SCREW AIR COMPRESSOR CONTROLLER

MAM-KY02S（ B） -（ Ⅷ ）

（Monitor-200）

USER

MANUAL

Shenzhen Plot Electronic Co., Ltd

Address：4-5F,5 Bldg,Highstar Industry Park,Guangtou Community,

Bantian,Longgang District,Shenzhen City，China

Telephone：（+86 0755）83173599 / 83172822 Postal code：518034

Fax：（+86 0755）83172966 E-mail：[email protected]

Web site：www.pltsz.com

1

VOTE OF THANKS

Thank you for your trustworthy and select of PLOT air compressor controller !

Shenzhen Plot Electronic Co., Ltd specializes on the manufacture and R&D of air compressor controller. We are devoted to win customer trust through our high quality products and service.

We try our best to ensure the completeness and correctness of the manual, but

PLOT Company shall reserve the rights for continuous research and improvement on its products and assume no obligation for the modification and improvement on the previously delivered products. The design of products is subject to the change without notice.

Please feel free to contact our after-sale service center if you encounter any problem with our product.

You are always welcome to make suggestions and advices!

2

NOTICE

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

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

Installation position shall be considered carefully in order to ensure good ventilation and reduce electromagnetic interference

.

Wiring shall be performed respectively according to regulations for heavy and weak current to reduce electromagnetic interference.

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.

Correct ground connection (the third ground)can help increase product capacity of resisting signal interference.

Set rated current of motor: the max current of motor/1.2.

Features：

● Chinese / English display.

● Short circuit, current block, current open phase, current overload, current unbalance protection for motor

● On-off control and running control of motor.

● Prevention for air compressor reversal

● Temperature measurement , control and protection

● Control pressure balance by adjust load rate automatically

● High integration , high reliability ,high cost performance.

● Remote control/Local control.

● Block mode/Independent mode.

● RS-485 communication function,

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Contents

1,Basic Operation..................................................................................................................................................... 5

1.1, Button Explanation................................................................................................................................... 5

1.2, Status Display and Operation .................................................................................................................. 6

2, Contoller Function and Technical Parameter ................................................................................................. 12

3, Model and Specification .................................................................................................................................... 12

3.1, Model explanation .................................................................................................................................. 12

3.2Power specification sheet for corresponding motor. .............................................................................. 13

4, Installation.......................................................................................................................................................... 13

4.1, Mechanical Installation .......................................................................................................................... 13

4.2, Electrical Connections ............................................................................................................................ 15

5, Alarm Function .................................................................................................................................................. 16

5. 1、Monitor Indication............................................................................................................................... 16

5.2,Controller Indicator ................................................................................................................................ 16

6,Controller Protection.......................................................................................................................................... 17

7, Troubleshooting ................................................................................................................................................. 18

7.1、This Fault Review ................................................................................................................................. 18

7.2、Common Failures and Causes: ............................................................................................................ 18

8, Schematic Diagram：........................................................................................................................................ 20

4

1,Basic Operation

1.1, Button Explanation

Picture 1

I——Start Button:

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

2,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.

O——Stop Button：

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

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

——Load / unload Button:

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

S——

Set Button:

1. When modifying data, press this button after modification to save and confirm the modified data.

2. When the compressor is at password setting status ,press this button to save and confirm the password

——Move up button/Increasing button:

1,when viewing the menu, press this button to move upward the cursor ;

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

——Move down button / Decreasing button:

5

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

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

——Shift button /Enter button:

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

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

C——Return button / Reset button:

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

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

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

1.2, Status Display and Operation

The display screen will show as below after power on:：

WELCOME

SCREW COMPRESSOR

After 5 seconds, the menu will switch as below:

DISC T：20℃

AIR P：0.60Mpa

RUN STATUS:NORMAL STOP

ADD:001 LOCAL

Press “” to enter into Selection Menu:

RUN PARAMETER

CALENDAR

CUSTOMER

PARAMETER

1.2.1, Operating Parameter and Menu

Press“” or“” to move the cursor to “RUN PARAMETER”, then press“” to switch to secondary menu:

MOTOR、FAN CURR

TOTAL RUN TIME

THIS RUN TIME

MAINTENANCE PARA

Move the cursor to “MOTOR,FAN CURR” ,press“” to switch to secondary menu:

CURR(A)：R S T

6

MOTOR： 56.1 56.2 56.0

FAN： 4.1 4.1 4.1

Press “RESET”， to return to the previous menu or the main menu. If no operation at the current menu for 120 seconds , controller will automatically return to the main menu and turn off the back light simultaneously.

According to above method, use move down “” ,move up button“”, enter button“”and return button

“RESET” to check TOTAL RUN TIME,THIS RUN TIME,MAINTENANCE PARA,FAULT RECORD,

PROD.DATE、SERIAL,THIS FAULT and return to previous menu.

1.2.2, Calendar

Check and set time of controller

TIME

2004-2-22

WEEK0

12:46:59

1.2.3, Customer Parameter

A, Customer parameter view and modification

It is not allowed to modify CUSTOMER PARAMETER and FACTORY PARAMETER in running status and

STOP DELAY

The check and modification of CUSTOMER PARAMETER is similar with RUN PARAMETER. Take

UNLOAD P as example: Move “”or“”to CUSTOMER PARAMETER and then press “”to switch to below menu

SET P、T

SET TIME

OPERATION MODE

BLOCK PARAMETER SET press“” to switch to below menu

LOAD P：00.65MPa

UNLD P：00.80MPa

FAN START T：0080℃

FAN STOP T：0070℃

Move the cursor to item LOAD P, then press “”

to switch to the following menu which requires a user password input.

INPUT PASSWORD

****

Note: User password can be modified in customer parameter and FACTORY PARAMETER

7

is fixed as

In this menu, the first data bit of password starts blinking，press “”or“” to modify the first bit of password，Press “” to move the cursor to the next data bit, modify the second data of password in accordance with the above , and modify the third and fourth data of password in sequence. Press“S” to confirm the input data and the menu will switch to the following menu after verification:

UNLD P：00.80MPa

FAN START T：0080℃

FAN STOP T：0070℃ indicates that the data is at a setting status

In the menu above , press “”, the first data of LOAD P starts blinking ,user can press “”or“”to modify the present data in accordance with the above method .Press“” to move to next data and modify the target data in sequence. When finished, press “S” to confirm and save the data.

B, Customer Parameter Sheet and Function

First menu

SET P、T

SET TIME

Second menu

LOAD P

UNLD P

FAN START T

FAN STOP T

MOTOR START

TIME

FAN

TIME

START

Preset Data Function

00.65MPa

00.80MPa

0080℃

0070℃

0008S

0003S

1,In AUTO load mode , compressor will load if pressure is below this set data

2,In STANDBY mode, compressor will start if the pressure is below this set data

1,Compressor will unload automatically if air pressure is above this set data

2.This data should be set above LOAD P ,also should be set below UNLD P LIM

Fan will start if DISC T is above this set data

Fan will stop if DISC T is below this set data

Set the MOTOR 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.

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

TIME

LOAD DELAY

TIME

0006S

0002S

Interval time from star start to delta start.

Unloading in this set time after enter delta running

STANDBY

DELAY

STOP DELAY

0600S

0010S

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

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

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OPERATION

MODE

BLOCK

PARAMETER

SET

RE-START

DELAY

OTHER

DRAIN OPEN

TIME

DRAIN CLOSE

TIME

0100S

0000S

0002S

0060H

START MODE

LOAD MODE

COM MODE

COM ADD

Machine can start only over this set time at any case(after normal stop, standby or alarm &stop)

Additional function

Auto drain control, continuously drain time

LOCAL/

REMOTE

AUTOMATI

CAL/MANU

AL

DISABLE/

BLOCK/

COMPUTER

0001

Auto drain control, continuously drain interval time

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;

MANUAL : only when the pressure is above

UNLD 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

DISABLE: communication function is not activated.

COMPUTER: compressor can communicate with computer or DCS as slave according to

MODBUS-RTU.

BLOCK: compressors can work in a net

Set the communication address in COMPUTER or

BLOCK mode. This address is unique for every controller in net

BLOCK STATUS

BLOCK ON/OFF

TURN TIME

BLOCK

NUMBER

MASTER/

SLAVE

ORDER/

ALONG

0002H

0002

BLOCK LOAD P 00.63MPa

1.When service as master in BLOCK, master controls slave; the COM ADD should be set as

No.1

2.When service as slave in BLOCK, slave is controlled by master

When master pressure is between BLOCK

LOAD P and BLOCK UNLD P, master determines slave to work alternatively after working over this set time

Number of air compressors in block net

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

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O/A

SEPERATOR

CLR

MAINTENANCE

TIME

AIR FILTER

LUBE

BLOCK UNLD P

OIL FILTER

O/A

SEPERATOR

GREASE

CHINESE/

ENGLISH

00.78MPa

0000H

0000H

0000H

0000H

2000H

MAX LIFE TIME

LANGUAGE

PHASE PRO

BLOCK DELAY

GREASE

OIL FILTER

AIR FILTER

LUBE

0020S

0000H

2000H

2000H

2000H

2000H

ENGLISH

ENABLE/

DISABLE

10

In BLOCK mode, one compressor will stop or unload when master AIR P is above this set data

In BLOCK 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 lubricant. If changing new lubricant, 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

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

ENGLISH: Displays in English

CHINESE: Displays in Chinese

Enable: PHASE PRO function is activated

Disable: PHASE PRO function is not activated

NEW

PASSWORD

USER

**** ****

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

1.2.4,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:

PARAMETER

Initial Data Function

MOTOR RATED

CURR

FAN

CURR

RATED

ALARM DISC T

STOP DISC T

STOP AIR P

UNLD P LIM

Maximum motor overload data /1.2

Maximum fan overload data/1.2

105℃

110℃

00.90MPa

0.85MPa

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 than the set data , the unit will stop for overload feature.

When discharge temperature reaches this set data, compressor will alarm

When the discharge temperature reaches this set data, compressor will alarm and stop

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

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

TOTAL LOAD

TIME

TOTAL RUN

TIME

FAULT

RECORD RESET

000095 H

000100 H

****

Modify the TOTAL LOAD TIME

Modify the TOTAL RUN TIME

CURR

UNBALANCE

OPEN PHASE

PROT

FREQ SEL

OPEN PHASE

PROT

PROD.DATE

SERIAL NO.

0006

002.0S

50Hz/60Hz

002.0S

9999-99-99

9999999999

Input”8888”and press “set“ button to clear all the history fault record.

When MAX -MIN CURRENT >=（1+ SET

DATA*MIN CURRENT/10

）,the unbalance protection is activated ,compressor will alarm and stop, reporting MOTOR CURR UNBAL

If the set data ≥ 15, the unbalance protection will not be activated.

If OPEN PHASE protection ≥20 seconds, OPEN

PHASE protection is not activated

Choose operation power frequency.(This parameter influences the sample current value. When this data is set incorrectly, the actual current is 1.2 times different from displayed current value)

If OPEN PHASE protection ≥20 seconds, OPEN

PHASE protection is not activated

Production date set by manufacturer

Serial No. set by manufacturer

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2, Contoller Function and Technical Parameter

2.1,Digital input &output：9 points of digital input，10 points of digital relay output

2.2,Analog input& output： 2 points of Pt100 temperature input，2 points of 4～20mA pressure signal input,2 groups of three phases current input (CT provided）；

2.3,Input voltage of phases：three phase 380V；

2.5,Measurement :

2.5.1Oil temperature：—20～150℃；A

ccuracy

：±1℃

2.5.2Discharge temperature：—20～150℃；A

ccuracy

：±1℃

2.5.3Running time：0～999999H

2.5.4Current：0～999.9A

2.5.5Pressure：0～1.60MPa A

ccuracy

:0.01Mpa

2.6,Phase protection: When compressor is at stop mode and detects open phase, response time≤2s；

2.7,Motor protection: This controller provides open phase, unbalance and overload protection to motor and fan.

2.7.1Open phase protection：When any phase opens, the response time equals to set time；This function is not activated when OPEN PHASE PROTECTION time is set over 20s

2.7.2Unbalance protection: when MAX-MIN current >= SET DATA *MIN current/10 ,respond time is

5s；

2.7.3Protection features of overload (time unit: second)，please see following table（table 2.1.1）for your reference. Multiple＝Iactual／Iset ,response time is shown in following table (table 2.1.1) according to overload multiples from 1.2 times and 3.0 times .

I

actual

/

I

set

Time parameter

≥1.2 ≥1.3 ≥1.5 ≥1.6 ≥2.0 ≥3.0

Response time（S） 60 48 24 8 5 1

Table 2 curve table for protection of motor

2.8, Temperature protection: when actual temperature measured is higher than temperature set; response time≤2s

2.9, Contact capacity of output relay: 250V,5A；Contact endurance :500000 times；

2.10, Current error is less than 1.0%.；

2.11,RS—485communication

3, Model and Specification

3.1, Model explanation

Control modeⅧ

T：RS—485communication

B：Pressure transmitter；K：pressure switch

Motor max operating current

V：Vane compressor；S：Screw compressor

02 controller（LCD display）

Model

12

3.2Power specification sheet for corresponding motor.

Current range

Corresponding

Specification main motor

(A) power (KW)

Remark

KY02（20）

KY02（40）

KY02（100）

8～20

16～40

100

Below 11

11-18.5

22-45

KY02（200）

KY02（400）

KY02（600/5）

200

400

600/5

55-90

110

200-250 With CT

Description

Fan has three levels of current, such as 0.2-2.5A,

1-5A and 4-10A, determined by current of motor

4, Installation

4.1, Mechanical Installation

4.1.1, CT Installation

The CT shall be installed at a place where the current of motor cable can be measured, thus, controller can be set according to instructions on motor nameplate, and the detailed dimension is shown as below:

A

B

Picture1、CT1 Structural dimension of CT1（ф36 hole） Picture2、CT1 Installation dimension

A

B

Picture 3、Structural dimension of CT2（ф10 hole） Picture 4、CT2 Installation dimension

13

4.1.2,Controller Installation

When install the controller, room should be left around controller for wiring. The specific dimension is shown as below:

The corresponding digital input terminal of 00、01、02、03、

04、05、06、07 is 20、 19、18、

17、16、15、14、13.

2、Indicator（OUT）

The corresponding digital input terminal of 00、01、02、03、

04、05、06、07、08、09 is 27、28、 29、30、31、35、

36、37、38、39

3、Power Indicator：PWR

4、Run indicator：RUN

5、Error indicator：ERR

Picture 5、Controller structure dimension

4.1.3,Panel Function and Installation Panel Structure 165

╳

102

╳

50（mm）

250

50

I

后 油

冷 冷

却

器

却

器

排气温度:80C

供压：0.80MPa

运行状态:设备已停止

0秒 本地

O

S

Picture 6,Panel Dimension

Picture 7, Hole dimension

14

22

3

14

4.2, Electrical Connections

Picture 8、Terminal arrangement diagram

Monitor connection terminal：

There are five connection cables and a communication cable which are used for display connection , RS-485 communication ,24V power supply.

Controller connection terminal：

Communication cable is used to connect monitor and controller.

1.2.3 CT1:Motor current transformer

23、24、25 Phase input

4.5.6

27

CT2:Fan transformer current

Motor contactor

7、9

28

Discharge temperature input

Star contactor

29

34

39

43,44

Delta contactor

Outlet valve

Alarm indicator

220V

30

37

40

Inlet valve

Run indicator

31

38

Communication port 2 42

Fan

Error indicator

GND(analog)

*

Note : Electromagnetism coil shall be connected nearest with RC snubber during wiring, Dotted line is for extra function

15

5, Alarm Function

5. 1、Monitor Indication

5.1.1, Air Filter Alarm

①. Air filter block check.

The monitor displays AIR BLOCK by checking pressure differential switch close.

②. Air filter running time alarm

The text displays AIR TIME END when running time of the air filter is exhausted.

5.1.2, Oil Filter Alarm

①. Oil filter block check.

The monitor displays OIL BLOCK by checking pressure differential switch close.

②. Oil filter running time alarm

The text displays OILTIME END when running time of the oil filter is exhausted.

5.1.3, O/A Separator Alarm

①. O/A separator block check.

The monitor displays O/A BLOCK by checking pressure differential switch close.

②. O/A filter running time alarm

The text displays O/A TIME END when running time of the oil filter is exhausted.

5.1.4, Lubricant Alarm

The text displays LUBE TIME END when running time of the lubricant is exhausted.

5.1.5, Grease Alarm

The text displays GREASE TIME END when running time of the grease is exhausted.

5.1.6, Discharge Temperature High Alarm

The text displays DISC T HIGH when DISC T is higher than ALARM DISC T set in FACTORY

PARAMETER.

5.2,Controller Indicator

Indicator Meaning and function Indicator status

Power

Run

Error

Digital input

Controller power on

Controller run

Failure and stop

Terminal 26～18 digital input

PWR indicator on

RUN indicator on

ERR indicator blink

IN00~08corresponding indicator on. Indicator will not be illuminated if input has no function

Digital output

Terminal 39、40、41、42、43、46、

47、49、50、51digital output

OUT00~09 corresponding indicator on

Data storage Data and time set PWR blink once

16

6,Controller Protection

6.1,,Motor protection

MAM—KY02Scompressor controller provide short circuit ,block, overload, lack phase, unbalance protection to motor.

Electronic failure

Failure display Reason

Short circuit Display “Motor/FAN OVER LOAD” Short circuit or wrong current set

Current Block Display “Motor/FAN BLOCK”

Overload

Lack phase

Unbalance

Display “Motor/FAN OVERLOAD”

Display “Motor/FAN *LACK PHASE”

Display “Motor/FAN UNBALANCE”

Overload, bearing wear and other mechanica l failure

Overload, bearing wear and other mechanica l failure

Power supply, contactor and open phase of motor

Poor contact of contactor, inside open-loop of motor

6.2,Protection of Discharge Temperature High

When DISC T is above the STOP DISC T, the controller will alarm and stop the machine. THIS FAULT displays DISC T HIGH

6.3,Protection of Air Compressor anti-reversal

When compressor is at stop status and three phases sequence is not in order, THIS FAULT displays PHASE

WRONG1, and the controller cannot start the motor. Change the position of any arbitrary two phase power lines and check the rotation of motor.

6.4,Protection of Air Pressure High

When the AIR P is above the MAX LIM P, the controller will alarm and stop the machine. THIS FAULT displays HIGH P.

6.5, Protection of Sensor Fault

When pressure sensor or temperature sensor is disconnected, the controller will alarm and stop the machine.

THIS FAULT displays **SENSOR FAULT.

6.6, Protection of Air compressor Open Phase

When compressor is at stop status and open phase is detected, THIS FAULT displays PHASE WRONG2, and the controller cannot start the compressor. Check the three phase.

17

7, Troubleshooting

7.1、This Fault Review

Alarm and stop caused by the external parts of controllers may be removed by checking THIS FAULT or

FAULT RECORD, method is shown as below:

Press“” to move the cursor to “RUN PARAMETER” menu, then press“”,the secondary menu will show as below:

MOTOR FAN CURR

TOTAL RUN TIME

THIS RUN TIME

MAINTENANCE

FAULT RECORD

PROD.DATE、SERIAL

THIS FAULT

Move the cursor to “THIS FAULT” menu Then press“”to switch to the following menu（display failure）：

STOP: DISC T SENSOR

FAULT

170℃

User can reset fault according to the information prompted

7.2、Common Failures and Causes:

Failure Reason Solution

High discharge temperature

Temperature Sensor

Failure

Bad vent condition, Oil shortage etc.

Cable broken or PT100 failure

Check the vent condition and lubricant amount etc.

Check the wiring and PT100

High Pressure

Pressure Sensor Failure

Pressure too high or the pressure sensor failure

Cable broken, Sensor failure or the cables connect reversely

Check the pressure and the pressure sensor

Check the wiring and pressure transmitter

Lack water Water pressure switch failure Check water pressure switch

Open Phase

Overload

Power open phase or the contactor failure

Voltage too low, tubes block, bearing wear off or other

Check the power and contactors

Check the set data, voltage, bearings, tubes and other mechanical system.

18

Unbalance

Wrong Phase Sequence

Fan fail to run

Motor overload during start

Main Contactor shakes frequently mechanical failure or wrong set data etc.

Current unbalance, contactor failure or the internal open loop of the motor

Phase sequence reversal or open phase

Fan failure, contactor failure,no control output

Check the power, contactor and the motor

Check the wiring

Check wiring

Master start time set to less than the star delta delay time

The emergency stop button is loose or controller is reset by interference

Reset the master start time longer than star delay + 2 seconds

Check if the coil of contactor connects with

RC snubber or not

19

8, Schematic Diagram：

20