User`s manual - Duncan Rogers
Contents
1. is less than the bottom threshold value It displays Dryer t too low and the machine does not stop The unit may be stopped following an error message by changing its mode with ERR it displays ERR Dryer t low the machine stops Dryer and By Pass replacement If the dryer is replaced or has a direct connection by pass it is necessary to disable the dryer functions in the drier menu accessible through SAV code The dryer dew point temperature acquisition is then disabled as well as the ON OFF control 9 Specific variable speed motor In certain applications the motor is equipped with motor temperature control probes A high motor temperature alarm is activated in order to alert the user about motor overheating A machine fault a complete compressor shutdown is triggered when the maximum temperature threshold of the winding is reached see Operation Incidents Check the compressor operation ambient temperature and the case internal temperature Worthington Creyssensac E x 09 04 62 205 930 11 Page 13 NOTES 09 04 Worthington Creyssensac Page 14 62 205 930 11 NOTES Worthington Creyssensac E 09 04 62 205 930 11 Page 15 Export Department U K Operation France Great Britain Phone 33 0 3 44 52 67 31 Phone 01709 87 69 20 Fax 33 0 3 44 52 67 35 Fax 01709 87 62 34 Zone industrie2. 1 1 Entering menus E Bar L lt gt PSI F E E E GE Ced Reset and or returning to the basic menu Selecting menus sub menus and parameter menus Going back to the previous menu Scrolling through sub menus and parameter menus 09 04 AMAA Worthington Creyssensac Page 4 62 205 930 11 How the different menus and sub menus can be entered is shown below O S lt A A Parameters gt Software version Basic menu Error log menu Timer menu Basic settings Settings menu GIG IO Y Y Error list Timer list 3 1 2 Parameter modification a Parameter modification without password protection e Within the entered menu select the parameter to be changed by scrolling through the menu with the up and down arrow button step 1 e Push the enter button and the parameter value will start blinking step 2 e Change the blinking value with the or button step 3 e Confirm with the enter button step 4 CU le OF lt gt el OOO Step 1 Step 2 and step 4 Worthington Creyssensac Z9 09 04 62 205 930 11 Page 5 3 2 Menu structure quick reference Date amp time Ready to start Standby Starting ing Logged error Nr 9 error type date amp time Logged error Nr 10 error type date amp time Pressur
3. Aim Worthington Creyssensac User s manual EN VCI07 For variable speed compressors 62 205 930 11 ed00 Applicable as of Version 12 D CO Table of contains 1 lt GENERAL INFORMATION coectetuer e mune RANA 3 2 USER INTERFAGE une die intuitus 3 2 0 DISPLAYS tete tete mette ett tetris 3 2 2 PUSH BUTTONS aaa enne c boe ere rp d Rr eMe dri 4 A TR A 3 MENUS AND FUNCTIONS orenen a ana 4 3 1 MENU CODE ENTRY PARAMETER MODIFICATION eren nennen cnn CNN rn nennen rsen annant annann nenne 4 3 1 1 EH ME mmn 4 3 2 Parameter modificalo seriis dp ca e ubt Ee a a Rd NN ia 5 3 2 MENU STRUCTURE QUICK REFERENCE enne AKNG ENE NA AKNG ENNA renes nennen inen AKNG KNANG 6 3 3 MENUS AND CHANGEABLE FEATURES nennen nennen ernie ee ee nen rr rra nn EEEE nennen enne eren nennen 7 3 3 1 StatUS MONU E 7 33 2 Error log menu iui epe ie co a een gen seas daa e RR Fee ax innards DE POR RE 7 3 3 8 Maintenance interval menu 7 3 34 Basic settings EE 8 3 3 5 X Machine configuration iii ee nd de hl ae n a e Ea eu Dua ren Ra ge La po tie 9 3 3 6 Regulating ee i reti pee cea ea ee ER eu REOR anita eile 9 3 4 MERO POWER INTERRUPTIONS sevice 2 o Erat die qid caved cte ca Fed Ut ALAN geed 10 4 CONTRAST EE 11 CEN MAINTENANCE m 11 6 START UP AND OPTIMISING FINAL MACHINE ADJUSTMENTS eee 11 ZC MAIN OCCURRENGES eee ul ee tara 12 8 DRYE
4. R MANAGEMENT eroe auque gesti e n d e Pe deuda d aed dde eua d te dee aad oe 13 9 SPECIFIC VARIABLE SPEED MOTOR see eene nennen eren nnne nnn 13 09 04 weotthington Creyssensac Page 2 62 205 930 11 1 General information The VCIO7 controller has been developed for the control of medium to large size variable speed compressors integrating Variable Speed The VCIO7 has a metal housing and can be mounted inside or outside the electrical cabinet of the compressor Two 3 digit LCD displays and an alphanumeric display with 2 lines of 16 characters permanently show the behaviour of the compressor We devoted special attention to the development of a simple user interface 2 User interface The VCIO7 controller is equipped with three bottom view side lighted displays 8 push buttons and 4 LEDS 3 digit seven segment display 2x16 character Display 2 1 Displays The VCIO7 is equipped with 3 bottom view side lighted displays Each display is dedicated for a specific purpose The following messages can be displayed Display type Message Meaning 3 digit seven segment e g 6 8 e Current pressure is constantly being left display displayed a5 e Indicating a pressure sensor error Y e e 3 digit seven segment e g 86 Current tem
5. e unload pressure The compressor will then unload and the Pl pressure control algorithm is disabled As the pressure goes down and reaches the load level again the compressor loads again and the PI control will take over see Table 6 Chap 3 3 4 Worthington Creyssensac 09 04 62 205 930 11 Page 9 ATTENTION Do not adjust correctors P and I They undergo in factory configuration for compatibility with more than 95 of installations During the setup the installer checks the settings If in doubt contact our after sales service Parameter Function Default Min EL Min value lt reflects the minimum output level of the control algorithm at which can be cut back Below this value the compressor will be 0 0 100 put offload The minimum value is expressed in P factor This proportional control factor determines how much the control will react to differences between actual and target pressure factor This integral control factor determines the weight of the 10 0 100 integral on the control action Model Maximum frequency management model Setting dependent upon machine type see VCIO7 settings instructions Unload Fr The frequency at which the machine turns in no load operation 200Hz Max Freq Maximum frequency of variator Setting dependent upon machine type see VCIO7 setting
6. e unload level Pressure load level Pressure time programming ON OFF Pressure time settings Drain spit time sec Drain dwell time sec Dr alarm 5 C 30 C Dryer start 0 15 min Accessible only for aftersales and factory settings Timer menu Basic settings Settings menu ME Air filter blocked Current time amp date set up Date 1 time pressure 1 Date 1 time pressure 2 Date 1 time pressure 3 Date 1 time pressure 4 etc up to 32 Note Dr alarm and Dryer Start are visible if the drier option is enabled in the factory or in the SAV menu 09 04 Page 6 Worthington Creyssensac 62 205 930 11 3 3 Menus and changeable features 3 3 1 Status menu The status menu can be considered as the default menu It is shown at start up of the controller and the VCIO7 will revert to this menu after one minute when the keyboard activity stops while displaying a different menu The following messages are displayed e Machine status e g standby blowing down onload offload etc e Time and day e Errors active faults are blinking e g air Temp Oil filt P warn etc 3 3 2 Error log menu The VCIO7 saves the 10 most recent occurred faults By using the up and down arrow button all the messages can de displayed Below an example is given Display message Meaning Occurred fault number 1 is being displayed High pressure fault Occurred fault number 2 is being displayed Emer
7. end the relay lifetime 09 04 5 _ _ _ _ ______________ Worthington Creyssensac Page 10 62 205 930 11 4 Contrast The only possible adjustment is the visual angle of the alphanumeric display In the factory this angle is already adjusted to its best position When another angle is wanted it can be changed by removing the black cap at the bottom of the unit Just behind the aperture a 270 degrees potentiometer is located Use a screwdriver with a 25mm blade or less to make the adjustment Do nat forget to replace the black cap E 2 5 mm plastic cap Int 5 Maintenance The VCIO7 does not need maintenance When the front panel is dirty it can be cleaned with a soft cloth drenched in soap water or methanol 6 Start up and optimising final machine adjustments The machine undergoes in factory configuration in order to limit the need for adjustments during installation Therefore only the pressure thresholds need to be set OnLoad P desired regulation pressure in vari speed In order to conserve energy to the maximum it is advised to lower the regulation pressure to the lowest possible level so as to optimize power Offload P Delayed stop pressure of the machine For energy consumption that is less than the minimum capacity it is advised to set it at 0 5 bar above the P load In certain rare cases it may prove useful to adjust the regulation settings see chapter 7 main o
8. gency stop Air filter P warning Occurred fault number 4 is being displayed Temperature probe fault See Table 1 on page 3 Etc Table 4 After a fault has been selected and the enter button is pushed continuously the date and time is displayed when the fault occurred 3 3 3 Maintenance interval menu In the timer menu the following timers can be checked Parameter Meaning Running hours Oil separator time Remaining hours to oil separator service is being displayed Oil change time Remaining hours to oil change is being displayed Motor lubrication Table 5 Note Setting and resetting the displayed values can be done in the service setting menu Worthington Creyssensac E 09o 62 205 930 11 Page 7 3 3 4 Basic settings menu Parameter Function Default Min Max Offload P From this level the machine starts working offload for P max max value see also factory settings After a timing slow down time the compressor stops except the pressure has reached the pressure load level On Load P Pressure target in Variable Speed Regulation 6 6bar Offload P P schedule Enabling or disabling the pressure schedule Press schedule The current time can be set as well as the configuration of the pressure schedule throughout the week see 3 3 4 1 below Drain spit time Opening time of the drain to release the moisture of 2sec 1sec 20sec a Dryer start temporization of drier starting before the compressor 15min time
9. ions Check that it is higher than the minimum frequency the capacity is thus higher than the minimum capacity If this is the case reduce the integral factor I factor so as to reduce fluctuations Attention reducing it too much will slow the rise in pressure Increase the P factor Wait or reduce the dem s ch drier starting time to 0 min for machine starting The variable speed motor is overheating RLR 220V Check that the machine is not operating at an excessive ambient temperature 40 C The drier low temperature threshold has been reached Contact your After Sales Service to check that the drier 8 THE MACHINE STOPS AND DRYER FAULT IS is not frozen if the drier is not frozen it is possible to DISPLAYED maintain the drier low temperature threshold in the drier menu 09 04 Worthington Creyssensac Page 12 62 205 930 11 8 Dryer Management This controller is compatible with the integral dryer and specific variable speed motor options Dryer Management The VCIO7 may be configured in three manners to control the dryer e no message e Ale Alert default setting e ERR Stop on FAULT Bottom Message Top Message Ale Dryer t too low Dryer t too high ERR ERR Dryer t low ERR Dryer t high A start time before compressor starting can be indicated see Chap 3 2 Base settings Dryer freezing The VCIO7 indicates a dryer alert when the dryer temperature
10. lle BP Worthington Creyssensac Air 4 rue Emile Zola Compressor Products Ltd F 60114 M ru Cedex Unit 4 Silverwood Court Fairfield Park Manvers Rotherham South Yorkshire S63 SDB Q Worthington Creyssensac AiQ p Worthingt http www airwco com Crayasonane 09 04 AAA WCorthington Creyssensac Page 16 62 205 930 11
11. n DI 06 is the low pressure switch input Placing a relay in series with this pressure switch makes it possible to remotely control the no load load operation Machine Address of the controller in an RS485 network number Selection of the pressure unit Selection of the temperature unit Defines and activates instantaneous power display Language Selection of the language in which the messages are English displayed Minimum oil temperature below which the machine does 10 C not start Relay 6 It defines R 06 output as Alarm Error State Alarm and fault reporting R 06 changes state in the event of a machine alarm Machine safety or maintenance counters to 0 or in the event of a fault the machine stops due to a safety problem Fault report only Machine state Output activated if the machine is operating stand by or if the motor is running Table 7 Important note It is always possible to stop the machine locally when remote start stop function is enabled 3 3 6 Regulating settings While the compressor is running loaded a variable output signal is being generated by the PWM output This signal is based on a Pl control algorithm and can be used to drive an actuator e g a proportional valve or a frequency inverter The pressure regulation algorithm will control the actuator in order to maintain the load pressure at all time If the actuator can not sufficiently cut back the compressor will rise until it reaches th
12. necessary to produce dry air Table 6 3 3 4 1 Pressure schedule The pressure time menu is used for programming over an entire week of up to 32 different pressure settings e g REF onload P or 7 bar pressure required associated with specific times To modify the parameters in this menu also see settings pressure time Chap 3 2 000060 WA O Required pressure CU COD CQ ug Time P load bo i 06 i 30 rosar GC do e x a CD Eer DD 4 Mon i 17 5 i 30 i OFF gt O O O 0 lt CO 19 i 00 orm O Y REF Onload pressure CB Time P load 4 Mon O 09 04 5 _ _ _ _ _ ____ _________ Worthington Creyssensac Page 8 62 205 930 11 3 3 5 Machine configuration In the machine configuration menu the following application specific parameters can be set Parameter Function Default Min Max A EA or possible values Auto restart Automatic restart of the machine after a power failure in ARR ARR MAR case when the machine was running before the power failure Start ctrl Select between local ON OFF on VCIO7 box or remote LOC LOC EXT 485 ON OFF via the digital input 3 ON OFF check can also be made via the RS 485 link For example with Leadair Press ctrl Selection between no load load operation locally or via the RS 485 link with Leadair Remark The DI 06 digital input has priority over this check functio
13. perational occurrences Worthington Creyssensac E 09 04 62 205 930 11 Page 11 7 Main occurrences THE MACHINE STOPS AND STARTS AGAIN BUT ONLY FOR A SHORT TIME THE MACHINE STOPS DISPLAYING THE MESSAGE MOTOR ERROR THE OIL TEMPERATURE IS TOO HIGH THE MACHINE STOPS OR AN ALERT IS GIVEN THERE ARE LARGE FLUCTUATIONS OF PRESSURE MORE THAN 0 2 BARS FOR FLOWS IN BETWEEN THE MAXIMUM AND MINIMUM CAPACITYI THE PRESSURE DOES NOT RISE QUICKLY THE MACHINE EQUIPPED WITH A DRIER DOES NOT START THE MACHINE STOPS AND ERR T MOTEUR IS DISPLAYED Increase unloading time for 5 to 20 s so that the motor doesn t stop so often the compressor runs for longer before stopping If this delay is insufficient increase the unloading time and the minimum unloading time by the same amount for example 30s Check that there is no mechanical blockage of the motor See variator instructions the fault comes from the variator Identify the fault Ne pas r initialiser la machine sans chercher la source du probl me Lower the pressure to the min level that the client will need Decrease the dry fact setting by 2 to 1096 In the event of failure proceed more progressively by consecutive steps of 1 to 296 testing each time the rise in machine temperature In this way machine cooling is steady and total absorbed power is reduced as is the case with the capacity Read the variator frequency see variator instruct
14. perature is being constantly right display displayed Indicating a pressure sensor error Alpha numeric 2 lines 16 e g emergency stop Error indications character e g standby Status indications e g oil service Service timers Table 1 Worthington Creyssensac 09 04 62 205 930 11 Page 3 2 2 Push buttons The VCIO7 is equipped with 8 tactile push buttons In the standard software each push button has its own specific function Button Function Exit current menu back to previous Modifying confirming variable settings Green rectangular Starting the compressor locally Red rectangular Stopping the compressor locally Reset Return to the basic menu or Reset the controller whenever an alarm warning occurred Table 2 2 3 LED s The VCIO7 is equipped with 4 LEDS Each LED has its own specific function LED Meaning The pressure unit is set at BAR see Table 7 on page 9 The pressure unit is set at PSI see Table 7 on page 9 The temperature unit is set at Celsius see Table 7 on page 9 The temperature unit is set at Fahrenheit see Table 7 on page 9 Table 3 3 Menus and functions 3 1 Menu code entry parameter modification This paragraph explains how to select a menu and how to scroll through the different parameters 3
15. s instructions Min Freq Motor compressor minimum frequency set into the variable 10Hz 0Hz 200Hz speed drive This parameter is useful for displaying the instantaneous power Max Maximum power of machine Setting dependent upon Power machine type see VCIO7 EECH instructions Defined for instantaneous power calculation loss Safety Safety factor and proportional correction BUNT dependent upon fac machine type see VCIO7 EE instructions OFF l Ventilator Ka l T Vent luda NEN NENENET between shaft stop and ventilator stop tempo at which STOP the ventilator continues to turn after shaft stop This safety feature prevents the oil temperature from rising after the machine has stopped Fan sp Activates the ventilation speed variation used to control the oil OFF entr temperature TH reg Visible when Var venti Is active this parameter is the oil 80 C 70 C 100 C temperature setpoint it is the desired oil temperature Table 8 3 4 Micro power interruptions The VCIO7 is standard equipped with a micro power interruption detection of 40ms function Every zero passage of the 24VAC main is detected When 2 consecutive cycles or a power failure of 40ms is detected the controller will automatically stop the machine At the same time all relays are released and 3 horizontal dashes are displayed on the LED display By stopping the machine during a micro power interruption sparks on the relay contacts are avoided which will ext
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