8/18/2019 worthington Instruction Book PCI07 En

Instructions manual EN 

Electronic module

PCI07
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CONTENTS

Chapter 1 - General description 2

Display language selection  2
1.1 - General 2
1) General description 2
2) Emergency stop, time-delayed stop 2
3) Analog sensors 2
4) Battery replacement 2

1.2 - Functions 2
1) Control 2
2) Data 2
3) Regulation 2
4) Control of condensate drain-off 2
5) Signalling of maintenance operations 2
6) Management of operating defects 2
7) Programmin compressor startup and stopping 2
1.3 - PCI front panel 3
1) LED indicators 3
2) Keys 3
3) Display 3
1.4 - PCI rear panel 4
1) Description of inputs/outputs 4
Schematics of PCI front and rear panels 5
1.5 - Definitions 6

Chapter 2 - Menus 7
2.1 - Initialisation Menu 7
2.2 - Programming Menu 8
2.3 - Machine status information menu 9
2.4 - Machine configuration information menu 10

Chapter 3 - Description of messages 11

3.1 - Setting of machine operating parameters 11
- Language selection 11
- Setting of maintenance cycles 11
- Setting startup and drain 11
- Setting the clock 11
- Setting the regulation pressure 12
- Setting regulation mode 12
- Selection and setting of timers 12
3.2 - Compressor data 13
3.3 - Warnings 15
3.4 - Maintenance 16
3.5 - Faults 16

Chapter 4 - Options 18
4.1 - Serial cable 18
4.2 - Serial interface 18

Chapter 5 - Temperature protection test 19

Chapitre 6 - Factory settings 20 

Chapitre 7 - Alphabetic list of messages 21

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Chapter 1 - General description

Selecting the language: • On ( )

• Open the menu by pressing on F1 (pushbutton • Stop (O)
at the rear of the PCI) • Stopped under pressure (F2)
• Select the required language using key F3 • Reset (F3)
• Exit the menu using key F1 • Scrolling (F4)
 A connector situated behind PCI07 can be used for compressor
remote control (option).
1.1 - General
2) Data
1) General description
The PCI07 display and the Leds provide:
The PCI07 is a micro-processor-equipped electronic module • display of the operating status of the compressor at a
used to start and stop the ROLLAIR ® , to manage ROLLAIR ®   given instant,
faults and alarms, generate information on the operating status, • display of maintenance messages (alarms, defects, etc.)
and control condensate drain-off and remote transmissions and • display of compressor control parameters.
remote control.
3) Regulation
The PCI07 executes the following functions in particular :
• Management of 2 analog inputs: a temperature probe and
a pressure sensor The PCI07 executes compressor regulation. These functions
include:
• Programming of compressor start-up and shutdown
• Control, fault reporting and remote display of compressor • control
measured of by
no-load operationanalog
the pressure as soon as the
sensor pressure
reaches the
operating status (option) regulation pressure
•  Automation of alternating operation between several • control of load operation as soon as the pressure
compressors (option) measured by the analog pressure sensor reaches the
• Timed On/Off management of a dryer (according to minimum regulation pressure (regulation pressure –
parameters) regulation deviation)
• ordering of motor shutdown after the period of no-load
2) Emergency stop, time-delayed stop operation
• inhibiting of motor restart if the pressure in the oil tank is
WARNING: above 1.5 bars (RLR 75 at 220 or automatic restart
 All compressors fitted with an electronic management board option).
PCI07 must be provided with an emergency knock off push
button which stops the compressor and the dryer.
4) Control of condensate drain-off
WARNING: The frequency and the duration of drain solenoid valve
The compressor shutdown time can be delayed by pressing
the PCI07 O key, although there is a minimum of 30 seconds no- opening
machine can
and be
theprogrammed in order totoadapt
volume of condensate to the size of the
be evacuated.
load operation prior to full machine shutdown. The shutdown
phase is indicated by the "STOPPING" and the green LED
associated with the key. 5) Signalling of maintenance operations
 As soon as a maintenance operation is required, either
3) Analog sensors because the machine has reached a number of hours requiring
work, or because a sensor has detected that a threshold has
The PCI07 manages 2 analogue measurement channels to been reached, a yellow light flashes and a message indicating
measure the service pressure (machine outlet) and the oil the operation to be executed is displayed. The machine does not
temperature (compression unit outlet). stop.

4) Battery replacement 6) Management of operating defects

The battery is used to keep date and time when the power
supply is off. Its working life depends upon the length of time the
machine is off.
We recommend replacing the battery every 4 years.
However, should the date and time disappear, change the
battery as follows (no other parameter is lost):
• Turn the power off
• Open the flap at the rear of the PCI07
• Replace the old battery with a new one ref. CR2032
• Close the flap
• Reset the date and time
1.2 - Functions
1) Control
5 keys on the front face of the PCI07 can be used by the
operator to control and monitor the compressor:
 As soon as a fault signal appears, the PCI07 stops the
compressor, signals the fault through the red light of the reset
key and displays a message allowing the cause of the incident to
be quickly located.
The 8 last faults occurring on the compressor are kept in the
memory and can be displayed by a technician holding the
electronic key (See 2.3).
7) Programming compressor startup and stopping
 After programming the timers, the real-time clock on the
PCI07 allows automatic starting and stopping of the compressor.
The clock which operates when the compressor is
deenergized is supplied by a lithium battery with 8 years' service
life. The maximum battery service life is 8 years with the
compressor energized.

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1.4 - PCI rear panel (Fig.2)

1) Description of inputs/outputs
• 8-pole withdrawable connector for the option or the
5 connectors on the rear of the PCI can be used to connect connection of the electronic key (X6).
the inputs/outputs and the PCI power supply.
• 10-pole withdrawable connector for the 5 control outputs (dry
• 7-pole withdrawable connector for the 6 on/off inputs (X3): contacts) (X2):
Controlled load: 250V, 6A nominal – Cos ϕ=1
11. Common
Common from all on/off sensors.
12. KM2 1 and 2. KM3
Star contactor Delta contactor
Controls the star phase on main motor startup. Controls the delta contactor.
13. PSH1 3 and 4. KM2
High pressure switch Star contactor
Provides high pressure protection. Controls the star contactor.
14. DPSH1 5 and 6. KM1
Clogging Line contactor
Detected by deoiler filter head losses. Control of the line contactor.
15. F1/Q1/F11 7 and 8. SOV2
Internal combustion engine, dryer or fan fault Regulation solenoid valve
Engine protection systems, main, dryer or fan. Controls the regulation solenoid and the
16. FS1 vacuuming valve.
Water circulation 9 and 10. Dryer
SOV1or condensate bleed solenoid valve.
Indicates the presence of water in cooling circuit.
17. PSL1 Dryer operation or bleed control.
Pressure above 1.5 bar
Low pressure protection (restart).
• 3-pole withdrawable connector to supply 12Vac (X4) (18, 19
and PE).
• 5-pole withdrawable connector for 2 analog inputs (X5): • Required power: 6VA / 12Vac

20 and 21. TS
Temperature probe
 Analog sensor for measuring the temperature at In addition to these 5 connectors, a double Faston lug  on
element output. rear plate of the PCI allows connection of the PE conductor
22 to 24. PT and cable screening.
Pressure sensor Push button F1  in the middle of the rear panel of the PCI
 Analog sensor for measuring the pressure at the allows access to the initializing menu.
machine output (user).

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Fig.1 : Front panel of the PCI07

Fig.2 : Rear panel of the PCI07

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1.5 - Definitions
•  Alarm
 An alarm informs the user that a maintenance operation
is necessary either because the machine has reached a
certain number of hours' operation, or because a sensor has
detected a threshold.
 An alarm does not lead to compressor shutdown. It is
indicated visually by the yellow alarm indicator light LED
flashing
nature ofand by a or
the alarm message informing
the operation to bethe operator of the
executed.
• Fault
 A fault leads to compressor shutdown and is linked to a
machine malfunction. It is signalled by the red LED
associated with the F3 reset key and by a message
informing the operator of the nature of the defect (e.g.:
overpressure, temperature fault, etc.).
•  Analog sensor
 An analog sensor is a sensor which has a continuous
measuring range.
The PCI07 manages two analogue inputs: one for the
pressure sensor (0 to 17 bar), and one for the oil
temperature probe (-20 to +151°C).
• Timer
 A timer is used to program automatic startup and
shutdown of the compressor. Starting and stopping can be
programmed for one day of the week, work days (Monday to
Friday), week-end or every day of the week.
8 timers can be programmed.
Examples:
• Timer 1 active for Monday, Start timer 1 = 8 a.m. and
stop timer 1 = 4 p.m.   the compressor will operate on
Mondays from 8 a.m. until 4 p.m..
• Timer 5 active for Thursday, Start timer 1 = 6.30 a.m.
and stop timer 1 = 8.15 p.m.   the compressor will
operate on Thursdays from 6.30 a.m. until 8.15 p.m..
When a compressor is pending restart by a timer, the
message « WARNING AUTO RESTART BY TIMER » moves
through the display.
If the compressor is pending restart by a timer, the
compressor can be forced to start manually by dual pressing
on the start key ( I ). This forced operation will not alter the
timer settings.
Examples :
In the examples above, if the key is double pressed
before Monday 8.00 a.m. or Thursday 6.30 a.m., the
compressor will start and stop automatically on Monday at 4
p. m. or on Thursday at 8.15 p.m..
• Regulation pressure / differential pressure
The regulation pressure is the use pressure from which
the compressor will begin operating in a no-load
configuration.
The differential pressure defines the no-load operating
range of the compressor. Load operation restarts when the
machine outlet pressure has fallen from the regulation
deviation relative to the regulation pressure.
• Stand-by pressure and differential stand-by
Regulation pressure and differential pressure of the
stand-by compressor when 2 compressors operate simultany
(OPTION ).
• Onload operation 
The compressor is generating at full load (inlet valve
100% open) or at part load (inlet valve partly open).
• Offload operation
The compressor operates at nil flow and with the oil tank
empty.
 
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• Remote control
Possibility of starting and stopping the compressor
remotely.
In all cases, local mode shutdown has priority. If the
compressor is stopped remotely, it will be possible to restart
it remotely and the ‘stopping’ message will be displayed.
If the compressor has been stopped locally, its remote
restart will be impossible.
The remote start/stop mode has priority
over timer operation:
- When a compressor is stopped remotely, the
« WARNING: REMOTE RESTART » message moves
through the display.
- If a compressor is started remotely when outside the
operating times programmed on the active timers, the
« WARNING AUTO RESTART BY TIMER » message
moves through the display.
• Remote control option
This option allows the compressor to be started or
stopped remotely and a general fault reported (light, siren,
etc.).
- Operation as main compressor and back-up for 2
compressors (serial cable).
- To control and display the status of a remote
compressor (serial interface).
• Serial port option
Using an interface, this option allows alternating
operation of 2 compressors or all the operating parameters
from the compressor to be displayed on the PC.
•  Automatic restart
This option enables automatic restart of the compressor
after a power outage.
• Max. number of starts authorized per hour
This function is for defining the minimum operating time
of the motor between its last startup and automatic shutdown
as a result of prolonged no-load operation.
If, on a prolonged no-load operation, the motor no-load
operating time is exceeded, compressor shutdown will only
be authorized if the number of maximum restarts per hour is
complied with.
Example:
- The maximum number of restarts authorized per hour is
set at 3,
- the motor operating time is 10 minutes.
In these conditions, the motor must be capable of
operating for 20 minutes minimum before its shutdown is
authorized (60/3). If, 5 minutes after restarting the motor, the
compressor transfers
will take place to no-load
5 minutes after theoperation,
end of themotor
motorshutdown
time lag
in order to reach the 20 minutes minimum operating time
(5+10+5 minutes).
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Chapter 2 - Menus

2.1 - Initialisation menu 

For selecting the display language, maintenance cycles, startups, condensate drain and real-time clock.
Menu access condition: machine shutdown
 Access to menu: press on F1 (PCI rear panel)
Exit the menu: press on F1 (PCI rear panel)
Modify selection: press on F3
Validate selection: press on F2

LANGUAGE
FRANÇAIS
ENGLISH
ESPANOL
ITALIANO Language
DEUTSCH
PORTUGUESA
NEDERLANDS
 AIR FILTER
OIL FILTER
SEPARATOR Maintenance cycles
OIL CHANGE
BEARINGS

OFFLOAD MINIMUM
TIME
UNIT NUMBER
CONDENSATE DRAIN
FREQ.
CONDENSATE DRAIN Startups and drains
DURATION
MOTOR STARTUPS
STAR TIME
MOTOR STARTUPS
No/HOUR

DRYER
DURATION
CLOCK
YEAR
CLOCK
MONTH
CLOCK
DAY Real-time clock

CLOCK
HOUR
CLOCK
MINUTES

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2.2 - Programming menu

For setting the regulation and the timers

Menu access condition: machine stopped
Menu access: press on F4 for more than 3 seconds
Exit the menu: press on F4
Modify the selection: press on F3
Validate the selection: press on F2

REGULATION
PRESSURE
DIFFERENTIAL
PRESSURE

INTERNAL REGULATION
Régulation
EXTERNAL REGULATION

STAND-BY
PRESSURE
DIFFERENTIAL
STAND-BY
OPERATION
WITH TIMERS
WITHOUT TIMER
TIMER 1
 ACTIF
ON
TIMER 1
OFF

TIMER 1 ON TIME Timers

HOUR
TIMER 1 ON TIME
MINUTES
TIMER 1 OFF TIME
HOUR
TIMER 1 OFF TIME
MINUTES

The back-up pressure and the back-up deviation are only adjusted for the 2-compressor mode, compressor A (option).

TIMER PROGRAMMING
8 timers are available. The choice of the active timers and their adjustment is only possible when operating 'with timers'.

Timer operating days:

Monday, Tuesday, … : weekdays
Weekend : Saturday and Sunday
Week: Monday to Friday
 All: everyday of the week (7 days out of 7)
Timer stop time:
--- : no stopping of the compressor by the timer.

TEMPERATURE SAFETY TEST (See Chapter 5) 

Pressing simultaneously on O  and when in the programming menu will set up the safety temperature test configuration. The message
'TEMPERATURE SYSTEM TEST' is displayed and the menu automatically exited. The test can be started by compressor startup (key ).

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2.3 - Machine status information menu 

For displaying hours' operation, maintenance cycles, date and hour

Menu access condition: compressor stopped, load or no-load configuration

 Access to the menu: press on F4
Scrolling: press on F4
Exit the menu: press on F3 (compressor operating) or key O (compressor stopped)

TOTAL HOURS

ONLOAD HOURS
Hours operation
LOAD
RATIO

 AIR FILTER

OIL FILTER

SEPARATOR Maintenance

OIL CHANGE

BEARINGS

Tuesday 01/01/98
Date and time
12 : 00

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2.5 - Machine configuration information menu

For displaying the startup mode, the pressure and temperature protection limits and the option.

Condition of access to menu: machine stopped

 Access to menu: press once on F3
Scrolling: press on F3
Exit the menu: press once on the O key

MANUAL
 AUTOMATIC
RESTART
Machine configuration
 AIR
WATER
COOLING
MAXIMUM
PRESSURE
TEMPERATURE
P and T protections
MAX
TEMPERATURE
MIN
OPTION
SERIAL PORT OFF
SERIAL PORT ON

SERIAL INTERFACE
SERIAL CABLE

COMPRESSOR A
DAILY
WEEKLY
Option
COMPRESSOR
B
DRYER
ON
OFF
DRAIN DURING SHUTDOWN
NO
YES

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Chapter 3 - Description of messages

3.1 - Setting of machine operating parameters

** LANGUAGE selection **
(Initializing menu)

LANGUAGE Select the language for displaying the information on the PCI (Eight language options).

** Setting the MAINTENANCE CYCLES **  

(Initializing menu)

AIR FILTER Input the air filter life (hours).

OIL FILTER Input the oil filter life (hours).

SEPARATOR Input the separator filter life (hours).

OIL CHANGE Input the oil life (hours).

BEARINGS Input the service life of the main motor bearings (hours). 100 to 9900h / 100h.
--- : counter inhibited

** Setting STARTUP and DRAIN **  

(Initializing menu)

OFFLOAD MINIMUM Input the compressor no-load operating time before motor stops (minutes).
TIME
UNIT NUMBER Input the machine number.
CONDENSATE DRAIN Input the frequency of condensate drain valve opening (minutes).
FREQ.
CONDENSATE DRAIN Input condensate drain valve opening time (seconds).
DURATION
MOTOR STARTUPS Input star startup phase time lag (seconds).
STAR TIME
MOTOR STARTUPS Input maximum number of motor starts/hour.
No/HOUR

** Setting the CLOCK **  

(Initializing menu)

CLOCK YEAR Input the year to set the clock real time.

CLOCK MONTH  Input the month to set the clock real time.

CLOCK DAY  Input the day to set the clock real time.

CLOCK HOUR  Input the hour to set the clock real time.

CLOCK MINUTES  Input the minutes to set the clock real time.
Once the date and time have been set, the clock only starts after quitting the setting menu using key F1 on the rear of the PCI.

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** Setting the REGULATION pressure **  

(Programming menu)

REGULATION Input the regulation pressure leading to compressor no-load operation (bars).
PRESSURE
DIFFERENTIAL Input the deviation between the regulation pressure and the pressurizing pressure corresponding to
PRESSURE the no-load operation range (bars).
OPTION

STAND-BY
PRESSURE When two compressors are operating alternately, inputting the regulation pressure leads to no-load
operation of the back-up compressor (bars).
OPTION
DIFFERENTIAL When two compressors are working alternately, input the deviation between the regulation pressure
STAND-BY and the pressurizing pressure for the backup compressor corresponding to the no-load operation
range (bars).

** Setting the REGULATION mode **  

(Programming menu)

OPTION
INTERNAL Operation with a serial interface. The regulation instructions set on PCI07 and the analog pressure
REGULATION sensor are used for load and no-load operation of the compressor. Regulation is dependent on the
internal compressor settings.
OPTION
EXTERNAL Operation with a serial interface. The load and no-load start orders are external to the compressor
REGULATION (load/no-load start inputs from the serial interface). The compressor internal pressure sensors remain
active for the protection functions.

** Selection and setting of TIMERS **  

(Programming menu)

OPERATION Compressor operation through timers (8 timers can be programmed to stop and start the machine
WITH TIMERS automatically).
OPERATION Compressor operation without timers.
WITHOUT TIMERS
TIMER X Timer x  is activated, and will be programmed.
ON
TIMER X Timer x  is deactivated.
OFF
Input the days of the week for compressor startup by timer x :
• Monday, Tuesday, …..: weekdays
TIMER X • Week-end: Saturday and Sunday
DAY • Week: Monday to Friday
•  All: all the days of the week (7 days in 7)
TIMER X ON TIME Input the hour for compressor startup by timer x. 
HOUR
TIMER X ON TIME Input the minute for compressor startup by timer x. 
MINUTES
TIMER X OFF TIME Input the hour for compressor stopping by timer x (-- : no stopping by timer).
HOUR
TIMER X OFF TIME Input the minute for compressor stopping by timer x (-- : no stopping by timer).
MINUTES

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3.2 - Compressor data

** RESTART and COOLING modes **
(Machine configuration menu)

MANUAL Manual restart of the compressor after a current outage lasting more than 250 ms.
RESTART

AUTOMATIC
RESTART OPTION restart of the compressor after a current outage.
 Automatic
AIR  Air-cooled compressor.
COOLING
WATER Water-cooled compressor.
COOLING
NO: condensate drainage operations only carried out during compressor load operation (default)
DRAIN DURING STOP YES: condensate drainage operations carried out whatever the compressor operating configuration
(load operation, no-load operation, energized, etc.)

** PRESSURE AND TEMPERATURE PROTECTIONS **

(Machine configuration menu)

Maximum value authorized for regulation pressure setting (bar) = maximum service pressure
MAXIMUM PRESSURE protection).
Maximum compressor operating temperature (C°) leading to compressor fault trip (temperature
TEMPERATURE MAX protection).
Minimum compressor operating temperature (°C) It is impossible to stop the compressor below the
TEMPERATURE MIN minimum operating temperature (temperature protection). --- : the low temperature safety
mechanism is inhibited.

** OPTION **
(Machine configuration menu)

SERIAL CONNECTION No option has been selected. The compressor operates in self-contained mode and makes
OPTION OFF adjustments based on its own settings and sensors. Default adjustment.
SERIAL CONNECTION Serial connection option selected (serial interface or connection cable between 2 compressors)
OPTION ON
SERIAL OPTION
Configuration allowing the connection of the serial interface. The compressor can operate without
INTERFACE the interface if the internal regulation mode is selected
SERIAL OPTION
The two compressors can operate alternately (one main compressor and one back-up). The PCI07
CABLE for both compressors have to be linked by their X6 option connectors to the connection cable.
COMPRESSOR A OPTION
When two compressors operate alternately, automatic permutation takes place every 24 hours.
DAILY Setting the regulation set points takes place on this compressor.
COMPRESSOR A OPTION
When two compressors operate alternately, automatic permutation takes place every week. The
WEEKLY regulation set points are input on this compressor.
OPTION
COMPRESSOR B When two compressors operate alternately, compressor A is controlled by compressor B.

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** DRYER **
(machine configuration menu)

DRYER ON  Actives the On/Off control of the dryer via the digital output SOV1.

(initialization menu)

DRYER Timeout for compressor startup after the dryer:

DURATION The
This cooling
timeoutdryer
is alsotemperature drops before
taken into account for thethe compressor
remote On/Off starts.
control.
The timeout is not taken into account with automatic restart.

** STATUS / PRESSURE **

00.0 BAR 000 °C Displays the use pressure measured at the machine output (bars) and the temperature at the
discharge of the compressor part (C°).
POWER ON The compressor is energized and stopped.

ONLOAD The compressor is operating at full load or at part load.

The pressure measured by the analog sensor at the machine output is less than the regulation
pressure.

OFFLOAD The compressor operates at nil flow and with the oil tank empty.
The pressure measured by the analog sensor at the use is within the regulation deviation.
• No-load operation start:
- The use pressure (analog pressure sensor) reaches the regulation pressure.
• End of no-load operation:
- The compressor output pressure falls and reaches the pressurizing restart pressure
(regulation pressure – regulation deviation).
- The offload operation time exceeds the offload minimum time and the compressor stops (if
allowed by the maximum number of starts per hour data).
In the event of alternating operation of 2 machines (optional), message displayed on the compressor
DUTY ONLOAD used as main compressor when this operates at full load or part load.
In the event of alternating operation of 2 machines (optional), message displayed on the compressor
DUTY OFFLOAD used as the main one when this operates at nil flow and with the oil tank empty.
In the event of alternating operation of 2 machines (optional), message displayed on the regulating
ST-BY ONLOAD compressor as the backup when operating at full load or part load.
In the event of alternating operation of 2 machines (optional), message displayed on the regulating
ST-BY OFFLOAD compressor as backup when operating at nil flow and with empty oil tank.
Flashing display during compressor time-lagged stop.
During compressor shutdown, the led associated with key flashes.
Before full shutdown of the compressor, the PCI operates at no load for a minimum of 30 seconds in
STOPPING order to bring down the pressure in the tank and thereby avoid back flow of oil via the air filter.
If, when pressing on stop key O , the compressor is already empty, the time lag is adapted in order to
ensure minimum 30 seconds no-load operation.
During compressor shutdown, this may be restarted by pressing on key . 

** HOURS' OPERATION **  

(Machine status data)

Displays the total number of hours of compressor operation (main motor rotating). Hourmeter
TOTAL HOURS incrementation takes place when output KM1 (line) is active.
Displays the number of compressor load operation hours. The load operation hours is incremented
ONLOAD HOURS when the output KM1 (line) and SOV2 (control valve) are activated simultaneously.
LOAD RATIO Displays the ratio between the number of hours load operation and the total number of hours.

** Maintenance **
(Machine status data)

AIR FILTER Displays the remaining service life of the air filter before next maintenance (hours).

OIL FILTER Displays the remaining service life of the oil filter before next maintenance (hours).
SEPARATOR Displays the remaining service life of the separator filter before next maintenance (hours).

OIL CHANGE Displays the remaining service life of the filter before drainage by maintenance (hours).
Displays the remaining service life for the main motor bearings before any maintenance work
BEARINGS (hours).

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** TEMPERATURE PROTECTION TEST **

(From programming menu)

TEMPERATURE SYSTEM Test of the temperature protection trip has been selected. The maximum temperature setting is
TEST lowered to 60 °C. The compressor is on operating standby ready to begin the test.
The temperature protection trip test has been executed and the compressor fault has been activated.
The test is valid.
SENSOR OK Reset by pressing on the reset key F3.
The maximum temperature setting is brought to its initial value for normal operation.

** OTHER information **

STAR STARTING Displayed during all the motor start star phase (based on the star duration setting).
Displayed while the microprocessor checks that transfer to delta mode has indeed been executed
(around 3 seconds).
DELTA TRANSITION  At the end of the passage onto delta, the compressor transfers to load and condensate drainage
takes place.
OPTION for belt drive compressor
PRESSURE The compressor is on restart standby.
ABOVE 1.5 BAR The pressure in the tank is greater than 1.5b.
Restart as soon as the pressure in the tank falls below 1.5 bar.

STOP UNDER The compressor has been stopped using the under pressure stop key F2.
PRESSURE, DOT NOT Restart is only possible after resetting (key F3) and for a pressure in the tank less than 1.5 b
RESTART (OPTION for belt drive compressor).
• Displayed on stopping the compressor after prolonged no-load operation.
WARNING: AUTO Restarts when the build-up pressure has been reached.
• Displayed in the event of compressor startup although the pressure measured by the analog
RESTART sensor is situated in the regulation deviation range.
Restarts when the build-up pressure has been reached.
• On a micro-break (less than 250 ms), message displayed for 10 seconds before compressor
restart.
• OPTION. If the compressor is in automatic restart configuration, message displayed as a result
of a current break (micro-break or long-duration break). After 10 seconds display, the compressor
restarts.
• Displayed for 10 seconds before compressor restart by a timer.

CAUTION: When operating with timers,

times. this messagestartup
is displayed when a timer(s) is active and outside the
RESTART AUTOMATIC
programmed operating Compressor possible:
•  Automatic by timer, when within the programmed operating times.
BY TIMER • Forced by double pressing on the start key (I) of PCI07.
AUTOMATIC LOW Displayed when the temperature meausured by the temperature probe at the element output is less
TEMPERATURE than or equal to the minimum operating temperature (protection).
RESTART The compressor cannot start as long as the temperature is below the minimum threshold.  
OPTION
WARNING : REMOTE Displayed on remote stopping of the machine.
START  Remote restart available.
On local mode stopping of the compressor, remote restart is not available.

3.3 - Warnings
Message is displayed when the temperature measured by the analog sensor at the element outlet
WARNING , HIGH reaches the maximum alarm threshold (max. temperature of the protection less than 5 °C).
TEMPERATURE The compressor continues to operate.
The alarm is cancelled after pressing on reset key F3, with the compressor stopped, if the
temperature has fallen below the max. alarm threshold.

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3.4 - Maintenance
1st display of the message when the remaining air filter life is 5 hours.
CHANGE AIR FILTER 2nd display of the message when the air filter life counter has reached 0.
 After changing the filter and resetting the life counter, cancellation after pressing on reset key F3.
2 case:
CHANGE AIR/OIL • displayed after deoiler clogging detected by differential pressure gauge.
1st display of the message when the separator filter life is 5 hours.
SEPARATOR 2nd display of the message when the separator filter life counter has reached 0.
 After changing
1st display the filterwhen
of message and resetting the lifeoilcounter,
the remaining cancellation after pressing on reset key F3.
life is 5 hours.
nd
CHANGE OIL 2  display of the message when the oil life counter reaches 0.
 After drainage and resetting the life counter, cancellation after pressing on reset key F3.
1st display of message when the remaining oil filter life is 5 hours.
CHANGE OIL FILTER 2nd display of the message when the oil filter life counter reaches 0.
 After changing the filter and resetting the life counter, cancellation after pressing on reset key F3.
1st display of the message 5 hours before main motor bearing lubrication.
MOTOR BEARINGS 2nd display of the message when the bearing lubrication counter has reached 0.
LUBRICATION   After bearing lubrication and reinitializing the counter, cancellation after pressing on the reset button
F3.

3.5 - Faults

SHORT CIRCUIT IN Compressor stopped.

Possible causes:
TEMPERATURE • sensor badly connected
SENSOR • faulty sensor
Restart after eliminating the fault and after resetting by pressing on reset key F3.
This fault can be associated to a low temperature fault.
Compressor stopped.
Possible causes:
TEMPERATURE • sensor badly connected
SENSOR NOT • faulty sensor
CONNECTED Restart after eliminating the fault and after resetting by pressing on reset key F3.
This fault can be associated to a high temperature fault.
PRESSURE SENSOR Compressor stopped.

FAILURE •Possible causes:

sensor badly connected
• faulty sensor
Restart after eliminating the fault and after resetting by pressing on reset key F3.
MAIN OF FAN MOTOR The compressor is stopped.
Possible causes:
OVERLOAD FAULT • heat setting
• insufficient supply voltage
• motor overload
• motor bearings
• imbalance between the 3 phases
• Dryer error: dryer temperature low (if the dew point display module is defective and connected
to the digital input F1/Q1/F11).
Restart after eliminating the fault and after resetting by pressing on reset key F3.
STAR CONTACTOR The PCI has not detected the star phase on main motor startup.
Compressor stops.
FAULT Possible causes:
• disconnected coil (KM2)
Restart after eliminating the defect and after resetting by pressing on reset key F3.

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HIGH PRESSURE FAULT The HP is tripped after detecting overpressure in tank or the analog pressure sensor at the machine
output has reached the safe HP level (max. pressure+1bar) .
Compressor stops.
Possible cause:
• intake chamber valve does not close
•  Analog pressure sensor fault
Restart possible if pressure falls below HP trip value after resetting by pressing on reset key F3.
The analog maximum
compressor temperature probe measures
operating temperaturea (temperature
temperature at the element outlet which is above the
protection).
HIGH TEMPERATURE The compressor is stopped.
FAULT Possible causes:
• low oil
• ambient temperature too high
• obstruction of cooling air passage through oil radiators
• clogging of oil/water exchanger
• obstructed oil circuit
• stopped fan
• defective temperature probe
Restart possible if the temperature has fallen below the maximum safe temperature and after
resetting by pressing on reset key F3.
This fault is detected when the compressor is onload or offload (water cooling).
The fault is displayed after a 6 second confirmation time laps.
WATER FLOW FAULT  The compressor stops.
Possible causes:
• general inlet closed
• solenoid valve has not opened
• clogging of exchangers
• water flow controller defective
Restart is possible after having eliminated the fault and after resetting by pressing on reset key F3.
The compressor is operating with the serial interface option. The EXTERNAL regulation mode has
been selected. The serial interface is not detected by PCI07. The compressor stops.
SERIAL Possible causes:
INTERFACE FAULT  • the communication cable connecting the electronic board to the serial interface has not been
connected
• the serial interface is not supplied
• communication cable fault
• serial interface electronic board fault.
Restart possible after eliminating the fault and resetting by pressing on the reset key F3.

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Chapter 4 - Options
The 8-pole connector situated behind the PCI07 is used to
connect up the 2 following options:
- Serial cable
- Serial connection interface
In order to connect one of the options, PCI07 has to be set to
'SERIAL CONNECTION OPTION ON' (machine configuration
menu).
4.1 - Serial cable
 Alternating operation of 2 compressors
(Kit ref.: 62 590 810 00, cable ref.. 62 363 691 00)
This option can be used to operate 2 compressors
alternately after connecting their PCI07 using the connection
cable.
Configuration of the PCI07:   Protection management
To allow alternating operation of 2 compressors, configure the
PCI07 of both compressors using the explanatory notice ref. 62
139 391 11.
Cabling:
The PCI07 of the two compressors must be with the option
cable by their X6 optional connectors. The shielded cable must
be connected to the earth of each PCI. The shielded cable must
not be installed near the main supply cables.
WARNING :
The earth connections of the two machines must be
equipotential.
Regulation:
When one of the 2 compressors is started by pressing on the
key, this compressor operates separately its own regulation
settings and pressure sensor.
 As soon as two compressors operate simultaneously, the
main/backup mode is activated. The pressure sensor used for
regulation is then the compressor A sensor.
On main/backup dual operation, the following are displayed:
- regulating compressor as main compressor:
‘DUTY ONLOAD’
‘DUTY OFFLOAD'
- compressor acting as backup:
‘ST-BY ONLOAD’
‘ST-BY OFFLOAD’
• When the pressure exceeds the backup pressure,
compressor the backup set transfers onto vacuum operation
and is then stopped by its motor time-delay and its number
of startups per hour.
• When the pressure exceeds the regulation pressure,
compressor the main set transfers onto no-load operation
and is then stopped in relation to its motor time-delay and its
number of starts per hour.
• If the pressure falls below the regulation pressure less the
regulation deviation, the main compressor transfers onto
load operation.
• If the pressure falls below the backup pressure less the
backup deviation, the backup compressor restarts if it had
stopped and transfers onto load operation.
 
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 Alternancy:
The operation described previously is reversed every 24
hours or every week based on the selected operating mode.
During a permutation, compressor A is regulated according
to the main set point and compressor B according to the backup
set point.
On the next permutation, compressor A regulates according
to the backup set point and compressor B according to the main
set point.
Timer management:
Each compressor operates through its own timers. As
soon as one compressor is outside its programmed operating
times, the « CAUTION: AUTOMATIC RESTART BY TIMER »
message is displayed. The second compressor then operates
independently and based on its own settings and its own sensor.
The « MAIN » and « BACKUP » display disappears.
When both compressors are in their programmed operating
times, the main/backup mode is automatically reactivated.
On a malfunction of one of the two compressors or shutdown
under pressure, this transfers to autonomous operation and each
one regulates according to its own measured pressure and its
own regulation set point. Thus, if a fault appears on one set or if
it is stopped by a user, the other set is not blocked and transfers
onto autonomous operation.
4.2 - Serial interface
(Kit ref.: 62 590 879 00, interface ref.: 62 363 784 00)
This option is used for remote control and display of
compressor status.
Interface description:
The bidirectional serial interface continually communicates
with the electronics board controlling the compressor. The data
are sent from the board to the interface and vice versa via a
cable.
This option takes the form of a box fixing on DIN rail.
The controls and data available on the interface are:
- Remote start / stop of the compressor
- Load / no-load start of the compressor
- Pressure switch type output (load/no-load)
- Regulation mode (internal or external)
- Compressor start (motor rotation)
- Machine availability
- General fault reporting
If this option is used, it will require selection of the type of
regulation in the programming menu:
-
Internal (regulation by the settings given by PCI07 and the
internal pressure sensor)
- External (use of load/no-load operation input)
Configuration / Cabling:
See diagram ref. 62 139 444 00.
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Inputs / outputs:
(See diagram ref. 62 139 444 00)
Inputs:
• input 1: remote start / stop 
This input controls starting and stopping of the compressor.
• input 2: load / no-load operation
This input can be used to force load or no-load operation of
the compressor. The input is activated if the external
regulation mode is selected in the programming menu.
Outputs:
• output 1: unused
• output 2: compressor internal regulation status   •
Pressure switch type output reflecting the compressor
theoretical operating mode (load or no load) relative to the
regulation instructions set on PCI07. Active output when
operating with load.
• output 3: local / remote regulation  TEST » message comes on.
This output reflects the regulation mode configured on PCI07
(internal or external regulation). With internal regulation, the
compressor uses its own settings and internal pressure
sensor to regulate operation. In external regulation, input 2 is
used for the load or no-load start order. Active output in
external regulation.
• output 4: load operation 
 Active output when the compressor motor is rotating
• output 5: availability   •
 Active output when the compressor is ready to operate (no
fault, machine energized and start pressed)
• output 6: general fault   •
 Active output when no fault.
On a break of the communication cable connecting PCI07 and
the interface, the outputs are inactive (open). If PCI07 is
configured for external regulation, this changes to fault.
Chapter 5 - Temperature protection
test 
The temperature protection trip of a compressor can be
tested. This test has to be carried out once every year in order to
check that this protection operates properly.
Test procedure: 
• Set the compressor to shut down, and energize.
When the temperature measured by the analog sensor
exceeds 60 °C, place the cursor in the programming
menu (press on key F4 longer than 3 seconds).
• In the programming menu, press on keys Ο  and | 
simultaneously. The « TEMPERATURE SYSTEM
When the « TEMPERATURE SYSTEM TEST » message is
displayed, the compressor is ready to carry out a temperature
protection trip test. For this test, the maximum operating
temperature setting is less than 60 °C in order to cause tripping
of a protection in the normal conditions of operation.
Set the compressor to On by pressing on key |.
• Wait for the temperature protection to trip. Check that
this trip takes place at 60 °C.
 After tripping the protection, the « SENSOR OK »
message is displayed. The fault indicator is on. The test
is valid.
• Eliminate the fault by pressing on the reset key F3.
 After eliminating the fault, the maximum temperature setting
automatically adopts its initial value. The compressor is able to
operate normally .

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Chapter 6 - Factory settings

Data Message example Unit Possible choices Factory setting
Français
English
Espanol
Italiano 
Language selection English / English
Deutsch
Nederlands
Portuguesa
Svenska
 Air filter service life Air filter h 500 to 9500 2000
Oil filter service life Oil filter h 500 to 9500 2000
2000 – 3000, 15 - 40 40 to 220
Separator service life Separator h 500 to 9500
4000 h 6000 h
Oil service life Oil change h 500 to 9500 2000
100 to 9900
Bearings service life Motor bearings h ---
--- : inhibited counter
No-load motor operating time Offload minimum time min 1 to 30 1
Machine number Unit number / 0 to 7 0
Condensate drain ≤100ch >100ch
Condensate drain frequency min 1 to 30
Freq. 3 2
Condensate drain <50ch 50/100ch >100ch
Condensate drain duration s 1 to 15
Duration 2 4 6
Motor startups <50ch ≥50ch
Star phase time s 1 to 15
Star time 7 10
Maximum number of motor starts per Motor startups
/ 0 to 15 6
hour No/Hour
Clock year 00 to 99
Setting of clock date Clock month / 1 to 12 Date
Clock day 1 to 31
Clock hour h 0 to 23
Setting of clock time Effective time
Clock minutes min 0 to 59
On/Off Prog
BD DD
Min.: 4
Regulation pressure Regulation pressure bar  A 8 8,5 8
Max.: as per version
B 10 10,5 10,5
C 13 13,5 13
Regulation deviation Differential pressure bar 0.2 to 4 1.5
Operation
or with
without timer Operation
with timers / Operationwithout
Operation with timers
timer Operation without timer
Timer x active
Timer activation Timer x active / /
Timer x inactive
Monday, Tuesday
Day setting for timer x Timer  x  day  / /
Weekday, weekend, all
Start timer  x hour   h 0 to 23
Timer x startup time /
Start timer  x minutes  min 0 to 59
Timer x stop time Stop timer  x  hour   h 0 to 23 or --
/
Stop timer  x minutes  min 0 to 59 or --
Dryer timeout Dryer duration  mm / 0
Manual restart Manual restart
Selection of restart mode Manual restart /
 Automatic restart (except option)
 Air cooling
Cooling type Air cooling /  According to machine
Water cooling
ON/OFF Prog
BD DD
Maximum use pressure Maximum pressure bar 4 to 16  A 8 8.5 8
B 10 10.5 10.5
C 13 13.5 13
Maximum operating temperature Max. temperature °C 80 to 150 110
Minimum operating temperature Min. temperature °C -10 to 20 or -- 2
Serial port option On OFF
Option Serial port option OFF /
Serial port option OFF (exception option)
Permanent drain Drain during stop / Yes / No No
Dryer activation Dryer ON/OFF / ON/OFF OFF

On/Off: on/off regulation Prog: progressive regulation BD: Belt Drive DD: Direct Driver 
h: hour min: minute s: second °C: degree Celsius /: NA  Setting by electronic key 

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Chapter 7 - Alphabetic list of messages

LISTE OF MESSAGES TYPE OF MESSAGE PAGE

*** A ***
 Air cooling info 10,13
 Air filter setting/info 7,9,11,14
 Automatic restart info/option 10,13

*** C ***
Change air filter maintenance 16
Change air/oil separator maintenance 16
Change oil maintenance 16
Change oil filter maintenance 16
Clock day setting 7,11
Clock hour setting 7,11
Clock minutes setting 7,11
Clock month setting 7,11 
Clock year setting 7,11
Compressor A daily info/option 10,13
Compressor A weekly info/option 10,13
Compressor B setting 10,13,17
Condensate drain duration setting 7,11
Condensate drain fréq. setting 7,11

*** D ***
Delta transition info 15
Differential pressure setting 6,8,12
Differential stand-by setting/option 6,8,12
Drain during stop info 10,13
Dryer setting/info 7,14
Dryer ON/OFF setting/info 10,14
Duty offload info 14,18
Duty onload info 14,18

*** E ***
External regulation setting/option 8,12,18

*** H ***
High temperature fault fault 17
High pressure fault fault 17

*** I ***
Internal regulation setting/option 8,12,18

*** L ***
Language setting 2,7,11
Load ratio info 9,14
Low temperature automatic restart info 15

*** M ***
Main or fan motor overload fault fault 16
Manual restart info 10,13
Maximum pressure info 10,13
Motor startups No/Hour setting 6,7,11
Motor startups star time setting 7,11

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LISTE OF MESSAGES TYPE OF MESSAGE PAGE 

*** O ***
Offload info 14
Offload minimum time setting 7,11
Oil change setting/info 7,9,11,14
Oil filter setting/info 7,9,11,14
Onload
Onload hours info
info 14
9,14
Operation without timer setting 8,12
Operation with timers setting 8,12

*** P ***
Power on info 14
Pressure above 1.5 bar info 15
Pressure sensor failure fault 16

*** R ***
Regulation pressure setting 6,8,12

*** S ***
Sensor OK info 15,19
Separator setting/info 7,9,11,14
Serial cable info/option 10,13,18
Serial interface fault fault 17
Serial Interface info/option 10,13,18,19
Serial port option OFF info/option 10,13,18
Serial port option ON info/option 10,13,18,19
Short circuit in temperature sensor fault 16
Stand-by pressure setting 6,8,12
Star contactor fault fault 16
Star starting info 15
St-by offload info 14,18
St-by onload info 14,18
Stopping info 2,14
Stop under pressure, do not restart info 15

*** T ***
Temperature max info 10,13
Temperature min info 10,13
Temperature sensor not connected fault 16
Temperature system test info 15,19
Timer x  day setting 8,12
Timer x  off setting 8,12
Timer x off time hour setting 8,12
Timer x off time minutes setting 8,12
Timer x  on setting 8,12
Timer x on time hour setting 8,12
Timer x on time minutes setting 8,12
Total hours info 9,14

*** U ***
Unit number setting 7,11

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LISTE OF MESSAGES TYPE OF MESSAGE PAGE

*** W ***
Warning : auto restart info 15
Warning auto restart by timer info 6,15,18
Warning, high temperature alarm 15
Warning : remote restart info 6,15
Water
Water cooling
flow fault info
fault 10,13
17

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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 industrielle – BP 80419 Worthington Creyssensac Air Compressor

4 rue Émile Zola ProductsPark
Unit 4 Silverwood Court, Fairfield Ltd
F-60114 Méru Cedex Manvers, Rotherham
South Yorkshire S63 SDB
 
Worthington - Creyssensac
Zone industrielle - BP 80419 - 4 rue Émile Zola - 60114 Méru Cedex
http://www.airwco.com  

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