CONTROL .............................................................................................................. - 77 -
Constant Flow Control Set Points ........................................................................................ - 77 -
Constant Flow Control Steps ................................................................................................ - 77 -
ProTech Control Loops .................................................................... - 78 -

INLET VALVE CONTROL LOOPS.......................................................................................................... - 80 -
Inlet Maximum Load Loop ..................................................................................................... - 80 -
Inlet System Pressure Loop .................................................................................................. - 80 -
Inlet Surge Control Loop ....................................................................................................... - 80 -
Inlet Valve Control Discussion ............................................................................................. - 80 -
BLOW OFF VALVE CONTROL LOOPS.................................................................................................. - 81 -
Blow Off System Pressure Loop .......................................................................................... - 81 -
Maximum Discharge Pressure Loop .................................................................................... - 81 -
Blow Off Valve Control Discussion ...................................................................................... - 81 -
CHAPTER 4………………………………………………………………..- 82 -
About This Guide.............................................................................. - 83 -
Installation ........................................................................................ - 84 -
Configuration .................................................................................... - 84 -
Modbus Protocol .............................................................................. - 85 -
Synchronization ............................................................................... - 85 -
Message Format ............................................................................... - 85 -
Address Field ................................................................................................................................ - 85 -
Function Field ............................................................................................................................... - 86 -
Data Field ....................................................................................................................................... - 86 -
Error Check Field .......................................................................................................................... - 86 -

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Error Detection ................................................................................. - 86 -
Exception Responses ...................................................................... - 87 -
Memory Notation .............................................................................. - 87 -
Function 3 – Read Holding Registers ............................................. - 88 -
Notes: ............................................................................................................................................. - 89 -
Exceptions ..................................................................................................................................... - 92 -
Function 4 – Read Input Registers .................................................. - 93 -

Notes: ............................................................................................................................................. - 93 -
Exceptions ..................................................................................................................................... - 94 -
Function 6 – Preset Single Register................................................ - 95 -

Notes: ............................................................................................................................................. - 96 -
Exceptions ..................................................................................................................................... - 96 -
Function 8 – Loop Back Test ........................................................... - 97 -

Exceptions ..................................................................................................................................... - 97 -
Upgrading to ProTech from the Quad 2000 .................................... - 98 -

Modicon PLC Memory Map for the ProTech Controller ................. - 99 -
Revision Date: 2013-10-09

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Chapter 1
ProTech V Series Control System
Installation and Service Manual

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ProTech Installation and Service Manual
About This Manual

This manual contains the basic information necessary for installing and servicing the ProTech Control
System. However, since installations may vary, these instructions may not cover all details or variations
in the equipment supplied or every question that may possibly arise during use.
All operating personnel should become familiar with the contents of this manual before the control
system is put into service. This is particularly important with regard to the safety precautions listed in
the Introduction section, and those included at relevant points of the procedures described in other
sections of this manual.
WARNING:
! Read, be sure to clearly understand, and then carefully follow all of the
directions and procedures included in this manual. Failure to adhere to the
guidelines and specific instructions provided could cause equipment damage
and serious personal injury or death.
AVERTISSEMENT:
Lit, est sûr clairement comprendre, et alors suivre toutes les directions et
procédures incluses dans ce manuel. Echec adhérer aux indications et
spécifique instructions fourni pourrait causer équipement et sérieux personnel
blessure ou mort.
Manual Revision 1.6, June 16, 2006.

ProTech is a trademark of Bay Controls, LLC.
Copyright  2002 - 2006 Bay Controls, Inc. All Rights Reserved

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-8-
ProTech Initial Startup Guide
Introduction
The ProTech controller uses two components, referred to as modules, with an interconnecting cable, to
provide a complete compressor control system (expansion modules can also be added to monitor
and/or control additional systems). This high integration architecture results in high reliability, simple
serviceability, and lower equipment and maintenance costs.
The two types of modules used with the ProTech are the User Interface Module (UIM), which contains a
graphic display and keypad, and the Main Logic Module (MLM), which contains the power supply,
microprocessor, memory, communications, and I/O processing circuitry.
Your ProTech controller may be packaged with other components in a control panel, or may have been
retrofitted into your previous compressor control system.
The control system software, configuration file, and set points, are loaded into the memory of the Main
Logic Module to tailor the control system for the specific compressor and control strategy to be used.
This software is licensed and configured for your specific compressor application.

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-9-
Safety Precautions
Compressors are powerful industrial machines that utilize high-speed rotating elements and high
voltages to produce high gas pressures. Therefore, it is very important to use extra safety precautions
whenever the compressor is in operation as well as when performing maintenance or making repairs.
Bay Controls, LLC expressly disclaims responsibility or liability for any injury or damage caused by
failure to observe specified or other common safety precautions or failure to exercise ordinary caution,
common sense, and due care required in operating the compressor and auxiliary systems even though
not specified herein.
If this equipment is used in a manner not specified by Bay Controls, LLC, the protection provided by this
equipment may be impaired.
The alert messages shown here appear throughout this manual to indicate those situations and
times when special care is necessary to prevent equipment damage or personal injury. There are
three degrees of urgency:
CAUTION:
! This indicates that there may be the possibility of equipment damage.
LA PRUDENCE:
Ceci indique que cela il peut y avoir la possibilité de dommages d'équipement.
!
WARNING:
This indicates that there could be the possibility of equipment damage or
personal injury.
AVERTISSEMENT:
Ceci indique cela là-bas pourrait être la possibilité de ou personnel.
!
DANGER:
This indicates that there will definitely be equipment damage and/or personal
injury or death if all proper safety precautions are not carefully followed.
DANGER:
Ceci indique cela là-bas sera équipement dommages personnel blessure ou
mort si tout propre sûreté ne sont pas suivi.

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Safety Labels
The following safety labels alerts the installer or operator to possible hazards and serves to remind the
user of specific safety precautions. Before installing and/or operating this control system, be certain to
review the pertinent safety labels.
CAUTION HAZARDOUS AREA.
!
DO NOT REMOVE THE COVER.
NO SERVICABLE PARTS INSIDE.
REFER SERVICING TO QUALIFIED PERSONNEL.
READ OPERATORS MANUAL THOROUGHLY
BEFORE OPERATING EQUIPMENT.
AVERTIR LE DOMAINE HASARDEUX.

Ne PAS ENLEVER LA COUVERTURE.
AUCUNES PARTIES DE SERVICABLE A L'INTERIEUR.
REFERER L'ENTRETENIR AU PERSONNEL QUALIFIE.
LIRE DU MANUEL D'OPERATEURS A FOND AVANT D'OPERANT
L'EQUIPEMENT.
CAUTION: DISCONNECT POWER BEFORE SERVICING.

This indicates that high voltage may be present which could result in personal
injury or death if all proper safety precautions are not carefully followed.
LA PRUDENCE: DEBRANCHER LE POUVOIR AVANT D'ENTRETENIR.

Ceci indique que cet à haute tension peut être actuel que qui a pour résultat la
blessure ou la mort personnelle si toutes précautions de sûreté propres ne sont
pas soigneusement suivies.
PROTECTIVE EARTH GROUND.

This symbol indicates a required connection to earth ground. The protection
provided by this equipment may be impaired if the protective earth ground
connection is not provided as directed in this manual. Refer to the section
“Installation, General Considerations” in this manual for more information on
earth grounding.
Ce symbole indique une connexion exigée au sol de terre. La protection fournie

par cet équipement peut être endommagéee si la connexion de sol de terre
protective n'est pas fournie comme a dirigé dans ce manuel. Se référer à la
section “l'Installation, les Considérations Générales” dans ce manuel pour plus
amples renseignements sur mettre à terre de terre.

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Limited Warranty
Subject to the limitations contained below, and except as otherwise expressly provided herein, Seller
warrants to the Buyer that all tangible articles supplied by Seller or services provided by Seller will be
free of defects in materials or workmanship under normal use and care until the expiration of the
applicable warranty period. Goods are warranted for twelve (12) months from the date of initial field
installation or eighteen (18) months from the date of shipment, whichever period expires first. If Buyer
discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty
period, Seller shall at its option promptly correct, repair, or replace F.O.B. point of manufacture that
portion of the good found by Seller to be defective, or refund the purchase price of the defective portion
of the goods/services. All replacements or repairs necessitated by inadequate maintenance, normal
wear and usage, unsuitable power sources, unsuitable environmental conditions, accident, misuse,
improper installation, modification, repair, storage or handling, or any other cause not the fault of Seller
are not covered by this limited warranty, and shall be at Buyer’s expense. Seller shall not be obligated
to pay any costs or charges incurred by Buyer except as may be agreed upon in writing in advance by
an authorized Seller representative. All costs of dismantling, reinstallation and freight and the time and
expenses of Seller’s personnel for site travel and diagnosis under this warranty clause shall be borne
by Buyer. Goods repaired and parts replaced during the warranty period shall be in warranty for the
remainder of the original warranty period or ninety (90) days, whichever is longer. Except as otherwise
expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF
ANY KIND, EXPRESS OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR
PURPOSE, OR ANY OTHER MATTER WITH RESPECT TO ANY GOODS OR SERVICES.
Limitation on Liability
THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY HEREUNDER SHALL BE
LIMITED TO REPAIR, CORRECTION, REPLACEMENT OR REFUND OF PURCHASE PRICE AS
PROVIDED UNDER THE FOREGOING LIMITED WARRANTY.
IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER

BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, TORT OR
OTHERWISE), SHALL SELLER’S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE
PRICE TO THE BUYER OF THE SPECIFIC GOODS SUPPLIED OR SERVICES PROVIDED BY
SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION.
BUYER AGREES THAT IN NO EVENT SHALL SELLER’S LIABILITY TO BUYER AND/OR ITS
CUSTOMERS INCLUDE “CONSEQUENTIAL DAMAGES”. FOR THIS PURPOSE,
“CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF
ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE AND LOSS OF CAPITAL.
Unauthorized Repair
In the event that the owner allows the ProTech Control System to be serviced or repaired by
unauthorized personnel, the coverage of the original warranty policy will be automatically terminated.

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Installation
General Considerations
Advance planning and preparation will help to simplify and expedite the installation of the ProTech
control system with a new or retrofit installation.
At least two weeks before the projected startup date contact Bay Controls Customer Service
Department (419-891-4390) to schedule startup service.
Insure that you have the latest wiring diagrams and drawings, provided with your licensed software and
configuration, for your specific compressor. Contact the Customer Service Department if you have any
questions related to the installation drawings or wiring diagrams.
When designing and installing the control system, it is necessary to meet the following minimum
requirements:
Assure que vous a le dernier télégraphiant diagrammes et dessins, fourni avec votre autorisé logiciel et
configuration, pour votre spécifique compresseur. Contacte votre autorisé service si vous a n'importe
quelles questions relaté à le ou télégraphiers diagrammes. En concevant et l'installer le système de
contrôle, c'est nécessaire de rencontrer le suivre les conditions minimum:
 Be certain that the main power supply meets the specifications, including voltage, frequency, and
most importantly the current carrying capacity of the wires.
Est certain que l'alimentation principale rencontre les spécifications, y compris la tension, la
fréquence, et le plus important le courant porter capacité des fils.
 Provide an appropriate separate earth ground that meets local and national codes. In the United
States refer to section 250-26 of the National Electrical Code for earth ground definition.
Fournit un approprie séparé terre qui rencontre local et national codes. Aux états-unis réfère à
section 250-26 du National Electrique Code pour terre sol.
 Include proper disconnects such as switches or circuit breakers to provide complete isolation from
the electrical supply. An approved external fused disconnect device (rated at 250 Volts AC, 15
Amps with 3.0 mm contact separation in all supply lines must be located near the equipment.
Inclure propre débranche tel que les commutateurs ou tel que les disjoncteurs pour fournir
l'isolement complet de la provision électrique. Un approuvé externe unifié débranche l'appareil
(évalué à 250 COURANT ALTERNATIF de Volts, 15 Amplis avec 3.0 mm la séparation de contact
dans toutes lignes de provision doit être localisée près de l'équipement.
 If the main power switch that controls the compressor is remotely located or if it difficult to lock out
the main switch, install a local switch to enable maintenance personnel to isolate the unit.
Si l'interrupteur général principal qui règle le compresseur est vaguement localisé ou s'il difficile à
verrouiller hors le commutateur principal, installer un commutateur local pour rendre capable le
personnel d'entretien pour isoler l'unité.
 Install and use a lockout system whenever performing maintenance procedures on this or any other
type of equipment.
Installer et utiliser un système de lockout quand les procédures d'entretien qui exécutant sur ceci
ou tout autre type d'équipement.

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DANGER:
!
To ensure a proper and safe initial startup and optimum operation of the
ProTech control system, a factory trained and authorized service representative
should be present to inspect the site, supervise the final installation steps, assist
with the startup procedure, and train operating personnel. Failure to follow these
guidelines may result in equipment damage and/or personal injury or death.
DANGER:
Assurer un propre et sûr initial démarrage et optimum opération de l'AProTech
contrôle , une Baie Règle usine entraîné et autorisé service doit être actuel
inspecter le site, surveille le final installation , aide avec le démarrage , et train
opération . Echec suivre ces indications peut résulter dans équipement
dommages personnel blessure ou mort.
DANGER:
!
Be certain that all electrical work is performed by qualified personnel according
to product specifications and all applicable local and national codes. Failure to
follow this requirement may result in equipment damage and/or personal injury
or death.
DANGER:
Est certain que tout électrique travail est exécuté par qualifié personnel selon
produit et tout applicable local et national codes. Echec suivre cette condition
peut résulter dans équipement dommages personnel blessure ou mort.
Enclosure Considerations
The ProTech User Interface Module and Main Logic Modules must be mounted in a watertight
enclosure that requires the use of a key or tool to gain access. A NEMA 4 rated enclosure is
recommended for indoor use, a NEMA 4X rated enclosure is recommended for outdoor use or where
corrosive chemicals are present.
L'AProTech Interface utilisateur et Principal Logique doit être monté dans un watertight qui exige
l'usage d'une clef ou outil gagner accès. Un NEMA 4 clôture évaluée est recommandée pour l'usage
intérieur, un NEMA 4X a évalué la clôture est recommandée pour l'usage extérieur ou où les produits
chimiques corrosifs sont actuels.
If the ProTech is installed in a hazardous atmosphere, or at a location where there is any possibility of
the atmosphere becoming hazardous, an enclosure must be used that is appropriately rated for the
operating environment.
Si l'AProTech est installé dans une atmosphère hasardeuse, ou à un emplacement où il y a n'importe

quelle possibilité de l'atmosphère qui devenant hasardeuse, une clôture doit être utilisée cela
correspondamment est évalué pour l'environnement qui opérant.

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DANGER:
! Failure to install the ProTech control system using the proper enclosure may
cause equipment damage and/or personal injury or death.
DANGER:
Echec installer l'AProTech contrôle système le propre clôture peut causer
équipement dommages personnel blessure ou mort.
Environmental Considerations
The ProTech User Interface Module and Main Logic Modules are designed to operate at an ambient
temperature range of 0° to 60° C, 95% relative humidity, and non-condensing. If the temperature inside
the control enclosure exceeds these limits, panel heaters or coolers must be installed to maintain the
specified operating temperature range.
L'AProTech Interface utilisateur et Principal Logique sont conçu opérer à un ambiant température de 0°
à 60° C, 95% relatif , et non-condenser. Si la température dans les dépasse ces limites, ou coolers doit
être installé maintenir le spécifié opérere température .
CAUTION:
! Operation of the control system outside of the specified operating temperature

range may cause equipment damage.
LA PRUDENCE:
l'Opération du système de contrôle hors de la portée de température spécifiée
qui opérant peut causer les dommages d'équipement.
Power Requirements, Grounding and Wiring
The ProTech controller operates on 100 – 240 VAC, 50 or 60 Hz, up to 10 amps per Main Logic Module
(MLM). Connector J15 of each MLM must be wired with a single-phase power feed of 10 amps with
circuit protection using 14 gauge THHN, 600 volt, 105°C insulation wire. Terminal L1 of connector J15
is the single-phase hot connection, black color. Terminal L2 of connector J15 is the single-phase
neutral, white color. Copper conductors for connection to J15 must be made in accordance with the
NEC/CEC and local codes.
L’AProTech opère sur 100 – 240 , 50 ou 60 , jusqu'à 10 Principal Logique (MLM). Le connecteur J15 de
chaque MLM doit être télégraphié avec un pouvoir de seul-phase nourrit de 10 amps avec l'utilisation
de protection de circuit 14 THHN de jauge, 600 volt, 105°le fil d'isolation de C. Délimitant L1 de
connecteur J15 est la seul-phase la connexion chaude, la couleur noire. Délimitant L2 de connecteur
J15 est la seul-phase neutre, blanc couleur. Les conducteurs de cuivre pour la connexion à J15 doivent
être conformément faits au NEC CEC et les codes locaux.
Terminal GND of connector J15 of the Main Logic Module must be connected to earth
ground using 14 gage THHN, 600 volt, 105°C insulation wire, green/yellow color.
GND délimitant de connecteur J15 du Module de Logique Principal doit être connecté à l'utilisation de
sol de terre 14 THHN de gage, 600 volt, 105°le fil d'isolation de C, la couleur vert/jaune.

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The case of the User Interface Module (UIM) must be connected to earth ground. This connection can
be accomplished either by attaching a ground wire directly to the module using one of the mounting
studs, or by attaching a ground wire to the enclosure door or plate that the UIM is mounted to. In either
case use 14 gage THHN, 600 volt, 105°C insulation wire, green/yellow color.
Le cas du Module d'Interface utilisateur (UIM) doit être connecté au sol de terre. Cette connexion peut
être accompli ou en attachant un directement au module en utilisant un des monters clous, ou en
attachant un sol A LA CLOTURE OU PLAQUE QUI LE UIM EST MONTE A. Dans ou le cas utilise 14
THHN de gage, 600 volt, 105°le fil d'isolation de C, la couleur vert/jaune.
!
DANGER:
Failure to properly ground the control system modules may cause equipment
damage and/or personal injury or death.
DANGER:
Echec convenablement mettre à terre le contrôle système peut causer
Analog Input Wiring
All of the analog input wiring, which is connected to connectors J5 and J6 of the Main Logic Module,
must be 18 gage twisted pair 2-conductor 300 volt cable, such as Belden # 9740 or equivalent.
Toute l'analogue données télégraphiant, qui est connecté à connecteurs J5 et J6 du Principal Logique ,
doit être 18 gage tordu paire a protégé 2-300-câble, tel que Belden # 9740 ou équivalent.
Analog wiring should be separated from digital and higher voltage wiring as much as possible. Do not
install analog wiring in the same conduit with higher voltage digital wiring.
Analogue installation éléctrique devrait être séparé de numérique et à haute tension installation
éléctrique autant que possible. Ne pas installe analogue installation éléctrique dans pareil conduit avec
A haute tension numérique installation éléctrique.
Temperature Input Wiring
All of the temperature input wiring, which is connected at connectors J7 and J8, must be 22 gage 3-
conductor 300 volt cable such as Belden # 8443 or equivalent.
Toute la température télégraphiant, qui est connecté à connecteurs J7 et J8, doit être 22 gage a
protégé 3-300-câble tel que Belden # 8443 ou équivalent.
Temperature input wiring should be separated from digital and higher voltage wiring as much as
possible. Do not install temperature input wiring in the same conduit with higher voltage digital wiring.
Température télégraphiant devrait être séparé de numérique et à haute tension installation éléctrique
autant que possible. Ne pas installe température télégraphiant dans pareil conduit avec A haute tension
numérique installation éléctrique.

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Digital Input Wiring

All of the digital input wiring, which is connected to connector J10 of the Main Logic Module, must be 18
gage twisted pair 2-conductor 300 volt cable, such as Belden # 9740 or equivalent.
Tout le numérique données télégraphiant, qui est connecté à connecteur J10 du Principal Logique , doit
être 18 gage tordu paire a protégé 2-300-câble, tel que Belden # 9740 ou équivalent.
Current Transformer Wiring
The current transformer wiring, which is connected at connector J11 of the Main Logic Module, must be
14 gauge THHN, 600 volt, 105°C insulation. The input voltage is 32 VAC, the maximum over current is
as follows: 6x (30 Amps) for 1 second, 4x (20 Amps) for 20 seconds, 2x (10 Amps) continuous.
L'installation éléctrique actuelle de transformateur, qui est connectée au connecteur J11 du Module de
Logique Principal, doit être 14 THHN de jauge, 600 volt, 105°l'isolation de C. La tension de données est
32 VAC, le maximum par-dessus le courant est comme suit: 6x (30 Amplis) pour de 1 seconde, 4x (20
Amplis) pour de 20 seconde, 2x (10 Amplis) continu.
The current transformer should typically be sized for twice the full load amps of the motor.
Le transformateur actuel typiquement devrait être sized pour deux fois les amplis de chargement pleins
du moteur.
Wiring of the current transformer (CT) should be separated from other wiring as much as possible. Do
not install the CT wiring in the same conduit with other wiring.
L'installation éléctrique du transformateur actuel (CT) devrait être séparé de l'autre installation
éléctrique autant que possible. Ne pas installer le CT qui télégraphiant dans le conduit pareil avec
l'autre installation éléctrique.

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Analog Output Wiring

All of the analog output wiring, which is connected at connector J4, must be 18 gage twisted pair 2-
conductor 300 volt cable, such as Belden # 9740 or equivalent.
Tout l'analogue production télégraphiant, qui est connecté à connecteur J4, doit être 18 gage tordu
paire a protégé 2-300-câble, tel que Belden # 9740 ou équivalent.
Digital Output Wiring

All of the digital output wiring, which is connected to connectors J13 and J14 of the Main Logic Module,
must be 14 gauge THHN, 600 volt, 105°C insulation.
Tout le numérique, qui est connecté à J13 et du Principal Logique, doit être, 600, 105°C.
Digital output wiring should be separated from low voltage wiring as much as possible. Do not install
digital output wiring in the same conduit with low voltage wiring.
L'installation éléctrique numérique de production devrait être séparée de l'installation éléctrique de

tension basse autant que possible. Ne pas installer l'installation éléctrique numérique de production
dans le conduit pareil avec l'installation éléctrique de tension basse.
Motor Control Output Wiring

The motor control and emergency stop pushbutton wiring, which are connected at connector J12 of the
Main Logic Module, must be 14 gauge THHN, 600 volt, 105°C insulation.
Le moteur l'arrêt de de contrôle et cas urgent installation éléctrique de bouton de, qui sont connectées
au connecteur J12 du Module de Logique Principal, doit être 14 THHN de jauge, 600 volt,
105°l'isolation de C.

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Communication Wiring
The communications wiring for the C-Link network (connector J2), MODBUS interface (connector J9),
and MLM Buss (connector J3), of the Main Logic Module must be 22 gauge 3-conductor shielded
twisted such as Belden # 3108A or equivalent.
Les communications télégraphiant pour la (connecteur J2), MODBUS (connecteur J9), et MLM
(connecteur J3), du Principal Logique doit être 22 jauge 3-protégé tordu tel que Belden # 3108A ou
équivalent.
Communication wiring should be installed in separate conduit and separated from other higher voltage
wiring as much as possible.
Communication devrait être installé dans séparé conduit et séparé d'autre à haute tension installation
éléctrique autant que possible.
The shields of the communication cables must be connected to earth ground at one point only. The
GND terminal of connector J2, J3, and J9 is used for this purpose. There should only be a single
connection to one GND terminal per network. The shield wires of communications cables connected to
modules that are in the middle of the network must be connected together without using a terminal in
the connectors.
Les protections des câbles de communication doivent être connectées au sol de terre à un point
seulement. Le GND de connecteur J2, J3, et J9 est utilisé à cet effet. Il seulement doit y avoir une
connexion seule à un terminal de GND par le réseau. Les fils de protection de câbles de
communications connectés aux modules qui sont au milieu du réseau doit être ensemble connecté
sans l'utilisation d'un terminal dans les connecteurs.
Main Drive Motor Control

The ProTech interfaces with the compressor main drive motor using a solid state, optically isolated,
digital control output at connector J12. This interface is designed to use an emergency stop pushbutton
wired in series with the ProTech output, providing fail-safe shutdown of the motor when the emergency
stop button is activated.
L'AProTech interface avec le compresseur principal unité moteur un solide état, , numérique A
CONNECTEUR J12. Cette interface est conçue pour utiliser un bouton d'arrêt de cas urgent
télégraphié dans le feuilleton avec le production d'AProTech, le fournir fonctionnement continu assuré
la fermeture du moteur quand le bouton d'arrêt de cas urgent est activé.
!
DANGER:
Failure to install and properly connect the emergency stop pushbutton may
cause equipment damage and/or personal injury or death.
DANGER:
Echec installer et convenablement connecter le cas urgent arrêt peut causer

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DANGER:
!
Be sure to properly connect the motor control interface as shown in the
installation drawings provided by a factory trained and authorized service
representative. Improper wiring of the motor control output may cause
equipment damage and/or personal injury or death.
LE DANGER:
Etre sûr convenablement de connecter l'interface de contrôle de moteur selon
les dessins d'installation fournis par une usine a entraîné et a autorisé le
représentant de service. Déplacé installation éléctrique du moteur contrôle peut
causer équipement dommages personnel blessure ou mort.
The ProTech controller limits the maximum motor current by limiting the maximum flow through the
compressor, however this function is not designed to replace the motor overload protection function of
the motor control center. An operator may be able to set the maximum motor load set point above a
safe operating value for a given motor installation.
Le contrôleur d'AProTech limite le courant de moteur maximum en limitant le flux maximum par le
compresseur, cependant cette fonction n'est pas conçue pour remplacer la fonction de protection de
surcharge de moteur du centre de contrôle de moteur. Un opérateur peut pouvoir régler le point de
série de chargement de moteur maximum au-dessus d'une valeur sûre qui opérant pour une installation
de moteur donnée.
DANGER:
!
The main drive motor control must provide all necessary protection functions,
including but not limited to, overload, phase imbalance, and under-voltage, to
insure safe operation. Failure to insure safe operation of the motor protection
functions of the motor control may cause equipment damage and/or personal
injury or death.
DANGER:
Le principal unité moteur doit fournir tout nécessaire protection , y compris mais
A, SURCHARGE, PHASE , ET SOUS-TENSION, ASSURER SUR
OPERATION. Echec assurer sûr opération du moteur protection du moteur peut
causer équipement dommages personnel blessure ou mort.

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Specifications
User Interface Module (UIM)
Part Number: CN-UIM2-P
Size: 12.5" (31.8 cm) W x 11.25" (28.6 cm) H x 1.5" (3.8cm) D.
Weight: 3 lbs. (1.36 kilograms).
Environmental: Operating temperature range: 32 F to 122 F (0 C to 50 C). Storage
temperature range: -10 F to 140 F (-23 C to 60 C). Maximum
relative humidity of 92.5% (non-condensing), up to 2000 meters
altitude.
Keypad: 15 keys tactile feel polyester membrane keypad with integral display
window, stainless steel domes, UV hard-coated.
Display: Monochrome 640 x 480 pixel graphic LCD with CCFL backlighting.
Safety Approvals: Entela Certified UL 61010A-1 / CSA C22.2 No. 1010.1
CE marking for the European Union. Compliance with applicable

requirements of the EMC and Low Voltage directives.

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Main Logic Module (MLM)
Part Number: CN-MLM2-P
Size: 17.5" (44.5 cm) W x 8" (20.3 cm) H x 3" (7.6 cm) D.
Weight: 5 lbs. (2.27 kilograms).
Environmental: Operating temperature range: 32 F to 122 F (0 C to 50 C). Storage
temperature range: -10 F to 140 F (-23 C to 60 C). Maximum
relative humidity of 92.5% (non-condensing), up to 2000 meters
altitude.
Power Requirements: 100 - 120 / 200 - 240 VAC (+/- 10%), 10 Amps, 50-60 Hz (+/- 3 Hz).
Power Fuse Specification: 10 Amps, 250 VAC, Type F.
Battery Specification: Lithium type VL2020, 3.0 Volts DC. This battery cannot be accessed or
changed by the customer. Warning – Only this type of battery can be
used.
Communications: (1) C-Link network port (RS-485).

(1) MODBUS network port (RS-485).
(1) MLM expansion port, supports expansion to a total of 3 Main Logic
Modules.
Monitoring Inputs: (13) 4-20 ma current loop analog inputs (24 VDC, 2 Wire).
(10) RTD temperature sensor inputs (3 Wire, 100-Ohm Pt).
(8) 24 VDC digital inputs (dry contact interface).
(1) 0 – 5 Amp current transformer input, 32 VAC,
Over current: 6x (30 Amp) for 1 seconds 4x (20 Amp) for 20 seconds,
2x (10 Amp) continuous.
(1) 100 – 240 VAC digital input (optically isolated E-stop motor start
circuit interface).
Control Outputs: (4) 4-20 ma current loop analog outputs (24 VDC, 2 wire).
(12) 240 VAC digital outputs (optically isolated, solid-state relay, 5 Amp
maximum load).
Digital Output Fuse

Specification: 5 Amps, 250 VAC, Type F.
Safety Approvals: Entela Certified UL 61010A-1 / CSA C22.2 No. 1010.1
CE marking for the European Union. Compliance with applicable

requirements of the EMC and Low Voltage directives.

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Troubleshooting
A general troubleshooting guide is listed below. It is intended to provide the user with possible solutions
to the most common problems that the support desk observes.
WARNING:
!
Do not attempt inspection, maintenance, or service procedures other than those
specified in this manual. For service of internal components, it is necessary to
contact a factory trained and authorized service representative.
AVERTISSEMENT:
ne tente pas inspection, entretien, ou service autrement que ces a spécifié dans
ce manuel. Pour service d'interne pièces, c'est nécessaire contacter une Baie
Règle entraîné et autorisé service.
DANGER:
!
When problems are encountered which are beyond the scope and experience of
operating or service personnel, always request assistance from a factory trained
and authorized service representative. Improper servicing of the ProTech
Control System may result in equipment damage and/or personal injury or
death.
DANGER:
Quand problèmes sont rencontré qui sont au delà de l'étendue et expérience
d'opération ou , toujours demande d'une Baie Règle usine entraîné et autorisé
service . Déplacé entretenir de l'AProTech Contrôle peut résulter dans
DANGER:
! No operator access is permitted to the inside of the control system enclosure

and the control system modules. Failure to secure the enclosure from operator
access may result in personal injury or death.
DANGER:
Aucun opérateur est permis à l'intérieur du contrôle système et le contrôle
système . Echec obtenir la clôture d'opérateur peut résulter dans personnel
blessure ou mort.
DANGER:
!
Service personnel must remove power to the control system prior to making any
connections to terminals J11, J12, J13, J14, and J15. Failure to remove power
may result in equipment damage and/or personal injury or death.
DANGER:
Service doit enlever pouvoir au contrôle avant de faire n'importe quelles
connexions à terminaux J11, J12, J13, J14, et J15. Echec enlever pouvoir peut
résulter dans équipement dommages personnel blessure ou mort.

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Compressor Start Failure
Possible Causes Check

Drive Motor Starter Fault Starter Indication
Drive Motor Starter Not Racked In Starter
Drive Motor Starter General Fuses, Overloads, Time-out Protection
Start Sequence Permissives Not Met Start Sequence Step "Failed"
Control Output Failure MTR or start SSR Indicator light on.
Start Relay Failure Start Relay Coil
Wiring Problem Terminal J12 on MLM, E-Stop, Start Circuit
Trip After Motor Start Protection History (Start High/Low)
Motor Failure Free rotation, phase balance
Emergency Stop E-Stop status normal
If motor does not energize at all, AND start sequence is completed, the ProTech will trip off the
compressor when the start sequence is complete and the stop sequence will execute. The Protection
history will display a “trip” for the motor running signal or motor amps < 10.
Check the start circuit wiring including terminal J12 on the main logic module (MLM), Emergency stop
wiring, and any relays wired to the main starter contactor. With the starter racked out, dry run the
compressor and verify that the indicator light on the MTR solid-state relay on the MLM turns on and that
any connected start relays are energized. The MTR indicator light will turn off quickly if there is no
motor running feedback signal.
If the MTR indicator light turns on at all, it indicates that, most likely, the ProTech controller is not the
source of the problem. Check the wiring, control relays, and starter.
If the MTR indicator light does not turn on at any point, then the problem lies with the ProTech control
system or related wiring. Verify that the wiring at J12 on the MLM is connected and that the E-stop is
not engaged. If the wiring is okay, then the solid-state relay or control output may have failed and the
SSR or MLM may need replaced.
SENSOR FAULT

Open Wiring Monitoring point status "open"
Failed Transmitter Monitor point status open/short/fail
Failed Input Try connecting device to other input channel,
monitoring point in "fault" status
Slave MLM not powered Power to slave modules, power all down, then
back up
A “short” status for a transmitter indicates that current loop for the device is greater than 20 mA.
An “open” status for a transmitter indicates that the current loop value is less than 3.8 mA and a wire
may be loose.

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A “fail” status for a transmitter indicates that the current loop value is somewhere between zero and 4
mA. Try re-zeroing the transmitter if possible.
A ‘fault” status for any input indicates that the ProTech controller does not recognize the monitoring
point. Try resetting the controller by turning off the power for 5 seconds on all boards, then powering up
all boards simultaneously. If this does not resolve the problem, verify the input problem by checking the
device on an input that is currently working.
CONTROL PANEL INOPERATIVE

No Control Power Control power wiring connection at J15 on all
MLM's, 100-240 VAC 50/60 hz
Blown Fuse on MLM Fuse above J15 on each MLM
Loose Cable Between User Interface Module Cable connection at J1 on UIM and MLM
(UIM) and MLM.
Failed UIM Plug in spare UIM
Failed MLM Install Spare MLM
DISPLAY CONTRAST POOR

Contrast Adjustment Needed Press VIEW and the Up or Down Arrow.
Failed Backlight Power down controller, wait five seconds, power

up controller.
Direct Sunlight Fabricate shield for display if required for better
viewing
MOTOR OVERLOAD

Motor Load % set too high Motor load % under Set Points/Operator
Inlet valve control problems Smooth operation of inlet valve in auto mode
and manual valve control mode.
Current transformer (CT) problem CT reading normal
Starter Problem Check starter overloads
Motor Problem Check motor stator temperatures and current
imbalance

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ABNORMAL CONTROL PERFORMANCE

Set Points Incorrect Set Points - system pressure, system pressure
offset, motor load %, and performance control
variables
Inlet or Blow off Valve Performance Observe during automatic operation. Stop
compressor and test manual valve control,
review control air supply
Discharge Blockage Check valve operation, block valve, and dryer.

Discharge pressure will be high with blow off
maintaining maximum discharge pressure.
Faulty Amperage or Kilowatt reading Monitoring point ready normal and reasonable
HIGH AIR PRESSURE

Set Points Incorrect Set Points - system pressure, system pressure
offset
Failed System Pressure Transmitter Monitoring point normal and reasonable
Failed inlet or blow off valve Normal valve operation
LOW AIR PRESSURE

Set Points Incorrect Set Points - system pressure
Air Demand Above Compressor Supply Turn on Additional Compressors
Capacity
Failed System Pressure Transmitter Monitoring point normal and reasonable
Failed inlet or blow off valve Normal valve operation, check supply air
Maximum Load % Set Point Incorrect Set Points - maximum load %

Blow off valve Won't Close Discharge Pressure Too High or Motor KW too
low. Control air Pressure Low

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HIGH AIR TEMPERATURE

Water Flow to Coolers Insufficient Water supply pumps and valves
Water temperature too high Supply water temperature
Failed temperature input Temperature status normal
Intercooler/aftercooler fouled Inspect after check all other possible causes
Surging Surge count and machine normal sound and

operation
SURGING OR HIGH SURGE COUNT

Max Discharge Pressure Set Point Too High Maximum Discharge Pressure
Inlet and/or blow off valve poor operations Normal operation of inlet and blow off valve
Deteriorating compressor Rise to surge test and constant pressure surge

test
Surge Watch too sensitive Adjust if too sensitive
INLET VALVE WILL NOT OPEN

System Pressure below Set Point System Pressure and Set Point
Controller is in Unload mode Press Auto
Valve problem Control Air and manual valve operation test
while compressor stopped
Motor Amperage reading too high Is reading above max amp Set Point
Motor Load % too low Set Points/Operator/Maximum Motor Load (%)
needs adjusting
Failed MLM inlet valve output Use electric meter to verify 4-20 mA or pulse AC
output depending on type of control action
Failed Valve/Positioner/Actuator Manual Valve Control while stopped

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BLOW OFF VALVE WILL NOT CLOSE

System Pressure below Set Point System Pressure and Set Point
Controller is in Unload mode Press Auto
Valve problem Control Air and manual valve operation test
while compressor stopped
Motor KW Reading is below Minimum Power Verify inlet valve is open and motor power value
Set Point is higher than minimum power on Performance
Control screen
High Surge Count Monitoring Points surge count. If surge count is

excessive, minimum power Set Point has
moved above the max load of the compressor.
Failed MLM blow off valve output Use electric meter to verify 4-20 mA or pulse AC
output depending on type of control action
Failed Valve/Positioner/Actuator Manual Valve Control while stopped

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Parts and Service

Factory authorized service, support, and replacement parts are available from Bay Controls, LLC.
Bay Controls Technical Support
Phone: (419) 891-4390

Toll Free: (800) 837-2292
The ProTech control system is manufactured by:
Bay Controls, LLC.

6528 Weatherfield Court
Maumee, Ohio 43537
!
WARNING:
Do not attempt inspection, maintenance, or service procedures other than those
specified in this manual. For service of internal components, it is necessary to
contact a factory trained and authorized service representative.
AVERTISSEMENT:
ne tente pas inspection, entretien, ou service autrement que ces a spécifié dans
ce manuel. Pour service d'interne pièces, c'est nécessaire contacter une Baie
Règle entraîné et autorisé service .
When contacting technical support, it is helpful to have the following information available before
calling:
 Compressor Type (Centrifugal, Rotary Screw, Reciprocating)

 Compressor Manufacturer
 Software Version and Serial Number
 Serial Number of Hardware (if applicable)
 Protection and Event History Data (if applicable)
Parts Ordering Procedure
Since the ProTech controller is specifically configured for each individual compressor application,
please be sure to supply the following information when ordering parts:
1. The compressor manufacturer and model.

2. The compressor serial number.
3. The ProTech software license number.
4. The part description.
5. The part number (if any).

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Parts Availability
ProTech modules are stocked for replacement purposes and are available for immediate shipment.
Standard instrumentation and control elements are also stocked for immediate service. Some specific
instrumentation and components supplied with engineered applications may require additional lead-
time to supply. Bay Controls may change the part number and/or may substitute a part of equal or
greater reliability.
Returning Parts
It is necessary to contact technical support for authorization before the return of any goods to the
factory. All approved returns are assigned a Return Materials Authorization (RMA) number to prevent
delays or loss of materials. Senders must include the RMA number on the outside of the package
whenever goods are being returned.
Replacement Parts List
The ProTech Control System is implemented with a minimum number of high integration components
providing optimum reliability, simplifying service, and reducing the cost of maintaining spare parts.
Your ProTech Control System may have been retrofitted to a pre-existing control system and/or
packaged with other components by an authorized OEM, distributor, or by the end user. Information on
the other specific components packaged with your controller is beyond the scope of this manual. In this
case, refer to the information provided by the packager for replacement parts.
Description Part Number

ProTech User Interface Module (UIM ) CN-UIM2-P
ProTech Main Logic Module (MLM) CN-MLM2-P
Cable – ProTech MLM to UIM, 3’ CN-MLM2UIM
Cable – ProTech MLM to UIM, 6’ CN-MLM2UIM-6
Interface Module – ProTech RS-232 to RS-485 USB CN-RS485-USB
Interface Module – ProTech RS-232 to RS-485 Serial CN-RS485
Replacing Controller Modules
DANGER:
! Insure that all power is removed from the control system and that the compressor
motor is locked out before replacing modules. Failure to follow this procedure may
result in equipment damage and/or personal injury and death.
LE DANGER:
Assurer que tout pouvoir est enlevé du système de contrôle et que le moteur de
compresseur est hors verrouillé avant de remplaçant les modules. Echec suivre
cette procédure peut résulter dans équipement dommages personnel blessure et
mort.

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CAUTION:
!
All connections to the ProTech modules use plug-in connectors. These
connectors are unidirectional and of differing sizes reducing the possibility of
incorrectly reconnecting modules, however, use care to insure that the correct
connections are made prior to applying power.
LA PRUDENCE:
Toutes connexions aux modules d'AProTech utilisent les connecteurs de
bouchon-dans. Ces connecteurs sont unidirectionnels et de différer de tailles qui
réduisant la possibilité de modules qui reconnectant inexactement, cependant,
le soin d'usage pour assurer que les connexions exactes sont faites avant la
demande de pouvoir.
The process of replacing a module is relatively simple:
1. Insure all power is removed from the control system, and the compressor motor is locked out.
2. Unplug the connectors to the module, make note of how the connector were plugged in.
3. Remove the nuts that secure the module to the enclosure.
4. Remove the module.
5. Install the replacement module using the nuts removed in step 3. Be sure to reconnect any
ground wires that were attached to the mounting stud of the User Interface Module.
6. Plug in the connectors.
7. Verify that the connections have been correctly made.
8. Apply power to the controller.
9. If the primary Main Logic Module was replaced, it will be necessary to set the software license
number and reload the controller software prior to use.

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Chapter 2
Initial Startup Guide

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INTRODUCTION
The following document is intended to assist in the startup of air compressors with ProTech control
systems running the Version 5.0 operating system. The document provides the control system steps to
be taken during the initial compressor startup.
NOTE: Be sure that all of the compressor installation items are properly completed
before proceeding with this ProTech startup guide.
Manual Revision June 16, 2006.

Copyright  2002 - 2006 Bay Controls, LLC All Rights Reserved

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JOBSITE PROTECH CHECKS: BEFORE TURNING POWER ON
Verify that the isolating air system Block Valve is closed
Check the location of the system pressure transmitter

Verify the system pressure sensor is located in the plant header down stream of the check
valve, block valve, dryers and filters. An isolation valve is required for the system pressure
sensor.
Check wiring for correctness, loose wires

It is important to verify that all devices connected to the panel are wired properly to prevent
damage to either the ProTech controller or external devices.
Verify earth grounding

For safe and proper operation of the compressor, proper earth grounding is required. Verify
grounding of the compressor base, main drive motor and control panel. Additionally verify
the ground connection to MLM J15-GND.
Check motor starter interface wiring from ProTech

To prevent accidental motor start or damage to either ProTech control system or the main
motor starter, the wiring and starter circuit must be reviewed before power is supplied to
either system. Verify correct operating voltage and motor starter interface wiring per
machine wiring diagrams
Check Main motor and auxiliary oil pump overload setting
Check the supplied panel power.

To prevent damage to the components of the control system from over voltage damage,
the power supplied to the panel must be checked before it is applied. Disconnect power to
the MLM(s) by unplugging the connector at MLM-J15. Turn on power to the panel and
check the voltage using a voltmeter at the connection point. Measure and record the
voltage between L1 to L2 and L2 to Ground.

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JOBSITE PROTECH CHECKS: INITIAL APPLICATION OF POWER
Verify oil pump operation
Supply power to the oil pump starter and check rotation of the oil pump. If the pump rotation
is incorrect, disconnect power and switch two of the oil pump leads at the starter.
If the Auxiliary oil pump is configured to be stopped when the compressor is stopped force
the pump on by setting the Set Point->Operator->Reset Oil Pump to YES.
Connect your PC to the ProTech using the C-Link cable at Terminal J2
Establish communication with the ProTech panel.
Save the existing configuration from the ProTech
Using ProTech Desktop, get the configuration from the ProTech panel and save it. Saving the
configuration synchronizes the laptop files with the existing ProTech configuration. In the ProTech
Desktop menus, select File -> New…and enter the license number and press Next. (the license number
can be obtained by pressing the View key on the ProTech controller and selecting the Information
page).

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In the Choose Configuration dialog (shown below), select ‘Get from the ProTech Controller’ and press
Next. Note if your PC is not connected to the ProTech MLM you can not select ‘Get from the ProTech
controller’.
After the configuration is downloaded, the License Key Code dialog will be automatically filled in with
the correct Key Code from the ProTech controller.

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When the upload to the PC is complete, the following dialog will appear. To complete the process, click
the FINISH button.
Note: To simplify the startup procedure, turn off the ProTechs access codes until the start up is
complete. The Access codes are accessed on the ProTech Desktop Security page. Set
each to ‘0000’.
Review Configuration
Using the ProTech Desktop; review the configuration. A review of the data on the General and the
Equipment screens will help to confirm the accuracy of the overall configuration. Using the “All” tab is
an easy way to verify that any optional monitoring and control options are configured as required for
your specific application.

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Send Configuration
If any changes were made to the configuration, send the changes to the ProTech using the
ProTech Desktop menu “ProTech/Send Configuration”.
If the original ProTech configuration is desired, use the “Revert” function in the File/Revert menu.

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INITIAL START OF COMPRESSOR
Check ProTech status
Using the VIEW menu options on the ProTech Controller; check the following screens.
● Monitoring Points:
 Check all points for valid Descriptions, Data and Status.
● Control Points:
 Check all points for valid Descriptions, Data and Status.
● Protection (Running):
 Check for correct Alarm and Trip set point values.
● Protection (Start-up):
 Check Startup Protection for correct Alarm and Trip set point values.
● Permissive Startup Status:
 Verify all permissive(s) are correct.
 Test the Emergency Stop operation check for Ready to Not Ready change.
Verify proper operation of the Inlet and Blow-off valves

Using the Manual Valve control, stroke both the inlet and blow off valves. Verify the closed
and fully open positions. Check for responsiveness and repeatability.
Turn-on coolant supply
Start the compressor and measure the acceleration time to full speed
Record the acceleration time, in seconds, as this is required for proper control settings in
the ProTech and motor starter.
Unload the compressor

Once the start sequence times out, the compressor will attempt to automatically load.
To prevent this, press the UNLOAD key immediately upon reaching full speed.
Hint: Setting the System Pressure Setpoint to 0 PSI will prevent the compressor from
automatically loading after the completion of the start sequence.
Verify normal compressor operation while unloaded

Verify proper compressor operation in the unloaded condition for at least 30 minutes.
● Check the position of the compressor inlet valve, to make sure the compressor is not in
surge, or excessively loaded.
● Check all operating parameters for proper values (motor current, pinion vibration, oil
pressure, temperatures, air pressures, etc.).
● Check for any air, water, or oil leaks at compressor.
● Verify proper drive motor operation, and check for leaks.

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INITIAL CONTROL LOOP TUNING PROCESS
Manually load the compressor

With the block valve closed, open the compressor inlet valve fully (or until maximum motor
load is reached). If a modulating blow-off valve is available, manually close the valve to
load the compressor to the design pressure and observe operation.
Verify proper operation of the condensate removal system
Tune the Inlet Valve Maximum Load loop

Access the Maximum Load Tuning tool, Set Point->Commissioning->Tune Inlet Maximum
Load. The first ProTech page you will see is the Manual Valve Control page. Start by
opening the inlet valve to near motor FLA. When ready press ENTER.
Manual Valve Control
Inlet Valve Blow Off Valve .

Position: 0.0 Position: 100.0
Description Tag Data Units Status .

1: System Air Pressure PT-101 102.7 PSI Normal
2: Discharge Air Pressure PT-102 103.4 PSI Normal
3: 3rd Stage Inlet Temp TE-104 111 DEG F Normal
4: 1st Stage Vibration VT-110 0.12 mils Normal
5: 2nd Stage Vibration VT-111 0.09 mils Normal
6: 3rd Stage Vibration VT-112 0.17 mils Normal
7: Oil Pressure PT-105 120.3 PSI Normal
8: Oil Temperature TE-101 121 DEG F Normal
9: Drive Motor Current IT-114 132.2 Amps Normal
10: Motor Running Signal ON Normal
11: Emergency Stop Signal NORMAL Normal
12: SurgeWatch Motor 9.1 % Normal
13: Surge Count 0 Normal
14: Surge Control Point 101 Amps Normal
Move to starting position then press ENTER
Using the down key, review each parameter and change as desired. After entering the last parameter,
the tuning graph will appear, watch the responses as you change the Maximum Load set point with the
‘+’ and ‘-‘ keys.
Note: The Set Point and Scale Minimum and Maximum are in % of motor FLA.
Press the BACK key to access the tuning parameters. Continue tuning until a satisfactory response to a
step change is achieved.
CAUTION: Both control valves are placed in manual while changing the tuning parameters. No
surge or over pressure protection is being provided.
NOTE: For 4-20mA controlled valves the Maximum and Minimum Pulse width changes to Rate Limits
on the screen above.
MANUALLY CLOSE THE INLET VALVE AND TEST YOUR TUNING AT 90 % MOTOR LOAD AND
OBSERVE TIME TO ATTAIN SET POINT AND STABILITY

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Tune the Inlet Surge Control loop

Tuning the Inlet Surge Control loop is very similar to the Inlet Maximum Load loop. The
difference is this loop controls the inlet valve minimum throttle position.
Access the Inlet Surge Control tuning tool through Set Point->Commissioning.
MANUALLY OPEN THE INLET VALVE TO FLA AND TEST YOUR TUNING AT 70 %
MOTOR LOAD AND OBSERVE TIME TO ATTAIN SET POINT AND STABILITY
Tune the Blow Off Discharge Pressure Loop

If a modulating blow off valve is being used, the next step is to tune the blow off valve
Discharge Pressure loop. If a solenoid (Open/Closed) blow-off valve is installed, no tuning
of the Blow Off Discharge Pressure loop is required.
At the Manual Valve Control page open the inlet to near FLA and press ENTER. Using the down key;
review each parameter, changing as desired. After entering the last parameter, the tuning graph will
appear. Watch the response. The Maximum Load set point is changed with the ‘+’ and ‘-‘ keys, forcing a
step response.
Tune Control Loop
Control Loop: Blow Off Discharge Pressure

Scale Minimum: +0080.0
Scale Maximum: +0130.0
Set Point: 100
Tune Adjustment: 5
Proportional Gain (Kp): 00.60
Integral Gain (Ki): 10.00
Rate Limit +: 15
Rate Limit -: 10
After entering the last parameter, the tuning graph will appear, watch the response. The discharge
pressure set point can be change with the ‘+’ and ‘-‘ keys, forcing a step response for the controller.
Press the BACK key to access the tuning parameters.
MANUALLY OPEN THE INLET VALVE TO FLA – OPEN THE BLOW-OFF VALVE AND TEST YOUR
TUNING AT DESIGN PRESSURE AND OBSERVE TIME TO ATTAIN SET POINT AND STABILITY
CAUTION: Both control valves are placed in “Manual” (frozen in place) while changing the tuning
parameters. No surge or over pressure protection is being provided. Be sure to return to Automatic
control mode when all tuning is completed.

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Surge Testing
Natural Surge test

To find the natural (rise to surge) point, use the Natural Surge Test feature of ProTech (SET POINTS-
>Commissioning->Natural Surge Test). Using the down arrow key review each parameter changing
as desired. The Test Ramp Rate is the rate at which the blow-off valve is ramped closed during the
surge test. The monitoring points selected as acquisition points will be displayed along with the surge
data on the surge result screen. Typically you want to select monitoring points that respond to when the
compressor surges.
NOTE: When surge testing a compressor equipped with a solenoid (Open/Closed) blow-off valve, surge
testing will need to be done manually.
With the compressor in Manual control and blow-off valve closed, use the manual system block valve to
ramp the compressor toward surge.
Natural Surge Test
Test Ramp Rate: 01.00
Acquisition Point 1: SurgeWatch Motor

Acquisition Point 2: Stage 3 Inlet Temperature
Acquisition Point 3: 1st Stage Vibration
Acquisition Point 4: 2nd Stage Vibration
After entering the fourth acquisition point, the Manual Valve Screen will be displayed. Open the inlet
100% and if a modulating blow-off valve is being used, close the blow-off valve to bring discharge
pressure to a point below surge pressure. If using a Digital (Open/Closed, solenoid) blow-off valve
leave the valve open.
Manual Valve Control
Inlet Valve Blow Off Valve .

Position: 88.0 Position: 58.0

12: SurgeWatch Power 9.1 % Normal
Move to starting position then press ENTER
Note: The Monitoring points displayed on the Manual Valve Control Screen may be changed in the Set
Point->Tools->Manual Valve Control Setup page.

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Press ENTER and the blow-off valve will ramp closed, to allow discharge pressure to increase to the
natural surge point. As it is doing this, the following screen is displayed.
Surge Test In Process
Drive Motor Current: 132.2

Discharge Pressure: 103.4

12: SurgeWatch Power 9.1 % Normal
When the compressor surges, press ENTER, and the Surge Test Results screen will display the last 19
data points collected. Using the data on this screen, record the discharge pressure and motor current
just prior to surge.
Surge Test Results
Time Pressure Current Point 1 Point 2 Point 3 Point 4

08:31:12 139.4 132.2 9.1 111 0.12 0.09
08:31:12 139.7 132.0 9.2 111 0.12 0.09
08:31:13 139.9 131.9 8.9 111 0.12 0.09
08:31:14 140.1 131.7 8.7 111 0.12 0.09
08:31:14 140.4 131.4 8.7 111 0.12 0.09
08:31:15 140.6 131.1 8.4 111 0.12 0.09
08:31:15 140.8 130.9 8.1 111 0.12 0.09
08:31:16 141.1 130.6 8.3 111 0.13 0.09
08:31:17 141.3 130.4 7.5 111 0.13 0.10
08:31:17 141.7 130.2 7.3 111 0.12 0.09
08:31:18 141.9 129.9 7.6 111 0.12 0.09
08:31:18 142.0 129.7 7.7 111 0.12 0.09
08:31:19 142.2 129.4 8.1 111 0.12 0.08
08:31:19 142.4 129.3 8.9 111 0.12 0.09
08:31:20 142.6 128.9 9.7 110 0.12 0.09
08:31:21 142.9 128.6 32.9 110 0.13 0.09
08:31:21 137.2 96.5 107.8 113 0.15 0.11
08:31:22 135.9 120.5 111.8 113 0.14 0.10
Natural Surge point: Discharge Pressure__________, Amps__________.

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High Throttle Surge Test
The High Throttle Surge test defines the high operating pressure surge point. This surge point should
be taken 10 to 15 psi below the natural surge pressure. Access through (SET POINTS-
>Commissioning->High Throttle Surge Test). Using the down arrow key review each parameter,
changing as desired. The test Ramp rate is the rate the inlet valve closes during the test. The
acquisition points are typically those used for the Natural Surge Test.
Surge Test Pressure: +130.0

Test Ramp Rate: 01.00
Acquisition Point 1: SurgeWatch Motor
Acquisition Point 2: Stage 3 Inlet Temperature
Acquisition Point 3: 1st Stage Vibration
Acquisition Point 4: 2nd Stage Vibration
The Manual Valve Control screen follows. Open inlet valve & press ENTER .
Surge Test Pressure: 130.0

Discharge Pressure: 128.4
Press Enter When Stabilized .
The ProTech will modulate the blow-off valve to control to the Surge Test Pressure. When the pressure
has stabilized, press Enter. The Surge Test in Progress screen appears, as the inlet valve ramps
closed while discharge pressure is maintained with the blow-off valve. When the compressor surges,
press Enter and record the High Throttle surge point.
Note: To acquire accurate surge data a slow ramp rate is required.
High Throttle Surge point: Pressure__________, Amps__________.
Mid Throttle Surge Test
Repeat the same process as above, accessing through (SET POINTS->Commissioning->Mid

Throttle Surge Test). Set the surge test pressure at the desired system pressure setpoint, following
the same steps as above.
Mid Throttle Surge point: Pressure__________, Amps__________.
Low Throttle Surge Test
Repeat the same process again, through (SET POINTS->Commissioning->Low Throttle Surge
Test). Set the surge test pressure at 80% of the Mid Throttle surge pressure, or the lowest expected
operating pressure.
Low Throttle Surge point: Pressure__________, Amps__________.
Note: Press the Unload key when surge testing is completed.

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Enter Commissioning Settings
(SET POINTS->Commissioning->Commissioning Settings).
Commissioning Settings
Discharge Pressure Limit: 130.0

Check Valve Offset: 3.0
Standby Offset: 10.0
Surge Curve Settings Current Pressure

High Surge Point: 118.6 116.3
Middle Surge Point: 104.3 100.8
Low Surge Point: 82.1 79.2
Surge Control Offset: 5.2
Surge Count: 0
SurgeWatch Settings Gain Time

SurgeWatch Motor: 13.0 2.00
 High, Mid and Low Surge Points: Define the actual compressor surge line and are set to
the values recorded during the surge tests.
 Surge Control Offset: Defines the proximity (in Amps) between the actual surge line and
the Surge Control Line. Typically set at an amperage value 5 % greater than the Mid
Throttle Surge Point amps.
 Discharge Pressure Limit: The maximum discharge pressure that the compressor is
allowed to operate. In the Auto Offline and Auto Standby control modes, ProTech will
modulate the blow-off valve to limit the discharge pressure to this value. In Auto Unload
mode, the compressor will unload if the discharge pressure reaches this setpoint.
 Check Valve Offset: This setpoint is used to verify that the check valve has closed. The
value indicates the result of subtracting actual discharge pressure from actual system
pressure (typically 3 psig). The compressor will unload in Auto-Offline mode, or decrease to
the Standby pressure setting if in Auto-Standby mode.
 Surge Count: Set to 0. This indicates the recorded number of surges. Each detected surge
will index the initial Surge Offset by the value of the Surge Watch Adapt setpoint.
 SurgeWatch: Multiple SurgeWatch parameters can be configured for detecting a

compressor surge. As standard, motor current must be configured as one of the
SurgeWatch points.
 Gain: The Gain setting is a multiplier used to adjust the SurgeWatch parameter. Gain
directly affects the results (doubling the Gain will double the SurgeWatch value at surge).
Set the Gain to achieve SurgeWatch point values exceeding 100 during a surge, while
remaining well below 100, when away from surge.
 Standby Pressure Offset (Auto-Standby mode only): Defines the discharge pressure
that the compressor will maintain while blowing off with the check valve closed. The
discharge pressure maintained equals the System Pressure setpoint minus the Standby
Pressure Offset setpoint.

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 SurgeWatch Adapt: defines the amount that the surge line offest is adjusted in the event
of a surge. Total surge offset = Surge Offset + Surge Count x SurgeWatch Adapt.
Additional Performance Control Parameters
You can use the ProTech Desktop to access the Performance control tab to set the additional
parameters shown below:

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Review all Control Parameters

The Control Parameters are the control loop tuning values and settings for the compressor inlet and
blow off valves. The values from the previous loop tuning will have already been set. Access is obtained
through (SET POINTS->Commissioning->Commissioning Settings).
Control Parameters
Inlet Control Kp Ki
System Pressure: 9.00 3.00
Surge Control: 1.50 15.00
Maximum Current: 1.50 15.00
Mass Flow: 9.00 3.00
Rate Limits (+/-): 20.0 20.0
Blow Off Control Kp Ki

System Pressure: 7.00 2.50
Discharge Pressure: 0.60 10.00
Mass Flow: 7.00 3.00
Rate Limits: 15.0 10.0
Review the Operator Settings and Setpoints

The Operator settings are access by pressing SETPOINT->Operator.
Operator
Operating Mode: Auto-Offline

Set Point: 95.0 PSI
Offset: 2.0 PSI
Home Page: Monitor Points
Strip Chart Speed: Fast
Date: 06-23-06
Time: 15:56:47
 Operating Mode: Selects the control mode for the application.
 Auto-Unload is used when the compressor does not have a modulating blow off
valve. The compressor is unloaded when reaching the System Pressure Offset
setpoint.
 Auto-Offline controls by modulating both the inlet and the blow-off valves to
maintain system pressure. The compressor unloads if the check valve closes
during blow off.
 Auto-Standby controls by modulating both valves to maintain system pressure.

The compressor ‘stands-by’ just below the system pressure setpoint, if the check
valve closes during blow off.
 Constant Flow maintains a constant delivered flow to the process based on a flow
setpoint and supplied delivered flow signal.
Note: See Appendix C of compressor Handbook for complete description of control modes.

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 Set Point: In the pressure control modes, this is the System Pressure setpoint for the inlet
valve System Pressure control loop. In the Constant Flow mode, it is the inlet Constant
Flow loop setpoint.
 Offset: In the pressure control modes, this establishes the blow-off valve’s System
Pressure Offset loop setpoint. In Constant Flow control this setpoint defines the Blow-off
Flow loop setpoint.
 Home Page: Defines the default View screen.
 Strip Chart Speed: Sets the update rate of the strip chart portion of the performance
control screen.
 Fast: The strip chart total (cycle) time is 7 minutes

 Medium: The strip chart total (cycle) time is 8 hours
 Slow: The Strip chart total (cycle) time is 24 hours
Run the Compressor In the Automatic Control Mode
Temporarily set the System Pressure setpoint a little bit higher than the actual system pressure to
ensure compressor loading. While tuning the System Pressure loops, it is important to have the highest
system pressure setpoint to ensure prevent other compressors in the system from interacting.
Place the compressor in automatic by pressing the Auto Key and watch the compressor’s performance
using the Performance View screen.
Tune the Blow Off and Inlet System Pressure loops
Observe the compressor’s operation in the automatic mode. If any additional tuning is required, access
the screens (SET POINTS->Commissioning->Commissioning Settings) and proceed as explained
previously.
Shutdown Compressor
To shutdown the compressor, press the Stop key. During the unload sequence note any compressor
surging. If the compressor surges during unloading, either
 If a 4-20mA controlled actuator, reduce the unload ramp rate.

or
 Open the inlet to move further from surge while unloaded.
Observe the Stop sequence to verify correctness. Make any required changes.
Note: the compressor can not be restarted until the stopping sequence is complete.

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Reset the Operation History
The operating history should be reset after completing the startup. It is accessed in (SET POINTS-
>Tools>Edit Operation History). Change ‘Reset Operation History’ from No to Yes and press ENTER.
Save the Configuration To Laptop
Obtain the final ProTech configuration settings using the ProTech Desktop menu “ProTech Get
Configuration”. Save it in a properly named folder.
Put In Access Codes and Send To ProTech
In the “Security” screen of the Desktop, set the access codes and send the final configuration to the
ProTech controller.

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ProTech Start-up Checklist
BEFORE TURNING POWER ON CHECK THE FOLLOWING:
Verify that all compressor installation items are properly completed
Verify that the isolating manual block valve is closed
Check the location of the system pressure transmitter
Check wiring for correctness, loose wires
Verify proper earth grounding
Check motor starter interface wiring from ProTech
Check Main motor and auxiliary oil pump overload settings
Check the supplied panel power.
TURN THE POWER ON AND PERFORM THE FOLLOWING:

Turn-on oil reservoir vent ejector and verify operation
Verify oil pump operation
Save existing configuration from the ProTech
Review Configuration
Send Configuration (if changed)
INITIAL START OF COMPRESSOR:

Check ProTech status (Monitoring points, control points, protection
values, permissives)
Verify proper operation of the Inlet and Blow-off valves
Turn-on coolant
Start compressor and measure the acceleration time
Unload the compressor and verify proper operation
Verify proper inlet valve unloaded position
Check for air, water, and oil leaks
Check main motor for oil leaks and over heating
Set the Compressor Acceleration time in the Equipment section

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CONTROL LOOP TUNING AND SURGE TESTING
Manually load the compressor
Verify proper operation of the condensate removal system
Tune Inlet valve Maximum Load control loop
Tune Inlet Minimum Flow control loop
Tune Blow Off Discharge Pressure control loop
Natural Surge test
Surge point: Pressure__________, Amps__________.
High Throttle Surge test
Mid Throttle Surge test
Low Throttle Surge test
FINAL STARTUP ITEMS

Unload compressor
Set Commissioning Settings
Set Control Parameters
Set the Operator Settings
Place the compressor in Automatic, load, observe proper control
Tune the Blow Off and Inlet System Pressure loops
Shutdown compressor
Reset the operation history
Save the configuration to laptop
Enter appropriate access codes and send to ProTech

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Chapter 3
Operator’s Guide

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ProTech Operator’s Guide
About This Guide

This guide contains the basic information necessary to operate the ProTech control system. However,
since installations may vary, these instructions may not cover all details or variations in the equipment
supplied or every question that may arise during use.
If a question or situation develops which is not answered directly in this guide, contact Bay Controls for
more information.
Guide Revision 5.1, June 16, 2006

ProTech is a trademark of Bay Controls, LLC
Copyright © 2003-2006, Bay Controls, LLC. All Rights Reserved.
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The ProTech Control Panel
The major components of the ProTech controller are mounted on the compressor in a weatherproof
electrical enclosure. The two main components are the User Interface Module (UIM) and the interior Main
Logic Module (MLM). Both these modules are self contained and neither contains any user-serviceable
parts.
The UIM is a full-page, back-lit liquid crystal LCD display with an integrated 15 key, tactile keypad. The
display provides detailed information on the operational condition and settings of the compressor.
One or more Main Logic Modules (MLM) are included in the panel. Each MLM contains a power supply, a
microprocessor, and I/O (input / output) channels. For applications that require increased I/O capacity, an
additional slave MLM may accompany a master MLM in a single control package.
Cleaning - If the MLM becomes dirty, use only a dry cloth to clean the part. Never apply water or any
solvent. If the display, or UIM, should become dirty, a mild detergent can be used for cleaning. Use a soft,
non-abrasive cloth to clean the display. Do not submerge any part.

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The ProTech User Interface Module
Function Keys
LCD Display
Input /Navigation Keys

Information Keys
LCD Display
The LCD display provides detailed information on the operational conditions and settings of the
compressor.
Information Keys
This key group enables access to various display screens for viewing current compressor operation,
historical event data, and network information if applicable.
Input / Navigation Keys

This group of keys allows the user move through the various screens and to change control parameters.
Function Keys
This key group lets the user operate the compressor and access certain screens for changing control
settings.
EMERGENCY STOP Push Button (not shown)

When pressed, immediately removes all power to the main drive motor. This device should only be used
in case of an emergency

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Information Keys
The four keys in this group provide access to informational screens that display current operating and
control data, historical logs and networking information. Accessing these view-only screens does not
affect operation of the compressor.
The descriptions and sample screens here show typical data from a specific compressor model and
configuration that may differ from your system.
Home
Press this key to display your selected Home page.
To change the Home page:

Press the Set Points key and select Operator [Enter].
Move the cursor [Up, Down] to Home Page
Use the Increase or Decrease key to scroll to the name of the screen you want.
Press Enter to select the page. Press Home to verify the selection.
View
Pressing the View key opens the menu of available view pages. To go to a specific
screen, use the Up [] and Down [] keys to move to the desired page, then press Enter.
You can adjust the display contrast (or backlight) by pressing the Up or Down key while
holding down the View key.
View Pages
The following section describes typical view pages that are available. Due to differences in installations or
options purchased, your controller may have additional or different pages than those shown.
View Pages
Performance Control
Monitor Points
Control Points
Protection (Running)
Protection (Startup) Press Up and
Permissive Status Down keys to
Information navigate. Use
Auxiliary Control Enter  key to select.

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Performance Control
The Performance Control screen displays current information on the operating state of the compressor.
The three sections on the left side of this screen show, Inlet, Blow-Off, and Status. The two graphs on the
right show Pressure over Current and Pressure over Time. The box labels and contents that appear
depend on the control mode selected and options available.
Inlet, Blow-Off and Status Boxes
Inlet [upper left]: Shows the inlet valve control mode and its activity or position.
 Mode indicates the inlet valves current control loop or mode (Manual, Unload, System, Min Flow,
Max Load, Sys Flow.)
 Position is the percentage of full modulation of the valve for applications with an analog (4-20mA)
controlled valve; for a modulating digital output, this shows relative move size.
 The bar graph is a graphical representation of the relative position of the valve.
Blow-Off [middle left]: Shows the blow-off valve control mode and activity or position.
 Mode indicates the inlet valves current control loop or mode (Manual, Unload, System, Dischg,
Standby, Sys Flow.)
 Position is the percentage of full modulation of the valve for applications with an analog (4-20mA)
controlled valve; for a modulating digital output, this shows relative move size.
 The bar graph is a graphical representation of the relative position of the valve.
Status [bottom left]: Shows the operating status of the compressor and relevant set point. The actual
items included in the status box will vary based on control method:

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Performance Control Graphs
The upper graph shows the compressor operating position relative to its control values.
 The sloped line is the surge control line.
 The vertical line on the right is the maximum motor load.
 The dotted horizontal line is the system pressure set point.
 The small solid square is the system pressure.
 The small hollow square is the discharge pressure.
The vertical bar in the lower dynamic graph moves left to right and plots the system pressure over time.
Monitor Points
The Monitor Points screen shows the current the value or status for each configured monitoring point.
The monitoring points include all analog and digital inputs to the MLM along with some calculated values
and control outputs. Use the Up () and Down () keys to view the full list when more than 20 monitoring
points are available.
The Data and Status columns in the Monitor Points screen are dynamic and reflect the current condition
for each point.
Monitor Points
Description Tag Data Units Status

6: 3rd Stage Vibration VT-112 9.99 mils Open
12: SurgeWatch Motor 9.1 % Normal
14: Surge Control Point 102.6 Amps Normal
The value that appears in the Status column for each point reflects that point’s condition, as follows:
 Normal: The signal is within the expected range for the sensor (for a 4-20mA sensor this
indicates a signal between 3.75 mA – 20.2 mA) and with in the expected operating range for the
monitored condition.
 Open: No signal at all (0 mA), indicating device failure wiring problem or input channel failure.
 Short: The input is shorted to 24 Volts (>20.25mA), indicating device failure, wiring problem, or
input channel failure.
 Fault: For RTD inputs fault indicates either a miss wired or failed RTD. For the CT input indicates
over 5 amps of current.
 Fail: An invalid monitoring point channel or communications problem between MLMs.
 Alarm: The monitored device is in an alarm state.

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Control Points
The Control Points screen shows the status and value of the ProTech configured outputs. Use the Up()
and Down() keys to view the full list, if more than 20 control points are available.
Control Points

1: Inlet Valve Position FY-101 0.00 % Normal
2: Blow-Off Position PY-102 0.00 % Normal
3: Auxiliary Oil Pump ON Normal
4: Alarm OFF Normal
5: Trip OFF Normal
6: Motor Enable OFF Normal
7: Start Signal OFF Normal
8: Cooling Fan ON Normal
9: Condensate Drain 0.00 Sec Normal
10: Shorting Contactor OFF Normal
11: Cooling Fan Speed 9.1 % Normal
The value that appears in the Status column for each point reflects that point’s condition, as follows:
 Normal: The output channel is operating normally.
 Fail: An invalid monitoring point channel or communications problem between MLMs.
The Protection (Running) screen displays all the monitoring points plus the alarm and trip values that
apply to each point when the compressor is in the running mode. Running protection levels take effect
upon completion of the start sequence and remain active until the stopping sequence begins.
Trip Alarm Alarm Trip .

Description Tag Low Low Data High High .
1: System Air Pressure PT-101 95.1
2: Discharge Air Pressure PT-102 102.2
3: 3rd Stage Inlet Temp TE-104 111 120 130
4: 1st Stage Vibration VT-110 0.12 1.50 2.00
5: 2nd Stage Vibration VT-111 0.09 1.50 2.00
6: 3rd Stage Vibration VT-112 0.05 1.50 2.00
7: Oil Pressure PT-105 70.0 80.0 120.3 180.0 200.0
8: Oil Temperature TE-101 60 70 121 135 145
9: Drive Motor Current IT-114 10.0 132.2
10: Motor Running Signal Enable OFF
11: Emergency Stop Signal NORMAL Enable
12: SurgeWatch Motor 9.1
13: Surge Count 0 12
14: Surge Control Point 101

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Protection (Startup)
The Protection (Startup) page displays all of the monitoring points plus trip values that apply when the
compressor is in the starting mode.
The startup protection levels take effect when the Start Sequence issues the Start command. These
levels remain active until the Start Sequence has completed, at which point the Protection (Running)
criteria takes effect.
Protection (Startup)
Description Tag Low Data High

1: System Air Pressure PT-101 95.1
2: Discharge Air Pressure PT-102 102.6
3: 3rd Stage Inlet Temp TE-104 111
4: 1st Stage Vibration VT-110 0.12 4.00
5: 2nd Stage Vibration VT-111 0.09 4.00
6: 3rd Stage Vibration VT-112 0.05 4.00
7: Oil Pressure PT-105 70.0 120.3
8: Oil Temperature TE-101 121
9: Drive Motor Current IT-114 132.2
10: Motor Running Signal OFF
11: Emergency Stop Signal NORMAL Enable
12: SurgeWatch Motor 9.1
13: Surge Count 0
14: Surge Control Point 101
Permissive Status
The Permissive Status screen displays the status of all permissives configured in Start Sequence. The
Sequence can begin only if Ready appears in the Status column for every item listed. A status of Not
Ready for any permissive item prevents the compressor from starting.
Permissive Status
Description Data Status

1: Discharge Air Pressure PT-102 < 2.0 0.0 Ready
2: Oil Temperature TE-101 > 60 85 Ready
3: Oil Temperature TE-101 < 145 85 Ready
4: 1st Stage Vibration VT-110 < 0.50 0.00 Ready
5: 2nd Stage Vibration VT-111 < 0.50 0.00 Ready
6: 3rd Stage Vibration VT-112 < 0.50 0.00 Ready
7: Emergency Stop Signal = Normal Alarm Not Ready

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Information
The Information screen displays the product serial numbers, ProTech software and hardware versions,
license numbers and installed options. The information is unique to the specific compressor system and
useful during compressor commissioning and for troubleshooting.
Information
Equipment Serial Number: F12345

ProTech Serial Number: 01-00-02-46
Software License Number: 00-00-01-04 : C614-8201
ProTech Software Version: 5.00.046
Main Logic Module Version: 2.05
User Interface Module Version: 2.06
Configuration Change: 08-04-06 07:22:15
Auxiliary Control: 1.00

Performance Log: 1.00
Compressor Networking: 1.01
Automatic Start/Stop: 1.01
 Equipment Serial Number: The Compressor Serial Number

 ProTech Serial Number: The serial number of the Main Logic Module (MLM)
 Software License Number: Used to track software features and configurations, specific to the
compressor.
 ProTech Software Version: Installed version of software.
 Main Logic Module Version: Identifies the Main Logic Module hardware/firmware version.
 User Interface Module Version: Identifies the User Interface (UIM) hardware and firmware
version.
 Configuration Change: Date of most recent configuration change.
 Software Option Versions: Shows any software options installed.
Auxiliary Control
The Auxiliary Control feature of the ProTech enables up to four additional control loops (P&I) which can
be configured to control auxiliary devices such as a cooling water valve, heat tracing, and dampers. The
Auxiliary Control view screen shows the process variable, its set point and the control variable or output
for each of up to four auxiliary control loops.
Auxiliary Control
Oil Temperature: 120

Set point: 120
Cooling Water: 47.3

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History Pages
Pressing the History key opens the menu that lists the history pages that are available
History Pages
Protection History
Event History
Operation History
Motor Trip History
Surge Test Results
Performance Log
Protection History
The Protection History screen shows a listing of all the most recent protection alarms and trips, each with
a date and time stamp. The type of monitoring point and its monitoring data are displayed in chronological
order, from newest to oldest. Up to 256 protection history events are stored in the ProTech controller. Use
the Up () and Down () keys to scroll through the entire list.
Protection History
# Date Time Type Description Tag Data

001 08-04-06 21:01:04 Start Fail Emergency Stop Signal Alarm
002 08-04-06 19:04:09 Trip High Oil Temperature TE-101 146
003 08-04-06 17:32:18 Alarm High Oil Temperature TE-101 136
004 08-01-06 01:32:15 Alarm High Inlet Filter Press Drop PDT-107 10.1
005 06-03-06 13:12:31 Alarm High Oil Filter Pressure Drop 40.1
Alarms and Trips are acknowledged by pressing the Home, View, History, or Network keys. This action
clears the display and turns off any associated alarm outputs (horn, light, pager etc), but it does not reset
the alarm. The alarm status returns to Normal only when the condition has been corrected and data from
the monitoring point no longer exceeds the alarm value.

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Event History
The Event History screen shows a history of all control actions including start, stop, sensor faults, power
resets, set point adjustments initiated by an operator, the controller, or by network or remote devices. Up
to 256 events are stored with date and time stamp, type, source, and comment fields. Use the Up() and
Down() keys to page through the event data.
Event History
# Date Time Type Source Comment .
001 08-04-06 21:01:04 Start Keypad

002 08-04-06 19:04:09 Set Points Keypad Operator
003 08-04-06 05:33:39 Stop Keypad
004 07-26-06 07:36:04 Start Keypad
005 07-26-06 07:33:02 Stop ProTech
006 07-26-06 07:33:02 Sensor Fault ProTech System Pressure
007 07-26-06 07:33:02 Power On ProTech
The potential Types of events are:

 Start: The start sequence was initiated
 Stop: The stop sequence was initiated
 Set Points: The Set Points menu was accessed.
 Power On: The ProTech went through the power on procedure.
 Mode: The control mode was changed (Auto or Unload).
 Access Fail: An unsuccessful attempt was made to access a password-protected menu or
page.
 Sensor Fault: A monitoring point registered a non-acceptable value
 Surge Watch: The Surge Watch limit was exceeded
The potential Sources of events are:

 Keypad: The action occurred using the ProTech keypad
 ProTech: The controller automatically initiated the action.
 C-Link: A command came through the C-link network.
 Modbus: A command came through the Modbus network.
 Remote: A command was initiated from a remotely located input,.
 Network: The ProTech Network (DCC) initiated a command.
Operation History
The Operation History screen shows a breakdown of the compressor the compressor running hours along
with the hours of the operating state.
Operation History
Operation From: 07-04-06 00:11:54

Running: 00314:12:130
Full Load: 00112:34:21
Modulating: 00008:23:14
Minimum Flow: 00000:00:00
Blowing Off: 00000:45:19
Unloaded: 00201:31:19

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Motor Trip History

The Motor Trip History screen shows a snapshot of the compressor’s operating state at the time of the
most recent shut down under normal conditions and the previous four shutdown trips. This data is useful
for diagnosing compressor and auxiliary problems that cause a compressor trip. Use the Protection
History page if necessary to determine what trip point was responsible for stopping the compressor.
Motor Trip History
Normal Trip Trip Trip Trip .

08-18 08-18 08-18 07-22 03-05.
Description Tag 16:56 12:53 10:16 07:05 03:51.
1: System Air Pressure PT-101 102.7 98.6 99.7 98.4 102.2
2: Discharge Air Pressure PT-102 103.4 99.8 100.5 99.6 101.4
3: 3rd Stage Inlet Temp TE-104 111 140 140 105 94
4: 1st Stage Vibration VT-110 0.32 0.29 0.29 0.31 2.05
5: 2nd Stage Vibration VT-111 0.19 0.15 0.15 0.12 0.20
6: 3rd Stage Vibration VT-112 0.15 0.15 0.15 0.14 0.18
7: Oil Pressure PT-105 120.3 115.3 114.2 116.3 80.0
8: Oil Temperature TE-101 121 141 138 145 95
9: Drive Motor Current IT-114 132.2 130.7 131.2 130.5 151.2
10: Motor Running Signal ON ON ON ON ON
11: Emergency Stop Signal NORMAL NORMAL NORMAL NORMAL NORMAL
12: SurgeWatch Motor 9.1 13.2 13.0 13.1 12.4
13: Surge Count 0 2 1 0 0
14: Surge Control Point 101.3 102.1 101.6 102.0 101.8
Surge Test Results

The four Surge Test Results screens show the results of the most recently performed surge tests. These
pages are used to refer to previously acquired surge test data, primarily during the commissioning of the
compressor. Use the Up () and Down () keys to navigate through the four result pages for natural,
high, mid, and low pressure surge tests.
Mid Surge Test Results

Surge Test Pressure: 125.0
Time Point 1 Point 2 Point 3 Point 4
Press UP/DOWN for other surge test results

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Performance Log
This screen displays the Performance Log menu which the operator to select display a daily or monthly
performance log or accumulated compressor data for each of the most recent 24 hour period or for each
of the most recent months. This function is available only on systems with the ProTech Performance Log
Software option.
Performance Log
Daily Performance Log

Monthly Performance Log
Clear Performance Log
Daily Performance Log
Running Online Unload Running Online Unload Compress

System .
Date Hours Hours Hours kWH kWH kWH kCF
kCF .
08-25 10.11 10.01 0.10 27.7 27.7 0 0
323
08-24 24.00 24.00 0.00 61.3 61.3 0 0
750
08-23 14.23 14.13 0.10 32.2 32.2 0 0
432
Network Pages
The Network key provides access to two menus, one for the optimal Compressor Network
package and the other for the standard Modbus Interface.
Network Pages
Compressor Network
Modbus Interface

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Compressor Network
The Compressor Network screen is available if the Distributed Capacity Control (DCC) feature of the
ProTech was purchased. DCC networks several ProTech controllers to provide energy-saving automation
of the compressors through coordinated control, reduced blow-off, lower overall operating pressure, and
reduced compressor run time. The listed information shows status of the compressors in the network as it
pertains to their sequence of operation.
Compressor Network
Network Set Point: 95.0
## Pri Net Mode Motor Availability Pressure Set Point Power Time
01 02 Lead Running Automatic 95.1 95.0 123.2 007
02 04 Follow Stopped Start Ready 95.5 97.0 0.0 011
The following explains the data displayed on the Compressor Network screen:
## Unit number of the compressor (defined during commissioning)

Pri Priority Number
Net Mode Status of networking mode
Unlinked
Master
Slave
Motor Motor status
Running
Stopped
Starting
Stopping
Availability Status of compressor loading
Unavailable: Not ready for network or auto start
Start Ready: Ready for network or auto start
Starting: In the starting sequence
Start Fail: Failed in the starting sequence
Manual/Tune: Running in manual unload mode or running tune loop control
Unloaded: Running unloaded in the automatic mode
Automatic: Running and attempting to put air into the system header
Pressure Individual compressor’s system pressure
Set Point Individual compressor’s system pressure set point
Power Individual compressor’s motor power draw
Comm Time Interval of time between controller communication

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Modbus Interface
The Modbus Interface screen enables the user to verify the Modbus mode and the quality of the
communication.
Modbus Interface
Access: Read-Only
Messages Received: 1247
Messages Sent: 1247
CRC Errors: 0
Function Errors: 0
The following explains the data displayed on the Compressor Network screen:
Access Defines the level of machine control allowed when using the
Modbus serial protocol.
The access levels are:
Read Only - Devices read information but not initiate control or
change Set Points
Read-Write - Devices change set points and initiate remote
control functions
Read-Write-DCC - Enables the distributed capacity control
network thru Modbus
Full Control - Allows full access
Messages Received Number of messages received
Messages Sent Number of messages sent
CRC Errors Number of CRC errors
Function Errors Number of function errors

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Function Keys
These keys are user to control the compressor and modify operating set points.
Start
Pressing the Start key initiates the compressor starting sequence. The ProTech controller
dynamically displays each step in the programmed start sequence. A typical start
sequence appears below.
Compressor Start Sequence
Description Data Status

1: Discharge Air Pressure PT-102 < 2.0 0.0 Ready
2: Oil Temperature TE-101 > 60 85 Ready
3: Oil Temperature TE-101 < 145 85 Ready
4: 1st Stage Vibration VT-110 < 0.50 0.00 Ready
5: 2nd Stage Vibration VT-111 < 0.50 0.00 Ready
6: 3rd Stage Vibration VT-112 < 0.50 0.00 Ready
7: Emergency Stop Signal = Normal Alarm Not Ready
8: Motor Enable
9: Start Signal
Stop
Pressing the Stop key initiates the programmed compressor-stop sequence. The
dynamic screen below appears during the sequence and is similar to the screen you see
after you press Start.
Compressor Stop Sequence
Description Status
1: Motor Enable = OFF Completed
2: Motor Running = OFF Completed

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Auto
Pressing the Auto key puts the compressor into the automatic control mode, where the
compressor responds automatically to changes in system demand in accordance with the
ProTech set points.
(The control method for each system is determined at the time of order to accommodate
the specific application. For information on control strategies and the methods available,
refer to the Control Logic Appendix.)
Unload
Pressing this key disables the Auto mode and immediately unloads the compressor by
opening the blow off valve and closing the inlet valve. The system continues to run in the
Unload mode and does not respond to either change in system demand or to any control
set point changes.
Set Points
Through this key, authorized users can access the various levels of set point control. The
first item on the opening set point menu (as shown below) permits the user to change the
language.
This function key provides access to a list of areas of set points that can be modified, and to switch to use
an alternate language. All but the first two screens, Change Language and Operator, are for the use of
authorized service personnel. Normal security settings for a typical system allow the operator/end user
access to only the first two functions. The remaining items listed are not discussed in this document.
Set Points
Change Language
Operator
Commissioning
Tools
Auxiliary Control
Compressor Network
Automatic Start/Stop
Change Language
The ProTech can be configured with two languages. English is always the primary language. The
secondary language, if desired, is selected during the commissioning of the controls. By highlighting this
menu choice and pressing Enter, the operator can toggle between English and the designated secondary
language. There is no additional screen associated with is function.

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Operator
The Operator screen lets the user change some of the ProTech control settings as explained below.
Operator .
Operating Mode: Auto-Unload

Set Point: 95.0 PSI
Offset: 5.0 PSI
Home Page: Monitor Points
Strip Chart Speed: Fast
Date: 06-23-03
Time: 15:56:47
Operating Mode Selects the basic control mode for the compressor. Modes available
depend on the presence of certain instrumentation and the type of blow off
valve. Refer to the Control Logic appendix for a full description of the
ProTech control modes.
Set Point The system pressure control set point for ProTech control modes. For
constant flow control, Set Point is the delivered flow setting.
Offset A control setting slightly above the system pressure (or delivered flow) set
point. The compressor blow off control loop typically uses the offset set
point.
Home Page Sets the Home page from any of the View or History screens. The home
page is the screen that opens at the end of the start sequence.
Strip Chart Speed Sets the sweep speed of the dynamic Pressure vs. Time graph on the
Performance Control screen.
Options:
Fast 7 minutes
Medium 8 hours
Slow 1 day.
Date Current date, used to set the date.
Time Current time, used to set time.

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Commissioning
This function is intended only for authorized service personnel at the time of initial start up and includes
screens for such items as:
 Equipment Settings  Commissioning Settings

 Control Loop Tuning  Control Parameters
 Surge Testing
Tools
This function allows the setting of various protective functions, manual control override options, and
software and firmware links within ProTech. All these tools are intended for authorized service personnel
only.
Additional Set Point Menu Items

The remaining items shown in the Set Points menu, above, appear only with certain installed software
options. The functions and their associated screens are intended for authorized service personnel only.

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Input / Navigation Keys

These six ProTech control keys are multi-functional and allow the operator to navigate and communicate
with the control system. The various functions available for each type of key are described below
Increase and Decrease

This pair of keys work together as follows:
 Raise or lower the value of any numeric or alpha character highlighted on a data
entry screen.
 Toggle between two conditions (e.g.: ON/OFF; Alarm/Normal; Yes/No).
 Manually step open or close the compressor inlet valve or inlet guide vanes.
(Requires access to Set Points / Tools screen)
Enter and Back

Enter:
 Opens a highlighted field or screen.
 Advances the cursor to the next entry data field or to the next digit within a data
entry field.
Back:
 Returns to the previous display screen.
 Moves the cursor back within a particular selection screen or data entry field.
Note - Using either of these keys to move away from a page confirms the
changed/displayed values.
Up and Down
 Displays additional information within a multi-paged screen. (Relocate "up" or

"down" to the next page.)
 Navigates up or down within a list.
 Manually steps open or close a modulating blow-off valve (requires access to Set
Points/Tools screen).
Note: To adjust the LCD display contrast, use the Increase and Decrease keys, while
holding down the View key.

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ProTech Control Methods

ProTech offers four distinct load control methods to provide flexibility in meeting our customer’s widely
varying compressed air needs. The control methods are:
Auto Offline Control* - The most flexible method

Auto Standby Control* - For very tight system pressure control
Auto Unload Control - When a modulating blow off valve is not present
Constant Flow Control* - In the case of a process requiring constant delivered flow
Each ProTech control method uses compressor inlet and blow off valve control loops, and their
associated control set point to match the compressor’s output to the system air requirement.
*Note: Auto-Offline, Auto-Standby and Constant Flow modes require a modulating blow off valve.
An overview of each control mode and each control loop is provided in the following pages.

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Auto-Offline Control
With Auto-Offline Control, the inlet valve is modulated to satisfy the System Pressure set point, within the
constraint of the Maximum Motor Load set point. In cases of low demand, the control throttles back to the
Surge Control Offset line. At this point, the control will modulate the inlet valve to allow the actual system
pressure to increase to the System Pressure Offset set point.
If the compressor output still exceeds demand, ProTech begins its blow off control loop, by modulating
the compressor blow off valve. If blow off increases to the point that the discharge check valve closes; the
compressor will unload. The compressor will automatically reload as soon as the system pressure decays
to the original System Pressure set point value.
Auto-Offline Control Set Points

Maximum Motor Load: The maximum allowable motor current, or power.
System Pressure: The desired operating system pressure.
Surge Control Offset: Establishes the maximum throttling point at a given pressure.
System Pressure Offset: Establishes the system pressure value for blow off control.
Discharge Pressure Limit: Additional blow off control, in sudden over-pressure conditions.
Check Valve Offset Pressure: Used to detect the closing of the discharge check valve.
Auto-Offline Control Steps

1. During the loading sequence, the inlet valve is opened to achieve the System Pressure set point, at
the maximum allowable flow and power (position 1)
2. If the compressor output exceeds the demand, the Inlet System Pressure control loop throttles the
inlet valve to the Surge Control Offset line (pos. 2).
3. If the compressor output still exceeds demand, the Inlet Surge Control loop modulates the inlet valve
to allow system pressure to increase to the System Pressure Offset point (pos. 3).
4. At this point (pos. 3), control switches to the Blow Off System Pressure control loop, which begins to
modulate the compressor blow off valve. If blow off increases to the point that the discharge check
valve closes, Auto-Offline unloads the compressor by first fully opening the blow off valve, and then
closing the inlet (pos.4).
5. The compressor automatically reloads when the system pressure drops below the System Pressure
set point.
Auto-Offline Control Operation

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Auto-Standby Control
This control mode operates in the same manner as Auto-Offline until reaching the System Pressure
Offset set point. Then, if the check valve closes during blow-off, Auto–Standby does not unload the
compressor. Instead, it continues to open the blow off valve until the compressor’s discharge pressure
drops to the Standby Pressure Offset set point. This method allows the unit to quickly load when the
system pressure drops below the System Pressure set point.
Auto-Standby Control Set Points

Check Valve Offset Pressure: Used to detect the closing of the discharge check valve.
Standby Offset Pressure: Sets the compressor’s standby discharge pressure.
Auto- Standby Control Steps
4. At that point (pos. 3), control switches to the Blow Off System Pressure control loop, which begins to
modulate the compressor blow off valve. If blow off increases to the point that the discharge check
valve closes, Auto-Standby continues to modulate the blow off valve open, until the compressor
discharge pressure drops to the Standby Offset set point (pos. 4).
5. When the system pressure drops below the System Pressure set point, the blow off valve closes, and
normal control is resumed.
Auto- Standby Control Operation

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Auto-Unload Control
This control mode operates in the same manner as Auto-Offline until reaching the System Pressure
Offset set point. Then, the compressor is automatically unloaded (blow-off valve fully opened, inlet valve
to the close position). The compressor remains unloaded until the system pressure falls below the System
Pressure set point. It will then be automatically reloaded.
This control mode is only used on compressors that do not have a modulating blow off valve.
Auto-Unload Control Set Points

Auto- Unload Control Steps
4. At that point (pos. 3), the Auto-Unload control method unloads the compressor by first fully opening
the compressor blow-off valve, and then closing the inlet valve to its minimum position (pos.4).
5. The compressor automatically reloads when system pressure drops below the System Pressure set
point.
Auto-Unload Control Operation

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Constant Flow Control

Constant Flow control provides a constant delivered flow to the process. When operating within the
turndown range of the compressor the inlet valve is modulated to match the delivered flow to the System
Flow set point. If the System Flow set point is set below the turndown range of the compressor the inlet
will control to the Surge control line while the blow off valve is modulated to maintain delivered flow at the
System Flow set point plus the System flow offset.
The operation of Constant Flow control is the same as with Auto-Standby except that both Inlet and Blow
Off System Pressure loops are changed to be System Flow.
Constant Flow Control Set Points

System Flow: The delivered flow control point.
System Flow Offset: Sets an upper level for allowable system pressure.
Constant Flow Control Steps
1. During the loading sequence, the inlet valve is opened to achieve the System Flow set point, at the
maximum allowable flow and power (position 1)
2. If demand is within the turndown range of the compressor, the inlet valve maintains the delivered flow
(position 2).
3. If the required flow is less than Inlet Minimum Load (as determined by the Surge Control line), then
the inlet controls to the surge control line.
4. If the delivered flow increases to the point that the Blow off System Flow is exceeded, the blow off
valve is modulated to maintain flow at that set point. (position 3).
Constant Flow Control Operation

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ProTech Control Loops

The ProTech control system typically performs load control through five independent control loops. Each
loop modulates either the compressor inlet valve or blow off valve (if able), with respect to an associated
set point.
In the case of ProTech’s Pressure Control modes, (Auto-Offline, Auto-Standby and Auto-Unload), the
control loops and set points are:
Inlet Valve Control

Blow Off Valve Control
Control Loop Set point
Inlet Maximum Maximum Motor Load
Control Loop Set point
Blow Off System Pressure Blow Off System
Load Pressure
2
Inlet System System Pressure Blow Off Discharge Pressure Discharge
Pressure Pressure Limit
1
Inlet Surge Control Surge Control Point
In the case of ProTech’s Flow Control mode (Constant Flow), the control loops and set point are:
Inlet Valve Control Blow Off Valve Control

Control Loop Set point Control Loop Set point
Inlet Maximum Maximum Motor Load Blow Off System Flow Blow Off System
3
Load Flow
Inlet System Flow System Flow Blow Off Discharge Pressure Discharge
1 Pressure Limit
Inlet Minimum Surge Control Point
Load
NOTES:
1. The surge control point is a function of the actual discharge pressure, the entered surge points
and the Surge Control Offset set point.
2. The Blow Off System Pressure set point is equal to the System Pressure set point plus the
System Pressure Offset set point.
3. Blow Off System Flow is equal to the System Flow Set point plus the System Flow Offset set
point.

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Inlet Control Set points Blow Off

Blow Off Control Set points Discharge
Actual Performance Curve Pressure
Programmed Surge Points
Surge
Control
Blow Off
Line
Surge System
Control C Pressure Set
Offset Point
B
Pressure
System
System Pressure Set
Pressure Point
A Standby Offset
Pressure Standby
Offset Pressure
Maximum
Motor Load
Motor Load (Amps)

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Inlet Valve Control Loops

The ProTech control system modulates the compressor inlet valve in response to the control set point
associated with the three control loops described on the preceding page.
Each control loop constantly reviews the operational status of the compressor relative to its set point.
ProTech sends opening and closing signals to the inlet valve in order to maintain the desired system
pressure setting while protecting the compressor from surge and motor overload.
All inlet valve moves are governed by adjustable tuning parameters for each control loop. Control of
the inlet valve is automatically transferred among loops to ensure that only one loop controls at a given
time.
Inlet Maximum Load Loop

Drive motor amperage is one indicator of the compressor’s load. The motor draws more amperage as
the inlet valve opens. The Maximum Motor Load set point establishes a limit on the opening of the inlet
valve to prevent running the motor in an excessive amperage condition. The inlet valve is modulated by
the tuning parameters established for this loop. The Maximum Motor Load set point is set as % of the
motor’s nameplate full load amp value.
Inlet System Pressure Loop

This control loop will attempt to maintain the system pressure as close as possible to the System
Pressure set point. The inlet valve is modulated by the tuning parameters established for this loop.
Inlet Surge Control Loop

This control loop will attempt to prevent a low flow surge by maintaining the compressor load above the
Surge Control Point settings. The inlet valve is modulated by the tuning parameters for this loop, until
the point that system pressure is allowed to increase to the System Pressure Offset.
Inlet Valve Control Discussion

In the Automatic control state, the ProTech controller begins to load the compressor if the actual system
pressure falls below the System Pressure Set point. During the load cycle, the inlet valve opens to a
minimum load value and then both the inlet and blow off valves switch to automatic control. During this
load cycle, the Inlet Maximum Load and System Pressure control loops control the inlet valve and
quickly load the compressor within the Maximum Motor Load set point constraint.
As the system air pressure approaches the System Pressure set point, the Inlet System Pressure
control loop obtains control of the inlet valve and modulates the inlet to maintain that pressure.
In cases of low air demand, the Inlet System Pressure control loop maintains the System Pressure set
point by reducing the compressor’s output by throttling the inlet valve. This throttling continues until the
compressor reaches the Surge Control Point, where the Inlet Surge Control loop assumes automatic
control of the inlet valve.
In this control loop, the inlet valve is controlled along the surge control line, allowing the system
pressure to increase to the Blow Off System Pressure set point. When this value is reached, control is
transferred to the blow off valve loops

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Blow Off Valve Control Loops

The blows off valve control loops are depended on the type of blow-off valve and control method. For
Auto-Unload control the blow-off valve acts as a discrete valve and is unaffected by the loop tuning.
Blow Off System Pressure Loop

If the actual system pressure reaches the Blow Off System Pressure set point, ProTech will then
gradually open the compressor’s blow-off valve (if so equipped). The modulation is done through the
tuning parameters set for this loop. If there is no modulating valve, the compressor is unloaded.
Maximum Discharge Pressure Loop

In the case of a sudden rapid increase in compressor discharge pressure, ProTech uses the Discharge
Pressure Limit set point to avoid a high pressure surge. If this value is reached, the control will then
quickly modulate the compressor’s blow-off valve (if equipped). If there is no modulating valve, the
compressor will be unloaded.
Blow Off Valve Control Discussion

The ProTech blow off valve control loops do not come into play until system pressure is allowed to
increase to the Blow Off System Pressure set point. Prior to that, the inlet valve control loops are used.
The loops are intended for compressors equipped with a modulating blow off valve.
If system pressure rises above the Blow Off System Pressure set point, the Blow Off System Pressure
control loop begins to modulate the compressor’s blow off valve.
The Maximum Discharge Pressure control loop, and its corresponding Discharge Pressure Limit set
point come into play under certain compressor operating conditions. This control loop provides a fast
response when the discharge pressure climbs suddenly. This can occur because of a sticking check
valve, closed block valve, or plugged dryer. The setting of the Discharge Pressure Limit set point is a
value below the natural high-pressure surge point of the compressor.

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Chapter 4
Modbus Interface Guide

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ProTech Modbus Interface Guide
About This Guide
This guide contains the basic information necessary to interface the ProTech control system with plant
automation systems, Man-Machine-Interface (MMI) software, and other data logging systems using the
Modbus communications interface. However, since installations may vary, these instructions may not
cover all details or variations in the equipment supplied or every question that may arise during use.
More detailed information on the Modbus protocol is available using the desktop under
Help/Documents.
Guide Revision 1.6, June 16, 2006

Copyright © 2003 - 2006 Bay Controls, LLC. All Rights Reserved.

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Installation
The communications interface is installed by connecting the Modbus Network Port, connector J9 on the
ProTech Main Logic Module (MLM), to the plant, MMI, or other equipment. The ProTech operates as
the slave device, the plant system or MMI operates as the Master device.
The physical link uses an RS-485 two-wire, half duplex, serial communications interface. The RS-485
standard defines the signal levels and other characteristics of the physical link. The equipment that is to
be connected to the ProTech must implement this same RS-485 standard. Refer to the documentation
of master device to be connected to confirm the standards used and how the connections are made.
The connection must be made using 22 Gauge, twisted 3-wire shielded cable, such as Belden # 3108A,
or equivalent.
The positive terminal on the ProTech is connected to the positive terminal on the master device, and
the negative terminal to the master negative terminal. The COM terminal on the ProTech is connected
to the common terminal on the master device. The common connection is used to insure that both
pieces of equipment have the same signal reference level.
Up to thirty one (31) ProTech controllers can be connected together with the master device. The
ProTech controllers should be connected together in a daisy chain and then connected to the master
device at one end.
The RS-485 standard specifies the maximum length of the physical connection at 5000 feet (1524
meters) between the farthest connections.
It is recommended that a RS-485 isolator be installed between the network of ProTech controllers and
the Master device if the Master is located in a different building, if the Master may have a different
ground reference, or if problems are experienced reliably communicating between the Master and
ProTech(s).
There are a number of RS-485 isolators that will work well for this application. The Westermo RD-48
repeater has been tested and known to work well in this application. Refer to www.westermo.com, also
available through Industrial Networking Solutions 800-889-1461, and Gross Automation 262-446-0000.
Configuration
The Modbus interface on the ProTech controller must be configured to match the speed and data
format used by the master device. If multiple ProTech controllers are connected together, they must all
be configured to use the same speed and data format.
The ProTech Desktop software is used to configure the ProTech controller. The Communications Tab
on the desktop contains the Modbus settings. The communication speed is in bits per second, referred
to as Baud rate. The data format is expressed as the number of data bits followed by the parity type,
and then the number of stop bits. The parity can be Even, Odd, or None. Set the ProTech Modbus
speed and data format to match that used by the master device. Refer to the online help in the ProTech
Desktop for more information.
The Modbus access is selected based on what type of functionality you wish to implement from the
master device. The default is Read-Only which prevents the master from changing any setting or
executing any control function in the ProTech. Refer to the online help in the ProTech Desktop for more
information.

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Modbus Protocol
The Modbus protocol describes an industrial communications and distributed control system developed
by Gould-Modicon to integrate PLC’s, computers, terminals, and other monitoring, sensing, and control
devices. Modbus is a Master/Slave communications protocol, whereby one device, (the Master),
controls all serial activity by selectively polling one or more slave devices. The protocol provides for
one master device and up to 247 slave devices on a common line. Each device is assigned an address
to distinguish it from all other connected devices. The RS-485 physical link used by the ProTech limits
the maximum number of slave devices to 31.
Only the master initiates a transaction. Transactions are either a query/response type, (only a single
slave is address), or a broadcast/no response type, (all slaves are addressed). A transaction
comprises a single query and single response frame or a single broadcast frame.
Certain characteristics of the Modbus protocol are fixed, such as the frame format, frame sequences,
handling of communications errors and exception conditions, and the functions performed.
Other characteristics are user selectable. These include a choice of transmission media (physical link),
baud rate, character parity, number of stop bits, and the transmission modes, (ASCII or RTU). The
ProTech only supports the RTU transmission mode of the Modbus protocol.
Synchronization
Frame synchronization can be maintained in RTU transmission mode only by simulating a synchronous
message. The receiving device monitors the elapsed time between receipt of characters. If three and
one-half character times elapse without a new character or completion of the frame, then the device
flushes the frame and assumes that the next byte received will be an address.
Message Format
A transaction consists of a single request from the master to a specific slave device, and a single
response from that device back to the master. Both of these messages, request and response, are
formatted as Modbus message frames. Each message frame consists of a series of bytes grouped into
four fields as described below:
ADDRESS FUNCTION DATA ERROR CHECK

1 byte 1 byte variable 2 bytes
Address Field
The address field immediately follows the beginning of frame and consists of one byte. This byte
indicates the user assigned address of the slave device that is to receive the message sent by the
master.
Each slave must be assigned a unique address and only the addressed slave will respond to a query
that contains its address. When the slave sends a response, the slave address informs the master
which slave is communicating. In a broadcast message, an address of 0 is used. All slaves interpret
this as an instruction to read and take action on the message, but not to issue a response message.
The slave address is configured for the ProTech using the ProTech Desktop software, in the General
Tab. The Unit Number specifies the Modbus slave address.

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Function Field
The Function field tells the addressed slave (ProTech) what function to perform. Modbus function
codes are specifically designed for interacting with a PLC on the Modbus industrial communications
system. The high order bit in this field is set by the slave device to indicate an exception condition in
the response message. If no exceptions exist, the high-order bit is maintained as zero in the response
message.
The following functions are supported by the ProTech controller:
FUNCTION CODE MEANING ACTION

03 READ HOLDING Obtains current binary value in
REGISTER one or more holding registers.
04 READ INPUT Obtains current binary value in
REGISTER one or more input registers.
06 PRESET SINGLE Place a specific binary value
REGISTER into a holding register.
08 LOOPBACK TEST Enables the master to test the
communication system.
Data Field
The data field contains information needed by the slave (ProTech) to perform the specific function or it
contains data collected by the slave in response to a query. This information may be values, address
references, or limits. For example, the function code tells the slave to read a holding register, and the
data field is needed to indicate which register to start at and how many to read.
Error Check Field
This field allows the master and slave devices to check a message for errors in transmission.
Sometimes, because of electrical noise or other interference, a message may be changed slightly while
it’s on its way from one device to another. The error checking assures hat the slave or master does not
react to messages that have changed during transmission. This increases the safety and the efficiency
of the Modbus system. The error check field uses a CRC-16 algorithm in the RTU mode.
Error Detection
There are two types of errors which may occur in a communications system: transmission errors and
programming errors. The Modbus system has specific methods for dealing with either type of error.
Communications errors usually consist of a changed bit or bits within a message. The most frequent
cause of communications errors is noise: unwanted electrical signals in a communications channel.
These signals occur because of electrical interference from machinery, damage to the communications
channel, impulse noise, (spikes), etc. Communications errors are detected by character framing, a
parity check, and a redundancy check.
When the character framing, parity, or redundancy checks detect a communications error, processing
of the message stops. A ProTech will not act on or respond to the message. (The same occurs if a
non-existent slave address is used.)

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When a communications error occurs, the message is unreliable. The ProTech cannot know for sure if
this message was intended for it. So the ProTech might be answering a message which was not its
message to begin with. It is essential to program the Modbus Master to assume a communications
error has occurred if there is no response in a reasonable time. The length of this time depends upon
the baud rate, type of message, and scan time of the ProTech. Once this time is determined, the
master may be programmed to automatically retransmit the message.
The Modbus system provides several levels of error checking to assure the quality of the data
transmission. To detect multibit errors where the parity has not changed, the system uses the Cyclical
Redundancy Check (CRC).
Exception Responses
Programming or operation errors are those involving illegal data in a message, no response from the
ProTech to the master, or difficulty in communicating with a ProTech. These errors result in an
exception response from either the master or the ProTech, depending on the type of error.
The exception response codes are listed below. When a ProTech detects one of these errors, it sends
a response message to the master consisting of the slave address, function code, error code, and error
check fields. To indicate that the response is a notification of an error, the high-order bit of the function
code is set to one.
CODE NAME MEANING

01 ILLEGAL FUNCTION The message function received is
not an allowable action for the
ProTech.
02 ILLEGAL DATA ADDRESS The address referenced in the data
field is not an allowable address for
the data in the ProTech.
03 ILLEGAL DATA VALUE The value referenced in the data
field is not allowable in the
addressed ProTech location.
07 NAK-NEGATIVE The function just requested could
ACKNOWLEDGMENT not be performed.
Memory Notation
Data points in the ProTech are referenced in the same manner as points in a Modicon PLC. This
notation allows for four different types of data: coils, discrete inputs, input registers, and holding
registers. Register variables consist of two bytes, while coils and discrete inputs are single bits. The coil
and discrete input data types are not used as they have no application to a ProTech controller.
Each function references only one type of data and uses a relative address in the message frame with
a zero offset. For example, holding register 40001 relative address is 0000, input register 30003 relative
address is 0002, and so on.

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Data Type Absolute Relative Address Function

Address
Input Registers 30001-39999 0-9998 4
Holding 40001-49999 0-9998 3,6
Registers
Function 3 – Read Holding Registers
The read holding registers function is used to obtain the values of set points, and status information
from a ProTech controller. The format of the request frame is as follows:
REQUEST FRAME
ADDRESS FUNCTION STARTING REGISTER ERROR
CODE REGISTER COUNT CHECK
1 BYTE 1 BYTE 2 BYTES 2 BYTES 2 BYTES
PROTECH 03 SEE NUMBER OF CRC-16
UNIT HOLDING REGISTERS
NUMBER REGISTER
MAP
The starting register number is shown in the following table. The register count specifies how many
consecutive register values will be returned in the response message. An exception message will be
returned when specifying a register number that is not defined. Note that the message frame uses
relative addressing; see Memory Notation above for more information.

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HOLDING REGISTER MAP

REGISTER DESCRIPTION NOTE
0 System Pressure Set Point 1
1 System Pressure Offset Set Point 1
2 Max Discharge Pressure Set Point 1
3 Standby Pressure Offset Set Point 1
4 Check Valve Offset Set Point 1
100 Motor Status 2
101 Motor Load (%) 3
102 Protection Status 4
103 Last Alarm Monitoring Point 5
104 Last Trip Monitoring Point 5
105 Inlet Control Mode 6
106 Blow Off Control Mode 7
107 Network Control Mode 8
108 Network Pressure Set Point 1
109 Network Priority Number 9
110 Network Time Constant 10
111 Network Dead band 1
112 Network Cascade Set Point Adjustment 1
113 Network Start Pressure Offset 1
114 Network Start Time Delay 10
115 Network Availability 9
116 Automatic Start/Stop Mode 11
117 Automatic Start/Stop Lockout 12
118 Automatic Start Pressure Offset 1
119 Automatic Stop Delay Time 10
120 Capacity Control Mode 14
121 Auto Start Lockout 15
1099 + N Monitoring Point (N) Alarm High Set Point 1
1199 + N Monitoring Point (N) Alarm Low Set Point 1
1299 + N Monitoring Point (N) Trip High Set Point 1
1399 + N Monitoring Point (N) Trip Low Set Point 1
1499 + N Monitoring Point (N) Start High Set Point 1
1599 + N Monitoring Point (N) Start Low Set Point 1
Notes:
1. Data is formatted as a signed integer in the range of -32767 to 32767. There is an implied
decimal point based upon the configuration of the corresponding monitoring point. The set point
is expressed in engineering units configured for the associated monitoring point. Refer to the
ProTech controller configuration. For example, if the ProTech is configured for the System
Pressure monitoring point with a precision of 1 and units of PSI, then a register value of 1123
indicates 112.3 PSI.

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2. Motor Status is enumerated as follows:
0 Stopped
1 Stopping
2 Starting
3 Running
3. An unsigned integer in the range of 0 to 65535 with an implied decimal place of 1. For example
a register value of 1001 indicates a data value of 100.1.
4. An unsigned integer in the range of 0 to 63 indicating the current number of monitoring points
with an alarm status.
5. An unsigned integer in the range of 0 to 63 referencing a monitoring point number. A value of 0
indicates that no point is referenced. Refer to the ProTech controller configuration for the
numbering of monitoring points.
6. Inlet control mode is enumerated as follows:
0 Manual
1 Unloaded
2 System Pressure
3 Minimum Flow
4 Maximum Load
7. Blow-Off control mode is enumerated as follows:
0 Manual
1 Unloaded
2 System Pressure
3 Discharge Pressure
8. Network mode is enumerated as follows:
0 Local Control
1 Networked Leader
2 Networked Follower
9. An unsigned integer in the range of 1 to 32.
10. An unsigned integer greater than or equal to 1 that expresses a time value in seconds.
11. Automatic Start / Stop mode is enumerated as follows:
0 No automatic functions configured
1 Local auto start enabled
2 Network auto start enabled
3 Local auto start and network auto start enabled
4 C-Link/Modbus start and stop enabled
5 Local and C-Link/Modbus start and stop enabled
6 Network auto start and C-Link/Modbus start and stop enabled
7 Local auto start, network start auto start, and C-Link/Modbus start and stop enabled
8 Local auto stop enabled
9 Local auto start and stop enabled
10 Network auto start and local auto stop enabled
11 Local auto start, network auto start, local auto stop enabled
12 C-Link start and stop, and local auto stop enabled
13 Local auto start, C-Link start and stop, and local auto stop enabled
14 Network auto start, C-Link start and stop, local auto stop enabled
15 Local auto start and stop, network auto start, and C-Link start and stop enabled

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12. Automatic Stop Lockout is enumerated as follows:
0 Lockout not enabled
1 Bypass; auto start disabled until local start successful, then auto start enabled
2 Locked out; auto start disabled, local start allowed
13. The network availability is enumerated as follows:
0 Stopped, not ready to start (permissive not ready)
1 Stopped, ready for local start
2 Stopped, ready for local auto start
3 Stopped, ready for network auto start
4 Stopped, ready for local auto or network auto start
5 Stopped, ready for C-Link/Modbus start
6 Stopped, ready for C-Link/Modbus start and local auto start
7 Stopped, ready for C-Link/Modbus and network auto start
8 Stopped, ready for C-Link/Modbus, local auto start, and network auto start
16 Stopping, not ready to restart (stop sequence lockout timer or permissive not ready)
17 Stopping, ready for local start
18 Stopping, ready for local auto start
19 Stopping, ready for network auto start
20 Stopping, ready for local auto or network auto start
21 Stopping, ready for C-Link/Modbus start
22 Stopping, ready for C-Link/Modbus start and local auto start
23 Stopping, ready for C-Link/Modbus and network auto start
24 Stopping, ready for C-Link/Modbus, local auto start, and network auto start
32 Starting, normal
33 Starting, failed start sequence
48 Running on automatic, unloaded
49 Running on automatic, loading
50 Running on automatic, blowing off
51 Running on automatic, minimum flow (no blow off)
52 Running on automatic, modulating
53 Running on automatic, maximum load
65 Running on manual, full manual control
66 Running on manual, unloaded
67 Running on manual, base loaded
68 Running on manual, tuning discharge pressure loop
69 Running on manual, tuning maximum load loop
70 Running on manual, tuning surge control loop
71 Running on manual, surge test in process
72 Running on manual, tuning blow off system pressure loop
14. The capacity control mode is enumerated as follows:

0 Automatic
1 Full manual (engineering mode)
2 Unload
3 Base Load
4 Tune discharge pressure
5 Tune maximum current
6 Tune surge control
7 Surge test
8 Natural surge test

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15. The auto start lockout is enumerated as follows:

0 Normal – Automatic start and stop are enabled.
1 Bypass – Disabled but will be re-enabled on successful start.
2 Locked – Automatic start and stopped are disabled.
RESPONSE FRAME
ADDRESS FUNCTION BYTE DATA ERROR
CODE COUNT CHECK
1 BYTE 1 BYTE 1 BYTES VARIABLE 2 BYTES
PROTECH 03 NUMBER OF SEE CRC-16
UNIT REQUESTED HOLDING
NUMBER REGISTERS REGISTER
X2 TABLE
The response message contains a variable length data field that is equal to the number of registers
requested multiplied by 2. The registers are ordered consecutively in the data field as 2 byte values;
high byte followed by low byte.
Exceptions
Exception code 02 is returned if the registers requested are not defined. Note that the protection set
point registers are defined based upon the configuration in the ProTech controller.

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Function 4 – Read Input Registers

The read input registers function is used to obtain the values of monitoring and control point data from a
ProTech controller. The format of the request frame is as follows:
REQUEST FRAME
ADDRESS FUNCTION STARTING REGISTER ERROR
CODE REGISTER COUNT CHECK
PROTECH 4 SEE INPUT NUMBER OF CRC-16
UNIT REGISTER REGISERS
NUMBER MAP
INPUT REGISTER MAP

REGISTER DESCRIPTION NOTE
N-1 Monitoring Point (N) Data 1
99 + N Control Point (N) Data 2
1099 Global Monitoring Status 3
1099 + N Monitoring Point (N) Status 4
1199 ProTech Software Version 5
Notes:
1. Monitoring point data is formatted as a signed integer in the range of -32767 to 32767 with an
implied decimal point determined by the ProTech configuration. The value is expressed in the
engineering units configured for the respective point. Refer to the ProTech monitoring point
configuration listing. Digital points are expressed as 0 for the OFF or inactive state, and 1 for
the ON or active state.
2. Control point data is formatted as an unsigned integer in the range of 0 to 65535. Refer to the
ProTech control point configuration listing. Digital points are expressed as 0 for the OFF or
inactive state, and 1 for the ON or active state.
3. An unsigned integer indicating the number of monitoring points that are in the faulted state.
4. Monitoring point status is an unsigned integer enumerated as follows:
0 Normal
1 Alarm
2 Open
3 Short
4 Fault
5 Fail
5. The ProTech software version is expressed as two unsigned integer bytes. The high byte
contains the major version number; the low byte contains the minor version number.

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RESPONSE FRAME
ADDRESS FUNCTION BYTE COUNT DATA ERROR
CODE CHECK
1 BYTE 1 BYTE 1 BYTE VARIABLE 2 BYTES
PROTECH 4 SEE MAP SEE MAP CRC-16
UNIT TABLE TABLE
NUMBER
The response message contains a variable length data field that is equal to the number of registers
requested multiplied by 2. The registers are ordered consecutively in the data field as 2 byte values;
high byte followed by low byte.
Exceptions
Exception code 02 is returned if the registers requested are not defined. Note that the monitoring and
control point registers are defined based upon the configuration in the ProTech controller.

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Function 6 – Preset Single Register

The preset single register function is used to change one of the set points in a ProTech controller, or
initiate a control action. Note that access to ProTech set points and control actions are configurable and
may not be permitted. Refer to the ProTech controller configuration to determine what access is
allowed. The format of the request frame is as follows:
REQUEST FRAME
ADDRESS FUNCTION REGISTER REGISTER ERROR
CODE NUMBER DATA CHECK
PROTECH 06 SEE PRESET SEE CRC-16
UNIT REGISTER REGISTER
NUMBER MAP MAP NOTES
PRESET REGISTER MAP

REGISTE DESCRIPTION NOTE
R
0 System Pressure Set Point 1
1 System Pressure Offset Set Point 1
100 Motor Start 2
102 Alarm Acknowledge 3
109 Network Priority Number 4
110 Network Time Constant 5
111 Network Dead band 1
112 Network Cascade Set Point Adjustment 1
113 Network Start Pressure Offset 1
114 Network Start Time Delay (Sec) 5
119 Auto Stop Time Delay (Min) 6
120 Capacity Control Mode 7
121 Auto Start/Stop Lockout 8
1099 + N Monitor Point (N) Alarm High Set Point 1
1199 + N Monitor Point (N) Alarm Low Set Point 1
1299 + N Monitor Point (N) Trip High Set Point 1
1399 + N Monitor Point (N) Trip Low Set Point 1
1499 + N Monitor Point (N) Start High Set Point 1
1599 + N Monitor Point (N) Start Low Set Point 1

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Notes:
1. Data is formatted as a signed integer in the range of -32767 to 32767. There is an implied
decimal point based upon the configuration of the corresponding monitoring point. The set point
is expressed in engineering units configured for the associated monitoring point. Refer to the
ProTech controller configuration. For example, if the ProTech is configured for the System
Pressure monitoring point with a precision of 1 and units of PSI, then a register value of 1123
indicates 112.3 PSI.
2. Set the motor start register to 1 to start the compressor, 0 to stop the compressor.
3. Set the alarm acknowledge register to 1 to acknowledge and silence the alarm.
4. An unsigned integer in the range of 1 to 32.
5. An unsigned integer greater than or equal to 1 that expresses a time value in seconds.
6. An unsigned integer greater than or equal to 1 that expresses a time value in minutes.
7. The capacity control mode is enumerated as follows:
0 Automatic
1 Unload
2 Base Load
8. The auto start lockout is enumerated as follows:
0 Normal – Automatic start and stop are enabled.
1 Bypass – Disabled but will be re-enabled on successful start.
2 Locked – Automatic start and stopped are disabled.
RESPONSE FRAME
ADDRESS FUNCTION REGISTER REGISTER ERROR
CODE NUMBER DATA CHECK
PROTECH 06 SAME AS SAME AS CRC-16
UNIT REQUEST REQUEST
NUMBER FRAME FRAME
The response frame is the same as the request message; returned to indicate that the specified
holding register was set to the data value in the request message.
Exceptions
Exception code 02 is returned if the registers requested are not defined. Note that the protection set
point registers are defined based upon the configuration in the ProTech controller.
Exception code 03 is returned if the register data is out of range or invalid for the specified holding
register.

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Function 8 – Loop Back Test

This function enables the master to test the communication system with the ProTech Modbus interface. The
diagnostic code of the request frame must be set to 0000; the Modbus RETURN QUERY DATA code. The data
value is a binary value from 0 to 65535.
REQUEST FRAME
ADDRESS FUNCTION DIAGNOSTIC DATA ERROR
CODE CODE VALUE CHECK
PROTECH 08 0000 TEST DATA CRC-16
UNIT
NUMBER
RESPONSE FRAME
ADDRESS FUNCTION DIAGNOSTIC DATA ERROR
CODE CODE VALUE CHECK
PROTECH 08 0000 TEST DATA CRC-16
UNIT
NUMBER
The response frame is identical to the request frame if the test is successful. Typically the data value is
checked in the response to confirm the same as the value sent. Successful completion of this test
confirms that the physical and protocol layers of the communication system are functioning properly.
Exceptions
Exception code 01 is returned if a diagnostic code other than 0000 is specified in the request frame.

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Upgrading to ProTech from the Quad 2000
Plant automation systems and/or other master devices that were configured to interface with a Quad 2000
controller will need to be modified for interfacing with the ProTech. The following configuration changes need to
be made in the master device:
1. The address of the data points need to be configured in the master to point to the new locations
in the ProTech. Refer to the ProTech Modbus Memory Map. Also there is additional information
available in the ProTech; you may want to add data values into the master system.
2. All of the data in the ProTech controller is expressed in engineering units. The data in the Quad
2000 had to be scaled by the master into the appropriate units to have meaning. The
temperature RTD inputs in the Quad 2000 required a look up table to translate the data value
into engineering units. The data scaling functions should be turned off in the master when using
the ProTech as they are not needed.

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Modicon PLC Memory Map for the ProTech Controller
The following table shows the ProTech data and control functions addressed as data points in a
Modicon PLC.
ProTech MODBUS MEMORY MAP

ABSOLUTE DESCRIPTION MODBUS
ADDRESS FUNCTION
30000 + N Monitoring Point (N) Data 4
30100 + N Control Point (N) Data 4
31100 Global Monitoring Status 4
31100 + N Monitoring Point (N) Status 4
31200 ProTech Software Version 4
40001 System Pressure Set Point 3, 6
40002 System Pressure Offset Set Point 3, 6
40003 Max Discharge Pressure Set Point 3
40004 Standby Pressure Offset Set Point 3
40005 Check Valve Pressure Offset Set Point 3
40101 Motor Status 3, 6
40102 Motor Load (%) 3
40103 Protection Status / Alarm Acknowledge 3, 6
40104 Last Alarm Monitoring Point 3
40105 Last Trip Monitoring Point 3
40106 Inlet Control Mode 3
40107 Blow Off Control Mode 3
40108 Network Control Mode 3
40109 Network Pressure Set Point 3
40110 Network Priority Number 3, 6
40111 Network Time Constant 3, 6
40112 Network Dead band 3, 6
40113 Network Cascade Set Point Adjustment 3, 6
40114 Network Start Pressure Offset 3, 6
40115 Network Start Time Delay 3, 6
40116 Network Availability 3
40117 Automatic Start/Stop Mode 3
40118 Automatic Start/Stop Lockout 3
40119 Automatic Start Pressure Offset 3
40120 Automatic Stop Delay Time 3, 6
41100 + N Monitoring Point (N) Alarm High Set Point 3, 6
41200 + N Monitoring Point (N) Alarm Low Set Point 3, 6
41300 + N Monitoring Point (N) Trip High Set Point 3, 6
41400 + N Monitoring Point (N) Trip Low Set Point 3, 6
41500 + N Monitoring Point (N) Start High Set Point 3, 6
41600 + N Monitoring Point (N) Start Low Set Point 3, 6

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Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Parts and Service ............................................................................. - 29 -

Enter Commissioning Settings ....................................................... - 45 -

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Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

ProTech Control Methods ................................................................ - 73 -

ProTech Control Loops .................................................................... - 78 -

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Function 4 – Read Input Registers .................................................. - 93 -

Function 6 – Preset Single Register................................................ - 95 -

Function 8 – Loop Back Test ........................................................... - 97 -

Upgrading to ProTech from the Quad 2000 .................................... - 98 -

Revision Date: 2013-10-09

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

About This Manual

Manual Revision 1.6, June 16, 2006.

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

! This indicates that there may be the possibility of equipment damage.

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

CAUTION HAZARDOUS AREA.

AVERTIR LE DOMAINE HASARDEUX.

CAUTION: DISCONNECT POWER BEFORE SERVICING.

LA PRUDENCE: DEBRANCHER LE POUVOIR AVANT D'ENTRETENIR.

PROTECTIVE EARTH GROUND.

Ce symbole indique une connexion exigée au sol de terre. La protection fournie

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Si l'AProTech est installé dans une atmosphère hasardeuse, ou à un emplacement où il y a n'importe

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

! Operation of the control system outside of the specified operating temperature

Power Requirements, Grounding and Wiring

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Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Digital Input Wiring

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Analog Output Wiring

Digital Output Wiring

L'installation éléctrique numérique de production devrait être séparée de l'installation éléctrique de

Motor Control Output Wiring

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Main Drive Motor Control

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

User Interface Module (UIM)

Part Number: CN-UIM2-P

Size: 12.5" (31.8 cm) W x 11.25" (28.6 cm) H x 1.5" (3.8cm) D.

Weight: 3 lbs. (1.36 kilograms).

Safety Approvals: Entela Certified UL 61010A-1 / CSA C22.2 No. 1010.1

CE marking for the European Union. Compliance with applicable

Bay Controls, LLC • 6528 Weatherfield Court, Maumee, OH 43537 • 419-891-4390

Main Logic Module (MLM)

Part Number: CN-MLM2-P

Weight: 5 lbs. (2.27 kilograms).