• Author / Uploaded
• Oswaldo restrepo

Citation preview

Compressor Controller MAM – 860

OPERATION MANUAL

Revision 1.0 04.08.2017

Notice Please read all the operation manual before operating the set and keep this manual for further reference.

Installation of MAM—8** compressor controller can be performed only by professional technicians.

RC snubber must be connected to the two terminals of coil (such as AC contactor, valve, etc),which are controlled by relay output. Port connection shall be inspected carefully before power on.

PARAMETER is not allowed to be modified in running and stop delay status. Only user parameter is allowed to be changed at running status

04.08.2017

Operation Manual MAM - 860 V1.0

-2-

Contents 1 Basic Operation ................................................................................................................................................... - 4 1.1 Button Explanation .................................................................................................................................. - 4 1.2 Indicator Instruction ................................................................................................................................ - 5 1.3 Status Display and Operation ................................................................................................................... - 6 1.4 Operating Parameter and Menu: ............................................................................................................. - 6 1.5 User Parameter View and Modification: ................................................................................................. - 7 1.6 User Parameter: ....................................................................................................................................... - 9 1.7 Factory Parameter: ................................................................................................................................ - 11 1.8 Calibration Parameter ............................................................................................................................ - 12 1.9 Operating Authorization and Password ................................................................................................. - 13 2 Controller Function and Technical Parameter .................................................................................................. - 13 3 Model and specification.................................................................................................................................... - 14 4 Overview .......................................................................................................................................................... - 15 5 Control process ................................................................................................................................................. - 16 6 Alarm Function ................................................................................................................................................. - 18 7 Alarm Function ................................................................................................................................................. - 19 7.2 Protection of High Discharge Air Temperature ...................................................................................... - 19 7.3 Protection of Air Compressor Reversal .................................................................................................. - 19 7.4 Protection of High Pressure ................................................................................................................... - 19 7.5 Protection of Sensor Failure................................................................................................................... - 19 7.6 Low Temperature Protection ................................................................................................................. - 19 8 Troubleshooting ................................................................................................................................................ - 20 9 Sequence Mode Control and Network ............................................................................................................. - 22 9.1 Sequence mode control ......................................................................................................................... - 22 9.2 Sequence Mode Setting ......................................................................................................................... - 23 9.3 Start, stop sequence control: ................................................................................................................. - 24 9.4 Sequence Communication Receiving and Sending Message: ................................................................ - 24 9.5 Network ................................................................................................................................................. - 25 10 Copyright ........................................................................................................................................................ - 26 -

04.08.2017

Operation Manual MAM - 860 V1.0

-3-

1 Basic Operation 1.1 Button Explanation

Start Button: 

When compressor is at stop status, press this button to start the compressor



When compressor is set as master (No.1) in block mode, press this button to start the compressor and activate block mode function at the same time.

Stop Button： 

When the compressor is at running status, press this button to stop the compressor



When compressor is set as master (No.1) in block mode, press this button to stop compressor and block mode function as well



When compressor is at stop status, long press this button to display software edition

Set Button /Loading / unloading Button: 

When the compressor is at running status, press this button to load, unload



When the compressor is at setting mode, press this button after modification to confirm and save the modified data

04.08.2017

Operation Manual MAM - 860 V1.0

-4-

Move down button / Decreasing button: 

When viewing the menu, press this button to move downward the cursor



When modifying data, press this button to decrease the data at current position

Move up button/Increasing button: 

When viewing the menu, press this button to move upward the cursor



When modifying data, press this button to increase the data at current position

Shift button /Enter button: 

When modifying data, press this button to move to the next data bit



When select menu, press this button to switch to submenu. If no submenu available, the controller will shift to data setting mode.

Return button / Reset button: 

When modifying data, press this button to exist data setting mode;



When viewing the menu, press this button to return to previous-menu;



When the controller is at failure stop status, long press this button to reset.

1.2 Indicator Instruction Power Indicator： Indicator on when controller is energized. Run indicator： Indicator is on when motor is running. Alarm indicator： Indicator is blinking when alarming; indicator on when fail to stop; indicator off when error is cleared

04.08.2017

Operation Manual MAM - 860 V1.0

-5-

1.3 Status Display and Operation The display screen will show as below after power on: WELCOME USING SCREW COMPRESSOR

After 5 seconds, the menu will switch as below: AIR T:

78°C

AIR P：

0.53MPa

NORMAL STOP C16

Press

0S REMOTE

to enter into selection menu: RUN PARAMETER USER PARAMETER FACTORY PARAMETER CALBR PARMETER

1.4 Operating Parameter and Menu: Press

or

to move the cursor to “RUN PARAMETER”, then press

to switch to secondary

menu: MOTOR、FAN CURRENT TOTAL RUN TIME THIS RUN TIME MAINTAIN PARAMETER

Press

to check MOTORS CURRENT, TOTAL RUN TIME, TOTAL LOAD TIME, and other running parameter.

Press

to return to the previous menu or main menu. If no operation in certain menu for 60s, machine

will return to the main menu automatically. 04.08.2017

Operation Manual MAM - 860 V1.0

-6-

1.5 User Parameter View and Modification: USER PARAMETER and FACTORY PARAMETER are not allowed to be modified in running and stop delay status.

In first menu press Press

or

to move the cursor to the “USER PARAMETER”.

to switch to the following menu

SET P、T SET TIME OPERATION MODE BLOCKING MODE

Move the cursor to the “SET P, T”, then press

to switch to secondary menu

LOADING P:

0.8MPa

UNLOADING P: FAN START T: FAN STOP T：

0.6MPa 80℃ 70℃

User can check the CUSTOMER PARAMETER in this menu or press

to switch to the following menu which

requires a user password input

ENTER PASSWORD ****

NOTE: Customer password can be set in CUSTOMER PARAMETER and is set as 1688.

04.08.2017

Operation Manual MAM - 860 V1.0

-7-

In this menu the first data bit of password blinking, press Press

or

to modify the first bit of password.

move the cursor to the next data bit, modify the second data bit of password in accordeance with the

above. Modify the the third and fourth data of password in sequence, press

to confirm the input data and the

menu will switch to the following menu after verification.

The upper right corner

BLOCK LOAD P:

0.8MPa

with “*” indicates the

BLOCK UNLOAD P:

0.6MPa

system verification

FAN START T:

80℃

of the password

FAN STOP T:

70℃

In the menu above press

*

, the first data of LOADING P start to blink, user can press

present data in accordance with the above method. Press sequence. When finished press

or

to modify the

to move to next data bit and modify the target data in

to confirm and save the data. The controller prompt sends out a short sound to

tip the completion of parameter set. Other CUSTOMER PARAMETER share the similar way for modification.

04.08.2017

Operation Manual MAM - 860 V1.0

-8-

1.6 User Parameter: First Submenu

P, T SET

TIMER SET

OPERATION MODE PRESET

04.08.2017

Second Submenu

Preset Value

Function 1. In AUTO LOADING status, compressor will load if pressure is below this set data 2. In STANDBY mode, compressor will start if the pressure below this set data 1. Compressor will unload automatically if air pressure is above this set data 2. This data should be set above LOADING P, also should be set below UNLD P LIM

LOAD P

0,65 MPa

UNLOAD P

0,80 MPa

FAN START

0080℃

Fan will start if AIR T is above this set data

FAN STOP

0070℃

Fan will stop if AIR T is below this set data

MOTOR START

0010s

Set the HOST START TIME. Record time when motor is activated, controller will not start overload protection during this time to avoid impulse starting current stopping the motor.

FAN START

0005s

Set the FAN START TIME. Record time when fan is activated, controller will not start overload protection during this time to avoid impulse starting current stopping the fan.

STAR DELAY

0005S

Interval time from star start to delta start.

LOAD DELAY

0003S

Unloading in this set time after enter delta running

EMPTY DELAY

0600S

When unloading continuously, compressor will automatically stop and enter to standby status if over this set time

STOP DELAY

0030S

For NORMAL STOP operation, compressor will stop after it continuously unloading over this set time

START DELAY

0030S

Machine cannot be restarted before this set time (stop and over time load free stop till this time)

RUN MODE

LOCAL / REMOTE

LOCAL: only the button on the controller can turn on and turn off the machine. REMOTE: both the button on the controller and the remote control button can turn on and turn off the machine;

LOAD MODE

AUTO/ MANUAL

COM MODE

MODBUS SEQ BAN

MANUAL: only when the pressure is above Unload P, compressor will unload automatically .For any other case ,the Load/Unload function can only be executed by pressing “load/unload” key. AUTOMATICAL: the load/unload function can be executed by the fluctuation of AIR P automatically BAN: communication function is not activated. MODBUS: compressor can communicate with computer or DCS as slave according to MODBUS-RTU. SEQ: compressors can work in a net

COM ADD

0255

Communication address

Operation Manual MAM - 860 V1.0

-9-

SEQUENCE SETTING

PARA

SEQ STATE

TURN TIME

99 Hours

SEQ NUMBER

0016

Number of air compressors in block net

SEQ LOAD

1.36MPa

In SEQ mode, one compressor will start or load when master AIR P is below this set data

SEQ UNL.

1.36MPa

SEQ DELAY

200S

OIL FILTER

0000H

O/A FILTER

0000H

AIR FILTER

0000H

LUBE

0000H

GREASE

0000H

BELT

0000H

OIL FILTER

0500H

O/A FILTER

3000H

AIR FILTER

0500H

LUBE

0500H

GREASE

3000H

BELT

3000H

CLR LIFE TIME

MAX LIFE PRESET

1. When service as master in SEQUENCE, master controls slave; the COM ADD should be set as No.1 2. When service as slave in SEQ, slave is controlled by master When master pressure is between SEQ LOAD P and SEQ UNLD P, master determines slave to work alternatively after working over this set time

HOST/ SLAVE

TIME

In SEQ mode, one compressor will stop or unload when master AIR P is above this set data In SEQ mode, when master sends two commands continuously, second command signal delays for this set data Record total running time of OIL filter. If changing new oil filter, the data should be reset by manual operation. Record total running time of O/A separator. If changing new O/A separator, the data should be reset by manual operation. Record total running time of AIR filter. If changing new AIR filter, the data should be reset by manual operation. Record total running time of LUBE. If changing lubricate, the data should be reset by manual operation. Record total running time of GREASE. If changing new grease, the data should be reset by manual operation. Record total running time of BELT. If changing new belt, the data should be reset by manual operation. 1, Alarm prompt when total running time of oil filter is above the set data . 2, Set this data to “0000”, alarm function for oil filter running time is not activated 1, Alarm prompt when total running time of O/A separator is above the set data. 2, Set this data to “0000”, alarm function for O/A separator running time is not activated 1, Alarm prompt when total running time of air filter is above the set data. 2, Set this data to “0000”, alarm function for air filter running time is not activated 1, Alarm prompt when total running time of lubricant is above the set data. 2, Set this data to “0000”, alarm function for lubricant running time is not activated. 1, Alarm prompt when total running time of grease is above the set data. 2, Set this data to “0”, alarm function for grease running time is not activated 1, Alarm prompt when total running time of belt is above the set data. 2, Set this data to “0”, alarm function for grease running time is not activated

LAN. SEL

English

Change the display language.

User password modification

****

User could modify the user password by old user password or factory password

04.08.2017

Operation Manual MAM - 860 V1.0

- 10 -

1.7 Factory Parameter: The view and modification of factory parameter requires a factory password, The modification step is same as customer parameter modification. Main function is as below.

Menu MOTOR CUR FAN CUR

Initial Data

Function

Maximum motor overload data /1.2 Maximum fan overload data/1.2

When the current of motor is more than 1.2 times of the set data , the unit will stop for overload feature. (see table2.1.1) When the current of fan is more than 1.2 times of the set data , the unit will stop for overload feature. When discharge air temperature reaches this set data, compressor will alarm When discharge air temperature reaches this set data, compressor will alarm and stop

ALARM T.

105℃

STOP T.

110℃

STOP P.

0.90MPa

When pressure reaches this set data ,compressor will alarm and stop

MAX U.L.

0.80MPa

This data is the maximum of UNLOADING P. The UNLOADING P in the customer parameter must be set no higher than this data.

RUN TIME

000100Hours

Modify the TOTAL RUN TIME

LOAD TIME

000095Hours

Modify the TOTAL LOAD TIME

CLR FAULT

****

CUR UN.BAL.

0006

LACK PAHSE

002.0s

DATA

****-**-**

Production date

SERIAL

********

Product serial No.

PHASE PRO.

ON/OFF

ON: turn on phase sequence protection OFF: turn off phase sequence protection

FRE. SEL

50HZ/60HZ

Set the operation power frequency

SEQ MODE

ADV/COMP

HIGH VOL.

0460V

LOW VOL.

0320V

LOW T PRO-

-0018℃

TIME LIM

0000H

ALM STOP

0010H

Input the password 8888 and press “set “button to clear all the history failure record. MAX-MIN >= SET*MIN/10, respond time is 5s If the set data ≥ 15, the unbalance protection will be invalid. If OPEN PHASE protection ≥20 seconds, OPEN PHASE protection is invalid

Set as compatible mode, block mode is the same as the other series. When block control with MAM 8*0 controller and set as advanced mode, more block mode function is available 1. Controller detects the voltage higher than this set data, the shutdown protection starts and reports HIGH VOL. 2. Set this data to 0000, the HIGH VOL. protection function is invalid 1. Controller detects the voltage lower than this set data, shutdown protection starts and reports LOW VOL. 2. Set this data to 0000, the LOW VOL. protection function is invalid 1. In stop mode, air compressor is not allowed to start when discharge air temperature is lower than this set data 2. Two minutes after turn on, when the air temperature is below this data, compressor will stop and display T SENSOR FAULT 1. When the compressor is in a stop status and the TOTAL RUN TIME exceeds this TIME LIM set, the controller will stop the compressor and display USER MISTAKE; 2. If this data is set to ‘0000’, TIME LIMIT function is invalid. Controller detects oil filter, O/A separator, air filter, lubricate oil, grease and belt running with alarming over this ALARM STOP set, compressor will stop and report ”ALARM LONG STOP ”

COM SET PARA

ON/OFF

1. When set as ON, User can use DCS to set data through MODBUS protocol 2. When set as OFF, User cannot use DCS to set data through MODBUS protocol 3, User can use DCS to set data only when compressor is at stop status

PARA1

****

User could modify the factory password by old factory password.

04.08.2017

Operation Manual MAM - 860 V1.0

- 11 -

PRES UNIT

MPA BAR PSI

Change the pressure unit

TEMP UNIT

°F °C

Change the temperature unit

1.8 Calibration Parameter You can set relative data of controller in CALBR PARA. It is not allowed to view and modify without manufacturers authorization, so please verify the password before view and modification. The modification of CALBR PARA is similar with CUSTOMER PARA. Main function is shown as below.

Menu MOTOR A

MOTOR B

MOTOR C

FAN A

FAN B

FAN C

04.08.2017

Initial Value TARGET CUR

0000

COEF

1.000

CUR

***.*A

TARGET CUR

0000

COEF

1.000

CUR

***.*A

TARGET CUR

0000

COEF

1.000

CUR

***.*A

TARGET CUR

0000

COEF

1.000

CUR

***.*A

TARGET CUR

0000

COEF

1.000

CUR

***.*A

TARGET CUR

0000

COEF

1.000

CUR

***.*A

Function Enter the current value, the controller will detect user input value divided by the current to the current value, calculate the current coefficient Calibration current, the input coefficients. Controller displays the current value = sample value × COEF Displays the current controller sampling current values. This value is the real value and cannot be set. Enter the current value, the controller will detect user input value divided by the current to the current value, calculate the current coefficient Calibration current, the input coefficients. Controller displays the current value = sample value × COEF Displays the current controller sampling current values. This value is the real value and cannot be set. Enter the current value, the controller will detect user input value divided by the current to the current value, calculate the current coefficient Calibration current, the input coefficients. Controller displays the current value = sample value × COEF Displays the current controller sampling current values. This value is the real value and cannot be set. Enter the current value, the controller will detect user input value divided by the current to the current value, calculate the current coefficient Calibration current, the input coefficients. Controller displays the current value = sample value × COEF Displays the current controller sampling current values. This value is the real value and cannot be set. Enter the current value, the controller will detect user input value divided by the current to the current value, calculate the current coefficient Calibration current, the input coefficients. Controller displays the current value = sample value × COEF Displays the current controller sampling current values. This value is the real value and can not be set. Enter the current value, the controller will detect user input value divided by the current to the current value, calculate the current coefficient Calibration current, the input coefficients. Controller displays the current value = sample value × COEF Displays the current controller sampling current values. This value is the real value and cannot be set.

Operation Manual MAM - 860 V1.0

- 12 -

1.9 Operating Authorization and Password Controller provides multiple passwords and access management. According to different levels of passwords, controller provides different levels of operating authorization. Details are as following: Customer Password: factory set ____________ Permissions: Allows to modify all Customer Parameter Factory Password: fixed ____________ Permissions: Allows user to modify all Parameter Calibrate Password: fixed ____________ Permissions: Allows user to modify CALBR PARAMETER

2 Controller Function and Technical Parameter 

Phase sequence protection: When compressor is at stop mode an detects open phase, response time