EasyTronic III MANUAL SERVICE

Transcription

1 rev.6 EasyTronic III MANUAL SERVICE General characteristics: Power supply 24 Vac ±15% Max consumption at 24Vac 300mA Relay outputs 6 Maximum relay current 8 A res. Serial standard RS232 2 Serial standard RS485 2 Digital inputs 14 Input for phase sequence 1 a 5 Vac Temp. analog inputs 2 (10 bit) LCD contrast regulation 20 levels Maximum life 50,000 hours Analog input 4-20mA 1 (12 bit) Analog output 4-20mA 1 (10 bit) Clock calendar with lithium battery CR2032. Internal alarm buzzer. Maximum distance of base from display: 2 meters, through Ethernet cable.

2 START PAGE, remains on screen for 3 seconds after the central is started. Easy Controll III Ver.0.0 data Easy Controll III NORMAL OPERATION SCREEN ----Screw temp.: 065 C 06.5Bar 000% STATUS=OFF Ora data Start screen: 1st line: use arrow keys and to display the following information (after 25 seconds without typing anything the display will automatically show screw temperature). 1. intern. temp.: indicates the temperature inside the electro-mechanical plant air temp.: indicates the temperature at the air outlet screw temp.: indicates the temperature of the screws total hours: indicates the total number of the engine s working hours 5. load hours: indicates the number of hours the compressor worked in a load cycle idling hours: indicates the number of hours the compressor worked in a IDLING cycle. 7. mainten. hours.: indicates the remaining number of hours until the next maintenance intervention. A negative number indicates the hours during which the machine has worked without maintenance. 8. air filter hours: indicates the number of hours left before the air filter has to be replaced. 9. bear. lubr.: indicates the number of hours left before bearings have to be lubricated. 10. oil filter hours: indicates the number of hours left before the oil filter has to be replaced. 11. oil change hours: indicates the number of hours left before the oil has to be changed. 12. Start/hours: indicates how many times the motor has started in the past hour. If an inverter is present, together with a communication cable with the inverter connected: 13. inverter temperature: indicates the temperature of the inverter. 14. Inverter frequency.: indicates the frequency at which the inverter is working. 2nd line: Pressure present at motor speed in %. If an inverter is present, together with a communication cable with the inverter connected, % inverter load. 3rd line: Machine status: 1. STATUS=IDLING, the motor is on but the load electro-valve is disabled. 2. STATUS=LOADED, the motor is on and the load electro-valve is enabled. 3. STATUS=STAND-BY, active status, but the motor is off. 4. STATUS=REMOTE-OFF, waiting for the remote start-up command. 5. STATUS=OFF, machine is being supplied but its functioning is disabled. 6. STATUS= REMO.PRESS. OFF, the machine is still, waiting for remote pressure. 4th line. Time and Date. If there is a programmed start-up a blinking clock will be displayed after the date. POSSIBLE ALARMS In case of alarm, the type of alarm is displayed on the first line. If there is more than one alarm present it is possible to scroll up and down the list of alarms by using and. To move to normal display during an alarm, use the right arrow key. To silence the alarms, press Reset. To cancel the alarm, keep Reset pressed for at least 2 seconds. All alarms that are no longer active will be deleted. The alarm of incorrect rotation direction can only be cancelled by cutting off power supply to the machine. Pag 2/12

3 List of alarms: 1. rot. dir. err.: In case of an incorrect phase sequence the central will display rotation direction error and the ALARM LED will light up. This alarm blocks the compressor. To restore function, restore the phase sequence. ATTENTION: This alarm can only be reset by cutting off power supply to the machine. 2. air temp. sens. faulty: This is controlled by the presence of the temperature sensor (open probe or short-circuit). The displayed message is Temperature sensor faulty. This alarm blocks the compressor. To restore function, check the probe and press Reset. 3. screw temp. sens. faulty: This is controlled by the presence of the temperature sensor (open probe or short-circuit). The displayed message is Temperature sensor faulty. This alarm blocks the compressor. To restore function, check the probe and press Reset. 4. max. oil temp.: When the oil reaches its maximum temperature the alarm max. oil temp. is displayed. This alarm blocks the compressor. To start up the compressor again you must wait until the temperature goes back below the programmed value and then press Reset. 5. min. oil temp.: When the oil reaches its minimum temperature the alarm min. oil temp. is displayed. This alarm blocks the compressor. To start up the compressor again you must wait until the temperature goes back up above the programmed value and then press Reset. 6. oil pre temp.: When the oil reaches its pre-alarm temperature the alarm oil pre temp. is displayed. This alarm does not block the compressor. Press Reset to silence the alarm. 7. motor thermal: This alarm is given when the motor thermal intervenes. This alarm blocks the compressor. To silence the alarm, check its cause then press Reset. 8. emergency pushbutton: This alarm means the emergency mushroom button which blocks the compressor has been pressed. To silence the alarm, restore the emergency button to its original position, then press Reset. 9. air filter: This alarm does not block the compressor. To silence the alarm, press Reset. 10. maintenance: This alarm warns the user that the machine requires an ordinary maintenance intervention. This alarm can only be silenced by the service centre which has carried out the maintenance operation; the counter will be reset to the desired value. 11. max. press. al.: This alarm is displayed when the maximum set pressure is exceeded. This alarm blocks the compressor. To silence the alarm, restore the correct pressure, then press Reset. 12. press. sens. broken: This alarm is displayed when the pressure sensor connected to the 4-20 ma input is not working correctly. This alarm blocks the compressor. To silence the alarm, restore the normal status of the pressure sensor, then press Reset. Pag 3/12

4 13. commun. error: This alarm is displayed when communication between the central and the display is lost. This alarm blocks the compressor. Check connections. 14. inverter error: This alarm is enabled when the inverter is active. This alarm blocks the compressor. Check the inverter. 15. screw mot. therm.: This alarm is displayed when the screw motor thermal intervenes. This alarm blocks the compressor. To silence the alarm, check its cause, then press Reset. 16. fan mot. therm.: This alarm is displayed when the fan motor thermal intervenes. This alarm blocks the compressor. To silence the alarm, check its cause, then press Reset. 17. remote press. error: This alarm does not interrupt the compressor. It warns the operator that for some reason the external remote pressure control has not intervened. If the remote pressure parameter is at ON, the alarm cannot be reset until the correct sequence of remote pressure control is restored. CONTRAST REGULATION While the machine is off (status=off), press and at the same time. The first line of the display will show the level of contrast. Contrast can be regulated from 1 (darker) to 20 (lighter) by using keys and. Press OK to confirm. The value is automatically saved in the memory. Pag 4/12

5 PARAMETERS PARAMETER MIN MAX DEF ID Unit of measur. HOURS OF GENERAL MAINTENANCE Hours HOURS OF AIR FILTER REPLACEMENT Hours OIL FILTER HOURS Hours OIL CHANGE HOURS Hours BEARING LUBRICATION HOURS Hours IDLING HOURS Hours TOTAL HOURS Hours PRE-ALARM TEMPERATURE C MAXIMUM TEMPERATURE C MINIMUM TEMPERATURE C FAN TEMPERATURE C IDLING OPERATION TIME sec STOP IDLING TIME AUTOMATIC START NO - INTERNAL PHASE SEQUENCE NO - LANGUAGE ITA - ENABLE RS485 YES - SET DATE AND TIME PSI/BAR BAR - WORKING PRESSURE 0.0 Max Pres 10.0 BAR WORKING DELTA BAR MAXIMUM PRESSURE 0.0 PreAll 0.5Bar 11.0 BAR MAXIMUM ALARM PRESSURE BAR REMOTE PRESSURE NO - START PROGRAM OFF - X01 DIGITAL INPUTS 1-8 Bit X07 DIGITAL INPUTS 1-6 Bit MOTOR THERMALS SEPARATED NO - TEMPERATURE UNIT OF MEASUREMENT C - MAXIMUM START UP/HOURS INVERTER YES - If the inverter is enabled: MINIMUM WORKING % % LOAD DELAY sec INVERTER INTEGRATIVE MAXIMUM FREQUENCY Hz ACCELERATION TIME sec DECELERATION TIME 000, sec S ACCEL. CURVE sec NOMINAL FREQUENCY Hz BOOST AT START UP % MAXIMUM VOLTAGE 0:max.100%v/ f SWITCH FREQUENCY 2 KHz ANALOG COMMAND 4-20 ma Pag 5/12

6 OPERATION Standard switch-on: Press (I). If there are no active alarms the switch-on cycle will start. a) Wait for switch-on: The display will show STAND-BY and the central will wait until the following conditions are present before it starts the compressor: 1) If the machine was previously spent the central must wait for 15 seconds before it starts the compressor. 2) The central must wait until the pressure goes below the value set at IDLING before it starts the compressor. b) Compressor start-up: the line and star remote control switch is switched and the display will show IDLING. c) Normal operating conditions: After 6 seconds the passage from star to triangle takes place. The display still shows IDLING. After the number of seconds programmed in the Delay Load parameter, if the remote control switch so requests the load electro-valve is excited and the display will show LOAD. Standard switch-off: Press OFF to start the switch-off procedure. a) The enabling of the load electro-valve is switched off and the IDLING cycle starts. The display will flash IDLING. When the IDLING Stop cycle ends the compressor will switch off and the display will show STATUS=OFF. Remote switch-on: The compressor can be remotely switched on by using the Remote Control Digital Input. Press (I): if there are no alarms the remote control will start. From this moment on the Remote Control Digital Input will switch the machine on and off. Buttons (I) and (0) have an upper hand over the Remote Control Digital Input. Switch-on procedure from remote pressure: When the remote pressure control is enabled through the menu, the Remote Pressure Digital Input is enabled as well. In this configuration the central will control the remote input as an external pressure gauge, and will also make sure that the gauge functions within the range of preset values (set loaded, set IDLING or working pressure and delta in case of inverter). If the Set pressure is exceeded due to an anomaly of remote pressure control, the central will take over the compressor cycle and force it to work with internally set values, signalling the alarm message Remote press. err. If the remote intervenes before the set IDLING of the central, pressure control is again entrusted to the remote pressure input (at this point the alarm can be reset). Inverter Minimum Protection: If the compressor with inverter remains in the load phase for the minimum % of load for longer than the IDLING time, it will automatically switch to IDLING, to limit working time to the minimum %. Pag 6/12

7 PARAMETER SET UP By pressing OK the machine will stop (Status=OFF) and you will be sent to the parameter set up menu: 0) ID: (service code): Selects the central ID. More than one ID can be selected in case there are more than one machine connected to the same RS485 line. 1) Maintenance (service code): Use keys and to scroll through the 7 possible values. Use keys and to change these values. The counter with a sign indicates the number of hours since maintenance expiry. 1. General Maint.: hours left until general maintenance. When the counter reaches 0 the central goes in Maintenance alarm. 2. Air filter change: hours left until next air filter change 3. Oil filter change: hours left until next oil filter change 4. Oil change: hours left until next oil change 5. Bearing lubric.: hours left until next bearing lubrication 6. IDLING hours: hours of IDLING operation 7. Total hours: total working hours If parameters IDLING hours or Total hours are changed, when leaving the menu the system will require the factory password as confirmation. 2) Alarm log: You can scroll through the last 100 alarm messages, with time, date and screw temperature. To delete the log press and at the same time while in the menu and type in the factory password. 3) Pre-alarm temperature: this value, not changeable, defines the temperature delta, expressed in C, from the maximum alarm temperature. This value can be set from 1 to 20. For instance, if maximum temperature is 120 C and delta is 10 C, the maximum temperature pre-alarm will be displayed at 110 C. 4) Maximum temperature this value, not changeable, defines the Maximum Allowed Temperature. Regulation range goes from 0 to 150 C. 5) Minimum temperature this value, not changeable, defines the Minimum Allowed Temperature. Regulation range goes from 0 to 14 C. 6) Fan temperature (service password): This menu contains the temperature which activates the fan. Regulation range goes from 0 to 150 C. The fan will start when the preset temperature is reached. The fixed hysteresis is 10 C. 7) IDLING time (service password): From this menu you can intervene to alter the machine s IDLING cycle time. Regulation range goes from 60 to 900 seconds, with 5-second steps. 8) Stop IDLING time (service password): From this menu you can intervene to alter the machine s IDLING cycle time before it goes into OFF. Regulation range goes from 30 to 250 seconds, with 5-second steps. 9) Automatic Start (service password): This parameter enables Automatic Stop. When activated, the compressor will start automatically even after a power failure. The initial start must be activated by pressing (I) on the push button panel. For safety reasons its use is absolutely not advisable. 10) Int. phase sequence (service password): This parameter enables the internal phase sequence control, or disables it by activating the phase sequence input on the terminal. 11) Language (free): This parameter changes the language of the menu. 12) Enable RS485 (free): This parameter enables transmission through RS485, and automatically disables transmission through RS232. Pag 7/12

8 13) Set time and date (free): Set date and time. If the battery is low the firmware date is automatically used. If the picture of a battery shows up right after the time, replace the CR2032 battery and set the correct time. 14) PSI/BAR (free): Selects one of these units of measurement for pressure. 15) This parameter is subject to the presence of the inverter. Functioning with inverter: Working pressure (free): In this parameter it is possible to set the working pressure at which the compressor will stop. Functioning without inverter: Set IDLING (free): In this parameter it is possible to set the working pressure at which the compressor will stop. 16) This parameter is subject to the presence of the inverter. Functioning with inverter: Working Delta (free): This parameter becomes the working delta, i.e., it indicates the pressure range at which the compressor must work. For instance, if set at 1.0 bar and if working pressure is 9.0 bar, this means the compressor will switch off at 9.5 bar and switch on again at 8.5 bar. Functioning without inverter: Set load (free): In this parameter it is possible to set the working pressure at which the compressor will start. 17) Maximum pressure (service password): This parameter defines the maximum possible pressure value from menu 14; it therefore limits the maximum pressure the compressor can achieve. 18) Maximum alarm pressure this value, not changeable, defines the maximum pressure value at which the central goes in alarm and blocks the machine. 19) Remote pressure (service password): When this parameter is enabled, the Remote Pressure Input is enabled as well, so that pressure control is demanded to the external pressure sensor connected to this input. In case of malfunctioning of the external sensor, the internal sensor is enabled, with our without inverter. 20) Start-up program (service password): There are 5 programs available (0-4). Use keys and to select the desired program. Press OK to alter it. Select the start time, the stop time and the day of the week in which it must be active. An X indicates that the preset day is active. To disable the program, insert identical start and stop hours. Press OK to confirm. 21) X1 Progr. NC-NO (service password): It is possible to invert the logic of the inputs of terminal X1: position the cursor with arrows and on the input to be altered and use arrows and to modify it. Press OK to confirm. 22) X7 Progr. NC-NO (service password): It is possible to invert the logic of the inputs of terminal X7: position the cursor with arrows and on the input to be altered and use arrows and to modify it. Press OK to confirm. 23) Separate Mot. Therm. (service password): If this parameter is ON the motor thermals of the screw motor and of the fan are separated in two inputs. 24) Temp. unit of measur.: (free) : Use arrows and to choose from degrees Celsius or Fahrenheit. 25) Maximum start/hours (service password): From this parameter you can select the maximum number of starts in a period of 1 hour. If this limit is exceeded the compressor will continue with a IDLING or load cycle according to need, and will return to stand-by when the time of the first start is reached. 26) INVERTER (service password): Enables the inverter. 27) Minimum working % (service password): Indicates the minimum percentage at which the inverter must work. The maximum value is always 100%. 28) Load delay (service password): Indicates the delay, in seconds, before the load electro-valve is enabled after the screw motor has reached its normal working conditions. Pag 8/12

9 29) Inverter integrative (service password): This parameter alters the time constant of the integrative part of the calculation for the Inverter percentage. 30) Inverter parameters (service password): Inverter parameters with KEB protocol: 1. Maximum frequency 2. Acceleration time 3. Deceleration time 4. S acceleration curve 5. Nominal frequency 6. Boost at start-up 7. Maximum tension 8. Switch frequency 9. Analog command Pag 9/12

10 EasyTronic III CONNECTION X03 X10 X07 X02 X X X09 RS485 Progr. Con. Display X06 CN1 CN2 RS232 CN3 1) Connector X8 outputs. Relay Terminal Function Relay No Star Relay No Line Relay No Triangle Relay No Load electro-valve Relay No Alarm Relay No Fan 2) Analog inputs X02 Input Terminal Function Positive +20 Vdc for pressure Transducer 4/20 ma 2 Input 4/20mA Pressure Transducer Temp. 1 3 Air temperature probe input Temp. 2 4 Screw temperature probe input Temp. 3 5 Fixture for further analog input (10bit) Mass 6 Common mass for temperature sensors Pag 10/12

11 3) Analog digital inputs X07 Input Terminal Function Analog 1 Fixture for further analog input (10bit) Dig. 1 2 INVERTER error Dig. 2 3 Fan motor thermal Dig. 3 4 Remote Pressure Digital Input Dig. 4 5 Digital Input Dig. 5 6 Digital Input Dig. 6 7 Digital Input Mass 8 Common mass for digital and analog inputs 4) Phase control input X10 Input Terminal Function GND 1 Earth connection 5 Vac 2 Input 5 Vac for Phase control N.C. 3 Not connected 5) General power supply input X03 Input Terminal Function 0 Vac 1 Input 0 Vac for power supply 24 Vac 2 Input 24 Vac for power supply 6) Digital inputs X01 Input Terminal Function Mass 1 Common mass for digital inputs Dig. 1 2 Emergency Digital Input Dig. 2 3 Oil Filter Digital Input Dig. 3 4 Air Filter Digital Input Dig. 4 5 Oil Mist Eliminator Digital Input Dig. 5 6 External Phase Sequence Digital Input Dig. 6 7 Minimum Pressure Gauge Digital Input Dig. 7 8 Remote Control Digital Input Dig. 8 9 Motor Thermal Digital Input* *: if both motor thermals are enabled, this will become the thermal of the screw motor. 7) Analog output 4/20 ma X09 Output Terminal Function +20 Vdc 1 Positive +20 Vdc for output 4/20 ma Inverter. N.C. 2 Not connected 4/20mA 3 Output 4/20mA Inverter N.C. 4 Not connected Pag 11/12

12 8) RS485 X06 Rs485 Terminal Function A 1 Channel A Rs485 B 2 Channel B Rs485 9) 6-way plug, CN1 programming 10) 8-way plug, communication through display board CN2 11) Interface RS232 CN3 Pag 12/12