CompAir AirBASIC Electronic Controller 9

9 AirBASIC Electronic Controller

9.1 Introduction 9.3.1 Display
The AirBASIC Controller is designed a) When the compressor is powered, the display
specifically for use in CompAir rotary screw air on the controller shows the “OFF” message.
compressors. These instructions will enable b) If a remote control is connected to the remote
you to operate the AirBASIC controller START/STOP input and its contact is open,
correctly and safely. that is, in a STOP condition, the display
shows the “---” message.
9.2 Safety
c) In normal operation, the controller display
Always read the safety instructions in shows the oil temperature value.
section 2 of this manual before starting work.
Note: The AirBASIC controller display can
In addition to these instructions, the local only show up to 3 digits. Numbers with 4 or 5
regulations in your country may impose digits are indicated by the illumination of LEDs
additional requirements that must be x10 or x100, which are termed "10 multiplying
observed. factor" and "100 multiplying factor"
respectively. The following examples show
how the LEDs work.
9.3 Description
1 2 Value to
Example Display LED LED
be
No. shows x10 x100
displayed

ON 3 1 697 697 OFF OFF

x10 x100
2 6970 697 ON OFF
OFF
3 69700 697 OFF ON

Reset
9.3.2 Button Functions
• ON: Switches on the compressor.
a03 A01 A03 A04 S. • OFF: Switches off the compressor.
• RESET: Resets alarms and displays hour
meter.
SM 1588 9.3.3 Indicator Functions
• x10 LED (green): indicates that the 10
Fig. 9.1 - AirBASIC Control Panel
multiplying factor is active.
1. LCD Display (3 Digits/7 Segments)
• x100 LED (green): indicates that the 100
2. LED Status Indicators (3 Green)
multiplying factor is active.
3. Control Pushbuttons (3)
• LED (green), steadily on: indicates load
The Control Panel is mounted on the operation mode.
compressor. It is used to operate the
compressor and observe system status using • LED (green), flashing: indicates unload
the LCD display, LED status indicators and operation mode.
buttons.
The Control Panel displays a comprehensive
9.4 Compressor Operation with the
overview of the compressor status and allows AirBASIC Controller
access to operational parameters such as 9.4.1 Starting The Compressor
alarm set points.
The starting procedure depends on the
current status of the compressor.
a) Starting the compressor in “OFF” status

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9 AirBASIC Electronic Controller
The “OFF” message on the controller display
indicates that the compressor is properly
powered, waiting to be started, and that the
last switch-off was caused by pressing the
“OFF” push button on the controller (local
switch-off).
To start the compressor, use local controls,
that is, press the “ON” button on the control
unit.
Note: In this condition, opening and closing
the remote contact will produce no effect
whatsoever.
b) Starting the compressor in “---” status
The “---” message on the controller display
indicates that the compressor is properly
powered, waiting to be started, and that the
remote START/STOP contact is in the OPEN
position (STOP position).
To start the compressor, use the relevant
procedure described below, depending on
how the last switchoff occurred.
- If the compressor was running (no matter
whether loaded, unloaded or in stand-by) and
was then switched off remotely, the “---”
message appears. To restart the compressor,
close the remote contact again.
- If the compressor was switched off locally,
that is, by pressing the OFF button on the
controller, and the remote contact was then
opened AFTER the switch-off, the “---”
message appears.
1. To restart the compressor, close the remote
contact.
2. Press the ON button on the controller.
This feature allows the operation of the
compressor to be disabled from a remote
position in order to prevent unauthorised
personnel from starting the compressor with
the push buttons on the controller.
Warning: If the remote control feature is to
be used with the START/STOP contact
connected to the controller, it is strongly
advisable to affix a sign by the machine
warning that the compressor may be
started at any time from a remote location.
Note: Machine start and machine restart
operations can be performed via a control
device other than the one provided, as long as
this does not pose any hazards.
c) Compressor Start-up Process
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CompAir
When the compressor is started (either locally
via the ON button or from a remote location),
the controller performs a number of checks at
the inputs to make sure that there are no
conditions likely to pose hazards to the
machine and/or the operators.
If abnormalities are found, the compressor
start-up is inhibited and an error message
appears on the controller display. If no
abnormality is found, the compressor is
allowed to start.
When start-up is initialised (and no alarms are
active), the controller checks the status of the
line pressure switch contact. If the pressure
switch contact is closed, the motor is started
according to the star/delta start-up sequence.
If the pressure switch contact is open
(pressure in the network ), the compressor
goes into stand-by mode and the motor is not
started until the network pressure drops to the
load value level.
When the load value level is reached, the
pressure switch contact closes. The relay
outputs relating to the line and star contactors
are energised for the equivalent of the star
time (parameter P06 - default 5 s). When the
star time has elapsed, the controller switches
from star to delta with a ‘safety’ delay (applied
between the release of the star contactor and
the coming into operation of the delta
contactor). This delay is equivalent to the time
value set up on the star/delta switching timer
(parameter P07 - default 20 ms). When the
switching timer has elapsed, the outputs
relating to the line and delta contactors are
energised.
In order to stabilise the motor’s rotation
speed, the load solenoid valve is energised
with a delay that is equivalent to the time
value set up on the “launch timer” parameter
(parameter P08 - default 2s). The delay is in
relation to the closure of the delta contactor.
Once the solenoid valve has been energised,
the compressor enters into load-operation
stage.
9.4.2 Controlling The Compressor Load/Unload
Operation
When the compressor is on load, the LED
on the right hand side of the display lights
steadily. When the pressure reaches the set
value of the pressure switch, the pressure
switch contact opens and the compressor
switches to unload operation for a period of
time that is equivalent to the time value set up
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on the “unload time” timer (parameter P09 -
default 3 min).
During the unload phase, the LED flashes
to indicate that the compressor is running in
unload mode. When the timer has elapsed,
the motor is stopped. As soon as the pressure
drops to the load value that is set up on the
pressure switch, the motor is restarted
automatically via a star/delta sequence. When
the motor is stopped, the LED is turned off
and if no alarms are active, the value of the oil
temperature appears on the display.
If the pressure drops to the load value level
before the unload timer has elapsed, the
compressor immediately switches back to
load mode without any stopping of the motor.
When the “Unload time” timer elapses, the
motor stops. The oil temperature remains
steady on the display to indicate that the
machine is not OFF but is still in stand-by
condition.
Warning: Be very careful, as in this
condition, the compressor will restart
without prior notice as soon as the
pressure drops to the load value level.
pressure
UNLOAD UNLOAD
LOAD
START
UNLOAD TIME
SM 1575
Fig. 9.2 - Example Of The Operating Cycle
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AirBASIC Electronic Controller 9
9.4.3 Switching Off The Compressor
The compressor can be switched off locally or
remotely (if a remote contact is connected to
the appropriate terminals). In both cases,
when the machine is commanded OFF, the
controller de-energises all the relay outputs
controlling the contactors as well as the
solenoid valve, thereby causing the
compressor to stop immediately.
The control unit activates a safety (“blowdown
time”) timer (parameter P10 - default 20 s) to
prevent the compressor from restarting with
pressure in the inner tank when the OFF
button is pressed (or when the remote
start/stop contact is opened). Compressor
restart is inhibited throughout the count down
of the blowdown time. Pressing the ON button
or closing back the remote start/stop contact
during blow-down produces no effect
whatsoever.
The blow-down stage is indicated by the
flashing of LED x10. When the count down of
the “blow-down time” is over, LED x10 is
turned off. At that point, you can restart the
compressor.
See fig. 9.2 for an example of the operating
cycle.
Motor running
Network pressure
STOP
Unload pressure
Load pressure
LOAD
Motor running
Motor OFF
time
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9 AirBASIC Electronic Controller
9.5 Timers
The AirBASIC Controller has two kinds of
control information: timers and parameters.
There are two kinds of timers: maintenance
timers (for viewing and resetting) and
operation timers (for viewing only).
9.5.1 Viewing maintenance timers
Maintenance timers count the time until the
next maintenance operation on the following
items (maintenance code number and
meaning):
• S01 = oil change
• S02 = air filter replacement
• S03 = oil filter replacement
• S04 = separator filter replacement
• S06 = general maintenance.
The maintenance timers can be viewed when
the compressor is ON. When the compressor
is ON, the display will normally show the oil
temperature value, unless an alarm is ON.
a) To view the first maintenance code, S01 (oil
change), press and release the RESET
button. The value for remaining hours will be
displayed automatically after about 1 second.
b) To view the second maintenance code, S02
(air filter replacement), press and release the
RESET button again. The value for remaining
hours will be displayed automatically after
about 1 second.
c) To view the rest of the maintenance codes,
press and release the RESET button again.
d) To return to the oil temperature display, scroll
through the remaining maintenance codes
(S03, S04, S06).
Notes:
(i) Maintenance timer counting (parameters
P12 - P 16) is based on motor running hours.
It works like a countdown; when the
countdown is at 0, it will continue with the
negative sign, and the first display will show
the “-” symbol.
(ii) Maintenance hours are stored to the
memory every 15 minutes; if a power failure
occurs during compressor operation, the
entire 15 minute fraction will be lost.
9.5.2 Resetting maintenance timers
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CompAir
Note: When a maintenance pre-alarm
message is manually reset, it will no longer
appear as long as the compressor is ON.
Maintenance timers can only be reset when
the compressor is OFF. When the compressor
is OFF, the display shows an “OFF” or “---”
message, depending on the conditions
described in section 11.7.1 a) - "Display".
a) To view the first maintenance code (S01),
press and hold RESET button for about 3
seconds.
b) To reset the first maintenance code, press
and hold the RESET button for about 3
seconds. The value is replaced by the default
value and the second maintenance code will
be displayed.
c) If you do not wish to reset the first hour meter,
but want to switch immediately to the second
one instead, press and release the RESET
button. The second maintenance code
appears on the display, and its timer value will
be visible after 1 second. To reset the value,
press and hold the RESET button for about 3
seconds.
d) Scroll through all maintenance timers as
described above, resetting their values if
necessary, until the “OFF” or “---” message is
displayed again.
9.5.3 Viewing operating timers
Operating timers count the total operating
hours (h-t) and total hours on load (h-L) of the
compressor. The operating timers are
available for viewing when the compressor is
ON.
a) To view the “h-t” message, press and hold the
RESET button for 3 seconds. Total operating
hours will be displayed.
b) To view the “h-L” message, press and release
the RESET button again. Total hours on load
will be displayed.
Notes:
(i) The counting of hours on load is based on
the length of time for which the relay
supplying the load/unload solenoid valve is
closed; the counting of total operating hours is
based on the length of time for which the line
contactor supplying the motor is closed.
(ii) Operating time is stored to the memory
every 15 minutes; if a power failure occurs
during compressor operation, the entire 15
minute fraction will be lost.
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CompAir AirBASIC Electronic Controller 9

9.6 Parameters e) To edit the value of another parameter, scroll

The parameters allow the user to change the
operating parameters of the compressor, such
as the maintenance pre-alarm hours or
maximum restarts per hour. The default
values for the adjustable parameters are listed
in the table on the next page.
The parameters can only be adjusted when
the compressor is stopped.
a) To enter the parameter programming mode,
simultaneously press and hold the OFF and
RESET buttons for 3 seconds. After 3
seconds, the code of the first parameter, P01,
will appear on the display.
b) To scroll up or down the parameter list, press
ON or OFF buttons respectively.
c) To view the current value of a parameter,
press the RESET button.
d) To edit the displayed value, press ON
(increase) or OFF (decrease) buttons. Once
the desired value has been entered, press
RESET button to store the value and to return
to the parameter list.
up or down the list until the ID Code of the
desired parameter is displayed, and repeat
step d).
f) To exit the programming mode after adjusting
all the desired parameters, press and hold the
RESET button for about 3 seconds. At this
stage, the OFF or “---” message appears on
the display and all the changes made to the
parameters are activated.
Notes:
(i) If no button is pressed for 60 seconds
during the programming procedure, the
controller will automatically exit the
programming mode, switch back to OFF and
store all the changes.
(ii) If the upper or lower threshold of a
parameter is reached when editing a
parameter, the value that appears on the
display will flash to warn that the min. or max.
value for that parameter has been reached.
The following table (fig. 9.3) contains all the
available parameters with their respective
codes, descriptions, units of measurement,
possible values and default values.

Param.code Description Unit Range Default

P01 MAX probe temperature range °C 130 - (P02+2) 130
P02 High oil temperature alarm threshold °C (P01-2) - (P03+2) 110
P03 High oil temperature pre-alarm threshold °C (P02-2) - (P04+2) 105
P04 Low oil temperature alarm threshold °C (P03-2) - -10 -10
P05 Oil temperature probe calibration °C -10 - +10 0
P06 Star time s 2 - 10 5
P07 Star-delta switch timer ms 10 - 50 20
P08 Launch timer s 1-5 2
P09 Unload time min 0 - 10 0
P10 Blow-down time s 1 - 60 20
P11 Max restarts per hour / 1 - 60 60
P12 Air filter maintenance pre-alarm hours h 100 - 3000 1500
P13 Oil filter maintenance pre-alarm hours h 100 - 9900 1500
P14 Separator filter maintenance pre-alarm hours h 100 - 9900 1500
P15 Oil maintenance pre-alarm hours h 100 - 9900 1500
P16 General maintenance pre-alarm hours h 100 - 1000 500
P17 Automatic restart status / 0-1 0
P18 Alarm relay function / 0-2 0

Fig. 9.3 - Table of Parameters

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9.6.1 Parameter descriptions
P01 - MAX probe temperature range
– Provides the highest value for oil
temperature reading.
– No adjustment is necessary.
P02 - High oil temperature alarm threshold
– Defines the high oil temperature alarm
value. As soon as this value is reached, a
dedicated alarm message (A01) appears on
the display.
P03 - High oil temperature pre-alarm
threshold
– Defines the high oil temperature pre-alarm
value. As soon as this value is reached, the
compressor stops and a dedicated alarm
message (a03) appears on the display, but
the normal operation of the compressor is
not interrupted.
P04 - Low oil temperature alarm threshold
– Defines the low oil temperature alarm value.
Under this value, compressor start-up is
inhibited and a dedicated alarm message
(A34) appears on the display.
P05 - Oil temperature probe calibration
– Compensates for possible reading errors
(either by excess or by defect) of the
temperatureprobe due to a defective probe.
– In normal conditions, this parameter needs
no adjustment.
P06 - Star time
– Defines how long the system should run in
star configuration during motor start-up.
– In normal conditions, this parameters needs
no adjustment.
P07 - Star-delta switch timer
– Defines the delay between the release of
the star contactor and the coming into
operation of the delta contactor, during the
switching stage.
– In normal conditions, this parameter needs
no adjustment.
P08 - Launch timer
– Defines the delay between the coming into
operation of the delta contactor and the
energisingof the load/unload solenoid valve;
such delay stabilises as much as possible
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CompAir
the motor’s rotation speed subsequent to
the star-delta switching.
– In normal conditions, this parameter needs
no adjustment.
P09 - Unload time
– Defines the duration of the unload operation
interval, at the end of which the controller
will power off the motor.
– Unload operation is identified by a flashing
LED.
P10 - Blow-down time
– Defines the duration of the blow-down
interval after the compressor has been
powered off. Its purpose is to prevent any
restarts of the compressor while pressure is
still in the tank.
– The blow-down condition is identified by a
flashing x10 LED. In this condition, motor
start-up is inhibited for the set time interval.
P11 - Max restarts/hour
– Defines the maximum number of permitted
start-ups per hour. Its purpose is to protect
the motor from damage. When the set
number of restarts is reached, the motor will
not stop for the rest of the following hour
and the compressor will work without
interruption, switching from load to unload
and vice versa.
– This condition is identified by the
simultaneous flashing of LEDs x10, x100
and .
– At the end of the hour period, the counter is
reset and the motor will be able to stop at
the end of the unload phase.
P12 - Air filter maintenance pre-alarm
hours
– Defines the air filter change countdown
timer value.
– When the set timer has elapsed, the
controller will warn the operator that
maintenance is needed by showing a
dedicated warning message (S02) on the
display.
P13 - Oil filter maintenance pre-alarm
hours
– Defines the oil filter change countdown
timer value.
– When the set timer has elapsed, the
controller will warn the operator that
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CompAir AirBASIC Electronic Controller 9

maintenance is needed by showing a restart automatically after a delay that is

dedicated warning message (S03) on the equivalent to blow down time delay.
display.
P18 - Alarm relay function
P14 - Separator filter maintenance
– Defines which function is to be assigned to
pre-alarm hours
the alarm remoting relay contact, in
– Defines the separator filter change accordance with the following arrangement:
countdown timer value.
P18=0
– When the set timer has elapsed, the Relay is energised in any alarm condition and
controller will warn the operator that in any pre-alarm condition.
maintenance is needed by showing a
P18=1
dedicated warning message (S04) on the
Relay is energised only in alarm conditions
display.
that will stop the compressor.
P15 - Oil maintenance pre-alarm hours
P18=2
– Defines the oil change countdown timer Relay is energised only when one of the
value. maintenance timers has elapsed.
– When the set timer has elapsed, the
controller will warn the operator that
maintenance is needed by showing a
dedicated warning message (S01) on the
display.
P16 - Overall maintenance pre-alarm hours
– Defines the general maintenance
countdown timer value.
– When the set timer has elapsed, the
controller will warn the operator that
maintenance is needed by showing a
dedicated warning message (S06) on the
display.
P17 - Automatic restart status
Warning: If the automatic restart feature is
to be used, it is strongly adviced to affix a
warning sign by the machine to alert
bystanders that the compressor may come
back into operation automatically and
without prior notice. It is also mandatory to
check that the automatic re-start of the
compressor will not pose any hazards
whatsoever.
– Enables or disables the automatic restart of
the compressor as soon as current is back
after a power failure.
P17=0 automatic restart is disabled.
When current is back after a power failure has
halted the compressor, the compressor will
NOT restart automatically and the controller
will display a dedicated alarm message (A33).
P17=1 automatic restart is enabled.
When current is back after a power failure has
halted the compressor, the compressor will

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9.7 Error Management 9.7.2 Shutdown Faults

9.7.1 Advisory Alarms The shutdown faults in the controller are

designed to protect the compressor from
The advisory alarms alert the user that component failure or extreme environmental
maintenance is needed, or that certain conditions. These alarms will stop the
parameters may be approaching their compressor and/or inhibit its start-up. To reset
shutdown level. Advisory alarms can be reset an alarm message, eliminate the cause of the
while the compressor is running or stopped by concern and press RESET.
pressing the RESET button. If the error
condition still exists after resetting the See the following table for shutdown faults
advisory alarm, the advisory alarm will occur that can occur in the AirBASIC Controller
again after the compressor is powered ON
Shutdown Faults
again after it has been powered OFF.
Code Meaning
See the following tables for advisory alarms
that can occur in the controller. A01 high oil temperature
A03 motor thermal overload relay trip
Pre-Alarms
A04 phase inversion/phase loss
Code Meaning
A07 temperature probe is faulty
a03 High oil temperature pre-alarm (message
alternates with temperature display). set data loss and acquisition of default
A26
data
Alarm automatically resets when
temperature drops below the set value power failure (only applicable if automatic
A33
of -2 °C. restart is disabled)
A34 low oil temperature
Maintenance Alarms
Code Meaning
S01 Oil change
S02 Air filter replacement
S03 Oil filter replacement
S04 Separator filter replacement
S06 General maintenance

Note: It is recommended that maintenance be

performed as soon as possible after a
maintenance message appears.

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9.8 Transducer Locations

9.8.1 See fig. 9.4
 



 

  

  
  
   



  
      
Fig. 9.4 - Wiring Diagram

9.8.2 Key to codes in fig. 9.4

Input
Pin Function Status
connector
M1 power supply connector 24 Vac
M2 digital input connector, type: 5 poles Combicon 5 mm
C3 1 Common digital inputs
l1 2 Line pressure switch Closed=loaded Open=unloaded
l2 3 Motor thermal relay Alarm if open
l3 4 Phase-sequence relay Alarm if open
l4 5 Remote Start/Stop Closed=start Open=stop
M3 alarm relay connector, type: 2 poles Combicon 5 mm
C2 1 Common relay
R 2 Auxiliary alarm relay Energised=closed De-energised=open
M4 output relay connector, type: 5 poles Combicon 5 mm
C1 1 Common relay
K1 2 Line contactor Energised=closed De-energised=open
K2 3 Star contactor Energised=closed De-energised=open
K3 4 Delta contactor Energised=closed De-energised=open
EV 5 Solenoid valve Energised=closed De-energised=open
M5 temperature probe connector, type: screw terminals welded on the I.C.
1 Temperature probe
2 Temperature probe

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