USER MANUAL
Contents
1. Current Block Display MOTOR FAN BLOCK failure Overload Display MOTOR FAN OVERLOAD parmi Vean an Oren anc chanical Lack phase Display MOTOR FAN LACK PHASE ds Supply contacto lt phase ot Unbalance Display MOTOR FAN UNBALANCE Poor contact of contactor inside open loop of motor 6 2 Protection of Air Temperature High When AIR T is above the AIR STOP T the controller will send out the alarm to shut down the machine and This fault displays AIR T HIGHT 6 3 Protection of Air Compressor reversal When compressor stops and three phases sequence is not in order THIS FAULT displays PHASE REVERSAL 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 STOP P the controller will send out the alarm to shut down the machine and THIS FAULT displays AIR P HIGH 16 6 5 Protection of Sensor Failure When pressure sensor or temperature sensor is disconnected the controller will send out the alarm to shut down the machine and THIS FAULT displays SENSOR FAULT 7 Troubleshooting 7 1 This Fault Review Failure stop caused by the external parts of controllers may be removed by checking THIS FAULT or HISTORY FAULT method is shown as below Press V or move the cursor to RUN PARA menu then pre2. B Pressure converter S Screw air compressor 16 compressor controller Series 3 2 Monitor Description MAM 200 T T Communication function B Pressure transmitter 200 monitor Series 11 3 3 Power consumption Table for Corresponding Motor Parameter Corresponding Current range ae main motor Remark Description Specification power KW KY16S 20 8 20 Below 11 Ban hag thee KY16S 40 16 40 11 18 5 levels of current KY16S 100 100 22 45 such as 0 2 2 5A KY16S 200 200 55 90 1 5A and 4 10A KY16S 400 400 110 determined by KY16S 600 5 600 5 200 250 Winer 4 Installation 4 1 Mechanical Installation D Current transformer 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 the detailed dimensions is shown as below 24 5 47 5 es Pic 4 1 1 Structure dimensions CT2 dlOthrough hole Pic4 1 2 Installation dimensions of CT2 Controller installation A certain room should be left around controller for wiring The specific dimension is shown as below 168 00 158 00 Poe 50 OT o 95 00 105 00 115 00
3. RM s dM _ e e o o o y i E AC 190V 40W d 0 5 7 f e ih n 2 m TS Rau 3513433 32 3130 29 36 7 38 56 55 5444 39 40 41 42 43 45 46 47 48 49 50 51 52 53 I 1 I E z E Mie T ies BE LE A Rs 485 D 1 Hi 3 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 u 10 9 8 7 65 4 3 2 1 _ c b fa 2 3 1 if A a 2AN Som Sn EXT WOES gu Wi CTARA BECESYL xr E A NEN ii pi niy E df Pic4 2 1 Terminal arrangement diagram Monitor connection cable There are six connection cable and a communication cable which are used for display connection RS 485 communication 24V power supply For detail please refer to the silk print in monitor Controller cable terminal Communication cable is used to connect monitor and controller 1 2 3 N A 4 5 6 Terminal for fan CT2 7 9 Input terminal for AIR input T 8 9 Input terminal for front 10 12 Input terminal for AIR 11 N A rotor temperature P 13 15 Input terminal for rear 14 15 Input terminal for coil 1 15 16 Input terminal for coil rotor temperature temperature 2 temperature 17 15 Input terminal for coil 18 High voltage ready 19 Remote on 3 temperature 20 Remote off 21 Differential pressure 22 Differential pressure switch for air filter swi
4. EI 9 6 dg S E 2 8 YOLVYadES 0 z S TO 8 EI OT m a YOU LRNIGV A 5 _ 5100 RI J E D n E 5 Sc hu 8 E P gpa E ca r s l 4 TE 7 218 amp e 2 LJ UJ 1 I 1 1 1 I FU2 0 5A 8 Electronic Diagram
5. HL s 00 EET Y 73 00 SIZE 168 115 73 mm 4 1 3 Controller structure dimension 1 Indicator CIND The corresponding digital input terminal of 00 01 02 03 04 05 06 07 15 26 25 24 23 22 21 20 19 18 2 Indicator COUT The corresponding digital output terminal of 00 01 02 03 04 05 06 07 08 09 is 39 40 41 42 43 46 47 49 50 SI 3 Powerindicator PWR indicator 4 Runindicator RUN indicator 5 Error indicator ERR indicator 8 Panel function and installation MAM 200 monitor in control cabinet 239 AIR T 80C AIR P 0 80MPa STATE NORMAL STOP NEAR ET e 150 138 40 65 139 0 14222 it Pic4 1 4 Panel and hole dimension 213 4 2 Electrical Wiring Installation te i d JT FUI BL
6. Phase sequence protection When compressor is at stop mode and detects wrong phase respond time lt 2s 7 Motor protection This controller has five basic protection function for motor and fan D Block protection After start When operation current is equal to 4 8 times the set current respond time lt 0 2s short circuit protection When operation current is equal to 8 times the set current respond time lt 0 2s 8 Phase lack protection When any phase lack the respond time equals to set time 2 Unbalance protection when MAX MIN gt SET MIN 10 respond time is 5s 10 5 Protection features of overload time unit second please see following table table 2 7 1 multiple Iset motor operates with delay time according to overload multiples and operation time shown in following table table 2 7 1 when motor working current is higher or equal to the set current from 1 2 times and 3 0 times Tactual Iset 21 2 21 3 21 5 21 6 22 0 23 0 Time parameter Response time S 60 48 24 8 5 1 Table2 7 1curve table for protection of motor 8 Temperature protection when actual temperature measured is higher than temperature set response time lt 2s 9 Contact capacity of output relay 250V 5A Contact endurance 500000 times 10 Current error is less than 1 0 11 RS 485 communication 3 Model and Specification 3 1 Main Controller Model Description MAM KYI16S
7. time to avoid stopping the motor by impulse starting current Set the FAN START TIME record time when fan is FAN START 0006S activated controller will not start overload TIME protection during this time to avoid stopping the fan by impulse starting current OTHER 0001S Fixed 1 8 AEN DEL 00028 Unloading in this set time after enter delta running When unloading continuously compressor will EMPTY DEE 0020M automatically stop and enter to standby status if TIME over this set time STOP DELAY For NORMAL STOP operation compressor will TIME 00108 stop after it continuously unloading over this set time Machine can be restarted only over this set time at d DELAY 0100S any case after NORMAL STOP STANDBY or FAILURE STOP OTHER 0000S Standby m OBEN 0002S Continuously drain time in auto mode zc CLOSE 0010M Interval drain time in auto mode 1 When set as NEAR only the button on the controller can turn on and turn off the machine ON OFF MODE NEAR FAR 2 When set as REMOTE mode both the button on the controller and the remote control button can turn on and off the machine 1 When set as the MANU only when the pressure is above UNLOAD P compressor will unload automatically For any other case the Load Unload AUTO MA function can only be executed by pressing LORD MODE NU load unload key OPERATION 2 When set as AUTO the loading unloading MODE fu
8. E 17 TIS This Fault cose te Ca Se Ud uet tas ete eA 17 7 25 Common Failures and Causes si n ct Ahead oie c hin dasa Baan 18 Electronic Diagr m 19 1 Basic Operation 1 1 Button explanation Pic1 O0 san Button gt When compressor is at stop status press this button to start the compressor gt When compressor is set as main 1 in block mode press this button to start the compressor and activate block mode function at the same time 9 s Button When the compressor is at running status press this button to stop the compressor gt When compressor is set as main No 1 in block mode press this button to stop compressor and block mode as well Q us unloading Button gt When the compressor is at running status press this button to load or unload 9 Set Button gt When the compressor is at setting mode press this button after modification to confirm and save the modified data Press this button after input password to verify the password O0 down button Decreasing button gt When viewing the menu press this button to move downward the cursor gt When modifying data press this button to decrease the data at current position up button Increasing button gt when viewing the menu press this button to move upward the cursor gt When modifying data press this button to increase the data at curren
9. O A separator the data should be reset by manual operation Record air filter total run time If changing new air filter the data should be reset by manual operation Record lubricating oil total run time If changing LUB RESET 0000H new lubricating oil the data should be reset by manual operation GREASE RESET 0000H Record grease total run time If changing new grease the data should be reset by manual operation 1 Alarm prompt when total run time of oil filter is over the data set PIE 2 Set this data to 0 to invalidate the oil filter alarm function 1 Alarm prompt when total run time of O A separator is over the set data Om RH 2 Set this data to 0 to invalidate the O A separator alarm function 1 Alarm prompt when total run time of air filter is MAX LIFE TIME over the data set AI MATES 2 Set this data to 0 to invalidate the alarm function of air filter 1 Alarm prompt when total run time of lubricating LUBE 9999H oil is over the parameter set 2Set this data to 0 to invalidate the alarm of lube 1 Alarm prompt when total run time of grease is over the parameter set CREASE DH 2Set this data to 0 to invalidate the alarm of grease LANGUAGE SEL CHINESE CHINESE Chinese display when set to CN ENGLISH English display when set to EN NEW UNSER diss User could modify the user password by old user PASSWORD password or factory password 1 5 Factory Parameter The view and modification o
10. SCREW AIR COMPRESSOR CONTROLLER MAM KY16S B MONITOR MAM 200 USER MANUAL Shenzhen Plot Electronic Co Ltd Address 4th Floor 5th Building Highstar Industry Estate Gangtou Bantian Shenzhen City China Telephone 0755 83172098 83172822 Postal code 518129 Fax 0755 83172966 E mail plt pltsz com Web site www pltsz com VOTE OF THANKS Thank you for your trustworthy and select of PLOT air compressor controller KY16S Shenzhen Plot Electronic Co Ltd specializes on the manufacture and R amp 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 N NOTICE N Please read all the operation manual before operating the set and keep this manual for further reference N Installation of MAM KY compressor controller can be performed only by professional technicians N Installation position shall be considered carefully in order to ensure good ventilation and reduce el
11. ata PROD TIME ae ee Production date PROD NUM NC Product serial No Alarm and stop when the coil temperature is higher than this set data In stop mode when coil 1 temperature is lower this set data heater relay will close COIL STOP T 0160 C WARM START T 0060 C WARM STOP T 0080 C In stop mode when coil 1 temperature is higher this set data heater relay will open COM SET PARA ENABLE DISABLE Set controller parameter through DCS center 1 6 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 as following 1 6 1 CUSTOMER PASSWORD factory set Permissions Allows to modify all CUSTOMER PRAMETER 1 6 2 FACTORY PASSWORD fixed Permissions Allows users to modify all CUSTOMER PARA and FACTORY PARA 2 Controller Function and Technical Parameter 1 Digital input amp output 9 points of Digital input 10 points of digital relay output 2 Analog input 6 points of Pt100 temperature input 1 point of 4 20mA pressure signal input 11 group of three phases current inputs CT provided 3 Input voltage of phases 380V 4 Compressor working power supply 220V 50Hz 20VA 5 Measurement AIR T 20 178 C Accuracy 1 C 2 Runtime 0 999999H S Current 0 999 9A 2 Pressure 0 1 60MPa Accuracy 0 01 6
12. ce with the above 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 LOADING 00 65 The upper right corner with indicate UNLOADING P 00 85MPa the system verification of the password FAN START T 0080 C FAN STOP T 0070 C In the menu above press the first data of LOADING P starts to blink user can press t V to modify the present data in accordance with the above method Press move to next data bit and modify the target data in sequence When finished press S to confirm and save the data Other CUSTOMER PARAMETER share the similar way for modification 2 Customer Parameter Table and Function First menu Second menu Preset Data 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 is below this set data l Compressor will unload automatically if air LOADING P 0 65 MPa SET P T ressure is above this set data ENECADINGE DONIS This data should be set above LOADING P also should be set below ULD LIM P FAN START T 80 C Fan will start if AIR T is above this set data FAN STOP T 70 C Fan will stop if AIR T is below this set data Set the HOST START TIME record time when HOST START HOST is activated controller will not start overload ee TIME nee protection during this
13. ectromagnetic interference N Wiring shall be performed respectively according to regulations for heavy and weak current to reduce electromagnetic interference N 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 N 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 On off process control of motor Delay on off process control of Drier Prevention for air compressor reversal Temperature measurement control and protection Balance pressure through automatic load rate adjustment High integration high reliability high cost performance Far Near Mode Block Alone Mode RS 485communication function Im 6 Ts Content Basic peratton ce Desa aca cte Dent a thse ten A etka teil thse 4 Dede Button explanation oreet tete eee ces Sadat bade eee eae 4 1 25 Status Display and Operations tette he de el e ER dei eaa etg 5 IP ESdLue 6 1 45 Customer Parameter eee reip ret erii m i ri En Ei EE in RSEN EUER QE 6 koy Kactory Paratmetet ste dee tede entente de esee eed eene t et ete eee ud 9 1 6 Operating Authorizatio
14. f factory parameter requires a factory password The modification step is same as customer parameter modification Main function is as below PARAMETER Initial Data Function HOST RATED Maximum host overload When the current of host is more than 1 2 times and less than 4 times of the set data the unit will shut down CUR data 1 2 according to overload feature FAN RATED Maximum fan overload When the current of fan is more than 1 2 times and less than 4 times of the set data the unit will shut down CUR data 1 2 according to overload feature PRE ALARM T 105 C Alarm prompt when actual AIR T is over the set data AIR STOP T 110 C Alarm and stop when actual AIR T is over the set data STOP P 1 00Mpa Alarm and stop when actual AIR P is above this set data UNLOAD LIMP 0 80Mpa The UNLOAD P in CUSTOMER PARA must be set no higher than this set data CLR LOAD TIME 000000H Modify the LOAD TIME d TOTAL Modify the TOTAL RUN TIME CLR FAULT Input the password 8888 and press set button to RECORD oe clear all the history failure record MAX MIN gt SET MIN 10 respond time is 5s UNAS LANCE 0006 If the set data gt 15 the unbalance protection will be SCOPE V UI invalid LACK PHASE 000 58 If LACK PHASE protection 220 seconds LACK STOP PHASE protection is invalid ROTOR STOPT 0160 C Alarm and stop when the rotor temperature is higher than this set d
15. l failure or wrong set other mechanical system data etc SHORT CIRCUIT TONE Check the cable set the data set data PHASE REVERSAL OPER Check the wiring Overload and block MAIN start time set to less than Reset the main start time to be longer than star during start the STAR DELTA delay time delta delay 2 seconds Main Contactor shakes frequently The emergency button loose controller reset by interference Check the wiring if the coil of contactor connect with RC snubber or not 18 19 YAAVTdSIC IXIL EE H N vy z 8 4015 2 5 E qM e gir Er E olL a Wan uv m 5 a mt amas m er 1 510 E NOILWuadO y 2 INOW 8 5 ia E E 2 UVA 4 3 Ha ae d Uy NIGHT H S wu 8 E 4015 1 1 aL 1 1100 Z 4 4 g 4 Vd e Wo s 2 J WAT ENT z zB dia 1100 T E 28 8
16. n and Password 10 Controller Function and Technical Parameter sse ennemi 10 Model and Specification maires airar sri REEE E E ANI AA EAE EE NEEE SEAE R EAER SEATS 11 3 1 Main Controller Model Description caran a A 11 3 25 Montor Description e ded BAe betel dde i e Qe a 11 3 3 Power consumption Table for Corresponding Motor sse eene 12 Trista asst ee re T E det d tinte 12 4154 Mechanical Install tion e e e t ea eus 12 4 2 Electrical Wiring Installation secese E A nennen 14 Alarm Function 15 e MORILOE actio Irae 15 5 2 Gontrollerzmdicator totae tee eT cer ce T Neate haan eee 16 Controller Protections dem delete ee bee AE WEE 16 6 15 Motor protection hee UE e Ere pe O e ER UE Een reed 16 6 2 Protection of Air Temperature High sse eene nnne enne nnne ens 16 6 3 Protection of Air Compressor reversal eren eterne eterne eterne nnns 16 6 4 Protection of Air Pressure Highness A E a enne nennen 16 6 5 Protection of Sensor i 17 ATOUBlES ho titi at tate Saat et Bat eA N
17. n t Enter button gt and Return button L to check COIL ROTORS TOTAL RUN TIME THIS RUN TIME MAINTENANCE PARAMETER HISTORY FAULT PRODUCTION DATE THIS FAULT and return to the previous menu 1 3 Calendar Check and set time for controller DATE AND TIME 2004 2 22 W 0 12 46 59 1 4 Customer Parameter 1 Customer Parameter View and Modification Customer Parameter and factory parameter is not allowed to modify in running and stop delay status When modify customer parameter please refer to run parameter modification method The modification process of LOADING P is showing as an example below Press V or t to move the cursor to Customer Parameter press to switch to the following menu SET P T SET TIME OPERATION MODE BLOCKING MODE Then press gt to switch to the following menu LOADING P 00 65 UNLOADING P 00 80M Pa FAN START 0080 C FAN STOP T 0070 C User can check the CUSTOMER PARAMETER in this menu or press gt to switch to the following menu which requires an enter password lt 6 ENTER PASSWORD Note Customer password can be set in CUSTOMER PARAMETER and FACTORY PARAMETER is fixed as In this menu the first data bit of password started blinking press V or t to modify the first bit of password Press move the cursor to the next data bit modify the second data of password In accordan
18. nction can be executed by the fluctuation of AIR P automatically 1 When set as PROHIBIT the communication COME compr icat COM MODE COMPUTE 2 pressor can communicate R BLOCK with computer or DCS as slave according to MODBUS RTU 3 When set as BLOCK compressor can work in net Set the communication ADD in block mode or COM ADD 0001 when communicate with monitoring center This ADD is unique for every controller in net 1 When service as main in BLOCK Main controls MAIN SLA slave the COM ADD should be set as No 1 BLOCK STATE VE 2 When service as slave in BLOCK slave is controlled by main BLOCK ON OFF ORDER standby When main pressure is between BLOCK LOAD P TURN TIME 9999H and BLOCK UNLOAD P motor determine slave BLOCKING work alternatively over this set time MODE 0016 Number of air compressors in block net BLOCK LOAD P 2 00MPa In BLOCK mode one compressor will start or load when pressure is below this set data BLOCK 2 00MPa In BLOCK mode one compressor will stop or UNLOADP unload when pressure is above this set data In BLOCK mode when main sends two commands BLOCK DELAY 00005 continuously second command signal delays for this set data CLR LIFE TIME OIL RESET 0000H Record oil filter total run time If changing new oil filter the data should be reset by manual operation Record O A separator total run time If changing O A RESET 0000H new
19. re switch 2 Set oil filter max time The monitor displays OIL LIFE END when the run time of the oil filter exhausts 5 1 3 O A Alarm 1 Use switching signal to detect Alarm The monitor displays O A BLOCK by checking O A differential pressure switch 2 Set oil air max time The monitor displays O A LIFE END when the run time of the O A exhausts 5 1 4 Lubricating oil Alarm The text displays LUBE LIFE END when run time of the lubricating oil exhausts 5 1 5 Grease Alarm The text displays GREASE LIFE END when run time of the grease exhausts 15 5 2 Controller indicator Indicator Meaning and function Indicator status Power Controller power on PWR indicator on Run Controller run RUN indicator on Error Failure and stop ERR indicator blink S E RS IN00 08corresponding indicator on Indicator Digital input al uy will not be illuminated if input has no function ya Terminal 39 40 41 42 43 46 ONT Digital output 506 OUT00 09 corresponding indicator Data storage Data and time set PWR blink once 6 Controller Protection 6 1 Motor protection KYl16Scompressor 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 Overload bearing wear and other mechanical
20. ss secondary menu would be prompted out MOTORS CURRENT COIL ROTORS T TOTAL RUN TIME THIS RUN TIME Press MAINTENANCE PARAMETER HISTORY FAULT PRODUCTION DATE NUM THIS FAULT Move cursor to THIS FAULT press to switch to the following error menu STOP T SENSOR FAULT 170 C User can reset the error according to the following information 2474 7 2 Common Failures and Causes Failure Reason Solution AIR T HIGH Bad vent condition Oil shortage Check the vent condition and lubricant amount etc etc AIR T SENSOR FAULT Cable off or PT100 failure Check the wiring and PT100 AIR P HIGH HE 109 Check the pressure pressure sensor sensor failure AIR P SENSOR FAULT Check the wiring and pressure transmitter cable reversal LACK WATER Water pressure switch failure Check water pressure switch LACK PHASE Power mE Posse Ob We Check the power and contactors terminal failure Voltage too low tubes block OVERLOAD bearing wear off or other Check the set data voltage bearings tubes and mechanical failure or wrong set other mechanical system data etc Power unbalance contactor failure UNBALANCE or the internal open loop of the Check the power contactor and the motor motor Voltage too low tubes block bearing wear off other Check the set data voltage bearings tubes and BLOCK mechanica
21. t position snin button Enter button gt When modifying data press this button to move to the next data bit When select menu press this button to switch to sub menu If no submenu available the controller will shift to data setting mode e Return button Reset button When modifying data press this button to exist data setting mode gt When viewing the menu press this button to return to previous menu gt When the controller is at failure stop status long press this button to reset 1 2 Status Display and Operations The display screen will show as below after powered on WELCOME USING SCREW COMPRESSOR After 5 seconds the menu will switch as below AIR T 20 C FR T 97 AIR P 0 60MPa BRT 95 C STATE NORMAL STOP ADD 001 Press to enter into Selection Menu IRUN PARAMETER CALENDAR CUSTOMER PARAMETER FACTORY PARAMETER Check RUN PARAMETER Press 4 or t to move the cursor to RUN PARAMETER then press to switch to secondary menu MOTORS CURRENT COIL ROTORS T TOTAL RUN TIME THIS RUN TIME Press gt to switch to the below menu R S T HOST 00 0 00 0 00 0 FAN 41 41 4 1 No black cursor appears in the last menu Press l to return to the previous menu or the main menu If no operation at the current menu for a few seconds controller will automatically return to the main menu Use Move down button 4 Move up butto
22. tch for oil air separator 23 Differential pressure 24 Lack water 25 High voltage cabinet switch for oil filter error 26 Emergency stop 27 24V output 28 24V output 29 32 35 Input terminal for 30 31 N A 33 34 N A phase sequence 36 37 38 N A 39 Output signal start high 40 Output signal stop high 14 voltage cabinet voltage cabinet 41 High voltage pre heater 42 Control valve 43 Control fan on off 44 Common terminal for 45 N A 46 Operation ready output control 47 Dryer 48 N A 49 Run indicator 50 Alarm stop indicator 51 Alarm indicator 52 Common terminal for indicator 53 N A 54 Terminal for ground 55 56 220V power supply connection Note 39 terminal start high voltage cabinet When turn on it will close for 5 s and then open 40 terminal stop high voltage cabinet When turn off it will close for 5 s and then open Note Electromagnetism coil shall be connected nearest with RC snubber during wiring 5 Alarm Function 5 1 Monitor text 5 1 1 Air Filter Alarm 1 Use switching signal to detect Alarm The monitor displays AIR FILTER BLOCK by checking air filter differential pressure switch 2 Setair filter max time The monitor displays AIR LIFE END when the run time of the air filter exhausts 5 1 2 Oil Filter Alarm 1 Use switching signal to detect Alarm The monitor displays OIL FILTER BLOCK by checking oil filter differential pressu
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