worthington instruction book pci07 en

8/18/2019 worthington Instruction Book PCI07 En

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Instructions manual EN Electronic module

PCI0762 205 827 15 ed00


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Worthington-Creyssensac62 205 827 15 1

CONTENTS

Chapter 1 - General description 2Display language selection 21.1 - General 2

1) General description 22) Emergency stop, time-delayed stop 23) Analog sensors 24) Battery replacement 2

1.2 - Functions 21) Control 22) Data 23) Regulation 24) Control of condensate drain-off 25) Signalling of maintenance operations 26) Management of operating defects 27) Programmin compressor startup and stopping 2

1.3 - PCI front panel 31) LED indicators 32) Keys 33) Display 3

1.4 - PCI rear panel 41) 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 82.3 - Machine status information menu 92.4 - 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 184.2 - 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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Worthington-Creyssensac62 205 827 152

Chapter 1 - General description

Selecting the language:• Open the menu by pressing on F1 (pushbutton

at the rear of the PCI)• Select the required language using key F3• Exit the menu using key F1

1.1 - General

1) General description

The PCI07 is a micro-processor-equipped electronic moduleused to start and stop the ROLLAIR ® , to manage ROLLAIR ® faults and alarms, generate information on the operating status,and control condensate drain-off and remote transmissions andremote control.

The PCI07 executes the following functions in particular :• Management of 2 analog inputs: a temperature probe and

a pressure sensor• Programming of compressor start-up and shutdown

• Control, fault reporting and remote display of compressoroperating status (option)

• Automation of alternating operation between severalcompressors (option)

• Timed On/Off management of a dryer (according toparameters)

2) Emergency stop, time-delayed stop

WARNING: All compressors fi tted with an electronic management board

PCI07 must be provided with an emergency knock off pushbutton which stops the compressor and the dryer.

WARNING:The compressor shutdown time can be delayed by pressing

the PCI07 O key, although there is a minimum of 30 seconds no-load operation prior to full machine shutdown. The shutdownphase is indicated by the "STOPPING" and the green LEDassociated with the key.

3) Analog sensors

The PCI07 manages 2 analogue measurement channels tomeasure the service pressure (machine outlet) and the oiltemperature (compression unit outlet).

4) Battery replacement

The battery is used to keep date and time when the powersupply is off. Its working life depends upon the length of time themachine is off.

We recommend replacing the battery every 4 years.However, should the date and time disappear, change thebattery 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 theoperator to control and monitor the compressor:

• On (

)• Stop (O)• Stopped under pressure (F2)• Reset (F3)• Scrolling (F4)

A connector situated behind PCI07 can be used for compressor

remote control (option).

2) Data

The PCI07 display and the Leds provide:• display of the operating status of the compressor at a

given instant,• display of maintenance messages (alarms, defects, etc.)• display of compressor control parameters.

3) Regulation

The PCI07 executes compressor regulation. These functionsinclude:

• control of no-load operation as soon as the pressuremeasured by the pressure analog sensor reaches theregulation pressure

• control of load operation as soon as the pressuremeasured by the analog pressure sensor reaches theminimum regulation pressure (regulation pressure –regulation deviation)

• ordering of motor shutdown after the period of no-loadoperation

• inhibiting of motor restart if the pressure in the oil tank isabove 1.5 bars (RLR 75 at 220 or automatic restartoption).

4) Control of condensate drain-off

The frequency and the duration of drain solenoid valve

opening can be programmed in order to adapt to the size of themachine and the volume of condensate to be evacuated.

5) Signalling of maintenance operations

As soon as a maintenance operation is required, eitherbecause the machine has reached a number of hours requiringwork, or because a sensor has detected that a threshold hasbeen reached, a yellow light flashes and a message indicatingthe operation to be executed is displayed. The machine does notstop.

6) Management of operating defects

As soon as a fault signal appears, the PCI07 stops thecompressor, signals the fault through the red light of the reset

key and displays a message allowing the cause of the incident tobe quickly located.

The 8 last faults occurring on the compressor are kept in thememory and can be displayed by a technician holding theelectronic key (See 2.3).

7) Programming compressor startup and stopping

After programming the timers, the real-time clock on thePCI07 allows automatic starting and stopping of the compressor.

The clock which operates when the compressor isdeenergized is supplied by a lithium battery with 8 years' servicelife. The maximum battery service life is 8 years with thecompressor energized.


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1.4 - PCI rear panel (Fig.2)

1) Description of inputs/outputs

5 connectors on the rear of the PCI can be used to connectthe inputs/outputs and the PCI power supply.

• 7-pole withdrawable connector for the 6 on/off inputs (X3):

11. CommonCommon from all on/off sensors.

12. KM2Star contactorControls the star phase on main motor startup.

13. PSH1High pressure switchProvides high pressure protection.

14. DPSH1CloggingDetected by deoiler filter head losses.

15. F1/Q1/F11Internal combustion engine, dryer or fan faultEngine protection systems, main, dryer or fan.

16. FS1

Water circulationIndicates the presence of water in cooling circuit.

17. PSL1Pressure above 1.5 barLow pressure protection (restart).

• 5-pole withdrawable connector for 2 analog inputs (X5):

20 and 21. TSTemperature probe

Analog sensor for measuring the temperature atelement output.

22 to 24. PTPressure sensor

Analog sensor for measuring the pressure at the

machine output (user).

• 8-pole withdrawable connector for the option or theconnection of the electronic key (X6).

• 10-pole withdrawable connector for the 5 control outputs (drycontacts) (X2):

Controlled load: 250V, 6A nominal – Cos ϕ=1

1 and 2. KM3Delta contactorControls the delta contactor.

3 and 4. KM2Star contactorControls the star contactor.

5 and 6. KM1Line contactorControl of the line contactor.

7 and 8. SOV2Regulation solenoid valveControls the regulation solenoid and the

vacuuming valve.

9 and 10. SOV1Dryer or condensate bleed solenoid valve.Dryer operation or bleed control.

• 3-pole withdrawable connector to supply 12Vac (X4) (18, 19and PE).

• Required power: 6VA / 12Vac

In addition to these 5 connectors, a double Faston lug onrear plate of the PCI allows connection of the PE conductorand cable screening.Push button F1 in the middle of the rear panel of the PCI

allows access to the initializing menu.


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Fig.2 : Rear panel of the PCI07

Fig.1 : Front 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 acertain number of hours' operation, or because a sensor hasdetected a threshold.

An alarm does not lead to compressor shutdown. It isindicated visually by the yellow alarm indicator light LED

flashing and by a message informing the operator of thenature of the alarm or the operation to be executed.

• Fault A fault leads to compressor shutdown and is linked to a

machine malfunction. It is signalled by the red LEDassociated with the F3 reset key and by a messageinforming 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 beprogrammed for one day of the week, work days (Monday toFriday), 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. andstop timer 1 = 4 p.m. the compressor will operate onMondays 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 willoperate on Thursdays from 6.30 a.m. until 8.15 p.m..

When a compressor is pending restart by a timer, themessage « WARNING AUTO RESTART BY TIMER » movesthrough the display.

If the compressor is pending restart by a timer, thecompressor can be forced to start manually by dual pressingon the start key ( I ). This forced operation will not alter thetimer settings.

Examples :In the examples above, if the key is double pressed

before Monday 8.00 a.m. or Thursday 6.30 a.m., thecompressor will start and stop automatically on Monday at 4p. m. or on Thursday at 8.15 p.m..

• Regulation pressure / differential pressureThe regulation pressure is the use pressure from which

the compressor will begin operating in a no-loadconfiguration.The differential pressure defines the no-load operating

range of the compressor. Load operation restarts when themachine outlet pressure has fallen from the regulationdeviation relative to the regulation pressure.

• Stand-by pressure and differential stand-byRegulation 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 operationThe compressor operates at nil flow and with the oil tank

empty.

• Remote controlPossibility 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 restartit 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 priorityover timer operation:

- When a compressor is stopped remotely, the« WARNING: REMOTE RESTART » message movesthrough the display.

- If a compressor is started remotely when outside theoperating times programmed on the active timers, the« WARNING AUTO RESTART BY TIMER » messagemoves through the display.

• Remote control optionThis 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 2compressors (serial cable).

- To control and display the status of a remotecompressor (serial interface).

• Serial port optionUsing an interface, this option allows alternating

operation of 2 compressors or all the operating parametersfrom the compressor to be displayed on the PC.

• Automatic restartThis option enables automatic restart of the compressor

after a power outage.

• Max. number of starts authorized per hourThis function is for defining the minimum operating time

of the motor between its last startup and automatic shutdownas a result of prolonged no-load operation.

If, on a prolonged no-load operation, the motor no-loadoperating time is exceeded, compressor shutdown will onlybe authorized if the number of maximum restarts per hour iscomplied 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 ofoperating for 20 minutes minimum before its shutdown isauthorized (60/3). If, 5 minutes after restarting the motor, the

compressor transfers to no-load operation, motor shutdownwill take place 5 minutes after the end of the motor time lagin 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 F3Validate selection: press on F2

LANGUAGEFRANÇAISENGLISH

ESPANOLITALIANODEUTSCH

PORTUGUESANEDERLANDS

Language

AIR FILTER

OIL FILTER

SEPARATOR

OIL CHANGE

BEARINGS

Maintenance cycles

OFFLOAD MINIMUMTIME

UNIT NUMBER

CONDENSATE DRAINFREQ.

CONDENSATE DRAINDURATION

MOTOR STARTUPSSTAR TIME

MOTOR STARTUPSNo/HOUR

Startups and drains

DRYERDURATION

CLOCKYEAR

CLOCKMONTH

CLOCKDAY

CLOCKHOUR

CLOCK

MINUTES

Real-time clock


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2.2 - Programming menu

For setting the regulation and the timers

Menu access condition: machine stoppedMenu access: press on F4 for more than 3 secondsExit the menu: press on F4

Modify the selection: press on F3Validate the selection: press on F2

REGULATIONPRESSURE

DIFFERENTIALPRESSURE

INTERNAL REGULATION

EXTERNAL REGULATION

STAND-BYPRESSURE

DIFFERENTIALSTAND-BY

Régulation

OPERATIONWITH TIMERS

WITHOUT TIMER

TIMER 1 ACTIF

ON

TIMER 1OFF

TIMER 1 ON TIMEHOUR

TIMER 1 ON TIMEMINUTES

TIMER 1 OFF TIMEHOUR

TIMER 1 OFF TIMEMINUTES

Timers

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

TIMER PROGRAMMING8 timers are available. The choice of the active timers and their adjustment is only possible when operating 'with timers'.

Timer operating days:Monday, Tuesday, … : weekdaysWeekend : Saturday and SundayWeek: 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 F4Scrolling: press on F4Exit the menu: press on F3 (compressor operating) or key O (compressor stopped)

TOTAL HOURS

ONLOAD HOURS

LOADRATIO

Hours operation

AIR FILTER

OIL FILTER

SEPARATOR

OIL CHANGE

BEARINGS

Maintenance

Tuesday 01/01/9812 : 00

Date and time


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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 F3Scrolling: press on F3Exit the menu: press once on the O key

MANUAL AUTOMATIC

RESTART

AIRWATER

COOLING

Machine configuration

MAXIMUMPRESSURE

TEMPERATUREMAX

TEMPERATUREMIN

P and T protections

OPTIONSERIAL PORT OFFSERIAL PORT ON

SERIAL INTERFACE

SERIAL CABLE

COMPRESSOR ADAILY

WEEKLY

COMPRESSORB

DRYERONOFF

DRAIN DURING SHUTDOWNNOYES

Option


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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 MINIMUMTIME

Input the compressor no-load operating time before motor stops (minutes).

UNIT NUMBER Input the machine number.

CONDENSATE DRAINFREQ.

Input the frequency of condensate drain valve opening (minutes).

CONDENSATE DRAINDURATION

Input condensate drain valve opening time (seconds).

MOTOR STARTUPSSTAR TIME

Input star startup phase time lag (seconds).

MOTOR STARTUPSNo/HOUR

Input maximum number of motor starts/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)

REGULATIONPRESSURE

Input the regulation pressure leading to compressor no-load operation (bars).

DIFFERENTIALPRESSURE

Input the deviation between the regulation pressure and the pressurizing pressure corresponding tothe no-load operation range (bars).

STAND-BYPRESSURE

OPTION

When two compressors are operating alternately, inputting the regulation pressure leads to no-loadoperation of the back-up compressor (bars).

DIFFERENTIALSTAND-BY

OPTIONWhen two compressors are working alternately, input the deviation between the regulation pressureand the pressurizing pressure for the backup compressor corresponding to the no-load operationrange (bars).

** Setting the REGULATION mode ** (Programming menu)

INTERNALREGULATION

OPTIONOperation with a serial interface. The regulation instructions set on PCI07 and the analog pressuresensor are used for load and no-load operation of the compressor. Regulation is dependent on theinternal compressor settings.

EXTERNALREGULATION

OPTIONOperation with a serial interface. The load and no-load start orders are external to the compressor(load/no-load start inputs from the serial interface). The compressor internal pressure sensors remainactive for the protection functions.

** Selection and setting of TIMERS ** (Programming menu)

OPERATIONWITH TIMERS

Compressor operation through timers (8 timers can be programmed to stop and start the machineautomatically).

OPERATIONWITHOUT TIMERS

Compressor operation without timers.

TIMER XON

Timer x is activated, and will be programmed.

TIMER XOFF

Timer x is deactivated.

TIMER XDAY

Input the days of the week for compressor startup by timer x :• Monday, Tuesday, …..: weekdays• Week-end: Saturday and Sunday• Week: Monday to Friday• All: all the days of the week (7 days in 7)

TIMER X ON TIMEHOUR

Input the hour for compressor startup by timer x.

TIMER X ON TIME

MINUTES

Input the minute for compressor startup by timer x.

TIMER X OFF TIMEHOUR

Input the hour for compressor stopping by timer x (-- : no stopping by timer).

TIMER X OFF TIMEMINUTES

Input the minute for compressor stopping by timer x (-- : no stopping by timer).


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3.2 - Compressor data

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

MANUALRESTART

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

AUTOMATICRESTART OPTION Automatic restart of the compressor after a current outage.

AIRCOOLING

Air-cooled compressor.

WATERCOOLING

Water-cooled compressor.

DRAIN DURING STOPNO: condensate drainage operations only carried out during compressor load operation (default)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 PRESSUREMaximum value authorized for regulation pressure setting (bar) = maximum service pressureprotection).

TEMPERATURE MAX Maximum compressor operating temperature (C°) leading to compressor fault trip (temperatureprotection).

TEMPERATURE MINMinimum compressor operating temperature (°C) It is impossible to stop the compressor below theminimum operating temperature (temperature protection). --- : the low temperature safetymechanism is inhibited.

** OPTION **(Machine configuration menu)

SERIAL CONNECTION

OPTION OFF

No option has been selected. The compressor operates in self-contained mode and makes

adjustments based on its own settings and sensors. Default adjustment.

SERIAL CONNECTIONOPTION ON

Serial connection option selected (serial interface or connection cable between 2 compressors)

SERIALINTERFACE

OPTIONConfiguration allowing the connection of the serial interface. The compressor can operate withoutthe interface if the internal regulation mode is selected

SERIALCABLE

OPTIONThe two compressors can operate alternately (one main compressor and one back-up). The PCI07for both compressors have to be linked by their X6 option connectors to the connection cable.

COMPRESSOR ADAILY

OPTIONWhen two compressors operate alternately, automatic permutation takes place every 24 hours.Setting the regulation set points takes place on this compressor.

COMPRESSOR AWEEKLY

OPTIONWhen two compressors operate alternately, automatic permutation takes place every week. Theregulation set points are input on this compressor.

COMPRESSOR BOPTIONWhen 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

DURATION

Timeout for compressor startup after the dryer:

The cooling dryer temperature drops before the compressor starts.This timeout is also taken into account for the remote On/Off 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 thedischarge 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 regulationpressure.

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 (ifallowed by the maximum number of starts per hour data).

DUTY ONLOAD In the event of alternating operation of 2 machines (optional), message displayed on the compressorused as main compressor when this operates at full load or part load.

DUTY OFFLOAD In the event of alternating operation of 2 machines (optional), message displayed on the compressorused as the main one when this operates at nil flow and with the oil tank empty.

ST-BY ONLOAD In the event of alternating operation of 2 machines (optional), message displayed on the regulatingcompressor as the backup when operating at full load or part load.

ST-BY OFFLOAD In the event of alternating operation of 2 machines (optional), message displayed on the regulatingcompressor as backup when operating at nil flow and with empty oil tank.

STOPPING

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 inorder 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 toensure minimum 30 seconds no-load operation.During compressor shutdown, this may be restarted by pressing on key .

** HOURS' OPERATION ** (Machine status data)

TOTAL HOURS Displays the total number of hours of compressor operation (main motor rotating). Hourmeterincrementation takes place when output KM1 (line) is active.

ONLOAD HOURS Displays the number of compressor load operation hours. The load operation hours is incrementedwhen 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).

BEARINGS Displays the remaining service life for the main motor bearings before any maintenance work(hours).


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** TEMPERATURE PROTECTION TEST **(From programming menu)

TEMPERATURE SYSTEMTEST

Test of the temperature protection trip has been selected. The maximum temperature setting islowered to 60 °C. The compressor is on operating standby ready to begin the test.

SENSOR OK

The temperature protection trip test has been executed and the compressor fault has been activated.The test is valid.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).

DELTA TRANSITIONDisplayed while the microprocessor checks that transfer to delta mode has indeed been executed(around 3 seconds).

At the end of the passage onto delta, the compressor transfers to load and condensate drainagetakes place.

PRESSUREABOVE 1.5 BAR

OPTION for belt drive compressorThe compressor is on restart standby.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 UNDERPRESSURE, DOT NOTRESTART

The compressor has been stopped using the under pressure stop key F2.Restart is only possible after resetting (key F3) and for a pressure in the tank less than 1.5 b(OPTION for belt drive compressor).

WARNING: AUTORESTART

• Displayed on stopping the compressor after prolonged no-load operation.Restarts when the build-up pressure has been reached.• Displayed in the event of compressor startup although the pressure measured by the analog

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 compressorrestart.

• OPTION. If the compressor is in automatic restart configuration, message displayed as a resultof a current break (micro-break or long-duration break). After 10 seconds display, the compressorrestarts.

• Displayed for 10 seconds before compressor restart by a timer.

CAUTION: AUTOMATICRESTARTBY TIMER

When operating with timers, this message is displayed when a timer(s) is active and outside theprogrammed operating times. Compressor startup possible:• Automatic by timer, when within the programmed operating times.• Forced by double pressing on the start key (I) of PCI07.

AUTOMATIC LOWTEMPERATURERESTART

Displayed when the temperature meausured by the temperature probe at the element output is lessthan or equal to the minimum operating temperature (protection).The compressor cannot start as long as the temperature is below the minimum threshold.

WARNING : REMOTESTART

OPTIONDisplayed on remote stopping of the machine.Remote restart available.On local mode stopping of the compressor, remote restart is not available.

3.3 - Warnings

WARNING , HIGHTEMPERATURE

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


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3.4 - Maintenance

CHANGE AIR FILTER1st display of the message when the remaining air filter life is 5 hours.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.

CHANGE AIR/OILSEPARATOR

2 case:• displayed after deoiler clogging detected by differential pressure gauge.1st display of the message when the separator filter life is 5 hours.2nd display of the message when the separator filter life counter has reached 0.


CHANGE OIL1st display of message when the remaining oil life is 5 hours.2nd 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.

CHANGE OIL FILTER1st display of message when the remaining oil filter life is 5 hours.2nd display of the message when the oil filter life counter reaches 0.


MOTOR BEARINGSLUBRICATION

1st display of the message 5 hours before main motor bearing lubrication.2nd display of the message when the bearing lubrication counter has reached 0.

After bearing lubrication and reinitializing the counter, cancellation after pressing on the reset buttonF3.

3.5 - Faults

SHORT CIRCUIT INTEMPERATURESENSOR

Compressor stopped.Possible causes:• sensor badly connected• faulty sensorRestart after eliminating the fault and after resetting by pressing on reset key F3.This fault can be associated to a low temperature fault.

TEMPERATURESENSOR NOTCONNECTED

Compressor stopped.Possible causes:• sensor badly connected• faulty sensorRestart 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

FAILURE

Compressor stopped.

Possible causes:• sensor badly connected• faulty sensorRestart after eliminating the fault and after resetting by pressing on reset key F3.

MAIN OF FAN MOTOROVERLOAD FAULT

The compressor is stopped.Possible causes:• 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

FAULT

The PCI has not detected the star phase on main motor startup.Compressor stops.

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 machineoutput has reached the safe HP level (max. pressure+1bar) .Compressor stops.Possible cause:• intake chamber valve does not close• Analog pressure sensor faultRestart possible if pressure falls below HP trip value after resetting by pressing on reset key F3.

HIGH TEMPERATUREFAULT

The analog temperature probe measures a temperature at the element outlet which is above thecompressor maximum operating temperature (temperature protection).The compressor is stopped.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 probeRestart possible if the temperature has fallen below the maximum safe temperature and afterresetting by pressing on reset key F3.

WATER FLOW FAULT

This fault is detected when the compressor is onload or offload (water cooling).The fault is displayed after a 6 second confirmation time laps.The compressor stops.

Possible causes:• general inlet closed• solenoid valve has not opened• clogging of exchangers• water flow controller defectiveRestart is possible after having eliminated the fault and after resetting by pressing on reset key F3.

SERIALINTERFACE FAULT

The compressor is operating with the serial interface option. The EXTERNAL regulation mode hasbeen selected. The serial interface is not detected by PCI07. The compressor stops.Possible causes:• 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 toconnect 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 configurationmenu).

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 compressorsalternately after connecting their PCI07 using the connectioncable.

Configuration of the PCI07:

To allow alternating operation of 2 compressors, configure thePCI07 of both compressors using the explanatory notice ref. 62

139 391 11.

Cabling:

The PCI07 of the two compressors must be with the optioncable by their X6 optional connectors. The shielded cable mustbe connected to the earth of each PCI. The shielded cable mustnot 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 thekey, this compressor operates separately its own regulation

settings and pressure sensor.

As soon as two compressors operate simultaneously, themain/backup mode is activated. The pressure sensor used forregulation 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 operationand is then stopped by its motor time-delay and its numberof startups per hour.

• When the pressure exceeds the regulation pressure,compressor the main set transfers onto no-load operationand is then stopped in relation to its motor time-delay and itsnumber of starts per hour.

• If the pressure falls below the regulation pressure less theregulation deviation, the main compressor transfers ontoload operation.

• If the pressure falls below the backup pressure less thebackup deviation, the backup compressor restarts if it hadstopped and transfers onto load operation.

Alternancy:

The operation described previously is reversed every 24hours or every week based on the selected operating mode.

During a permutation, compressor A is regulated accordingto the main set point and compressor B according to the backupset point.

On the next permutation, compressor A regulates accordingto the backup set point and compressor B according to the mainset point.

Timer management:

Each compressor operates through its own timers. Assoon as one compressor is outside its programmed operatingtimes, the « CAUTION: AUTOMATIC RESTART BY TIMER »message is displayed. The second compressor then operatesindependently and based on its own settings and its own sensor.The « MAIN » and « BACKUP » display disappears.When both compressors are in their programmed operatingtimes, the main/backup mode is automatically reactivated.

Protection management

On a malfunction of one of the two compressors or shutdownunder pressure, this transfers to autonomous operation and eachone regulates according to its own measured pressure and itsown regulation set point. Thus, if a fault appears on one set or ifit is stopped by a user, the other set is not blocked and transfersonto 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 ofcompressor status.

Interface description:

The bidirectional serial interface continually communicates

with the electronics board controlling the compressor. The dataare sent from the board to the interface and vice versa via acable.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 ofregulation 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 ofthe compressor. The input is activated if the externalregulation mode is selected in the programming menu.

Outputs:• output 1: unused• output 2: compressor internal regulation status

Pressure switch type output reflecting the compressortheoretical operating mode (load or no load) relative to theregulation instructions set on PCI07. Active output whenoperating with load.

• output 3: local / remote regulation This output reflects the regulation mode configured on PCI07(internal or external regulation). With internal regulation, thecompressor uses its own settings and internal pressuresensor to regulate operation. In external regulation, input 2 isused for the load or no-load start order. Active output inexternal 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 (nofault, machine energized and start pressed)

• output 6: general fault Active output when no fault.

On a break of the communication cable connecting PCI07 andthe interface, the outputs are inactive (open). If PCI07 isconfigured for external regulation, this changes to fault.

Chapter 5 - Temperature protectiontest

The temperature protection trip of a compressor can betested. This test has to be carried out once every year in order tocheck 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 programmingmenu (press on key F4 longer than 3 seconds).

• In the programming menu, press on keys Ο and | simultaneously. The « TEMPERATURE SYSTEMTEST » message comes on.

When the « TEMPERATURE SYSTEM TEST » message isdisplayed, the compressor is ready to carry out a temperatureprotection trip test. For this test, the maximum operatingtemperature setting is less than 60 °C in order to cause trippingof 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 testis valid.

• Eliminate the fault by pressing on the reset key F3.

After eliminating the fault, the maximum temperature settingautomatically adopts its initial value. The compressor is able tooperate normally .


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Chapter 6 - Factory settings

Data Message example Unit Possible choices Factory setting

Language selection English /

FrançaisEnglishEspanolItaliano Deutsch

NederlandsPortuguesaSvenska

English

Air filter service life Air filter h 500 to 9500 2000Oil filter service life Oil filter h 500 to 9500 2000

2000 – 3000, 15 - 40 40 to 220Separator service life Separator h 500 to 9500

4000 h 6000 hOil service life Oil change h 500 to 9500 2000

Bearings service life Motor bearings h100 to 9900

--- : inhibited counter---

No-load motor operating time Offload minimum time min 1 to 30 1Machine number Unit number / 0 to 7 0

Condensate drain frequencyCondensate drain

Freq.min 1 to 30 ≤100ch >100ch

3 2

Condensate drain durationCondensate drain

Durations 1 to 15

100ch2 4 6

Star phase timeMotor startups

Star times 1 to 15


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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 16Change air/oil separator maintenance 16Change oil maintenance 16Change oil filter maintenance 16Clock day setting 7,11Clock hour setting 7,11Clock minutes setting 7,11Clock month setting 7,11

Clock year setting 7,11Compressor A daily info/option 10,13Compressor A weekly info/option 10,13Compressor B setting 10,13,17Condensate drain duration setting 7,11Condensate drain fréq. setting 7,11

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

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

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

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

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

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


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*** O ***Offload info 14Offload minimum time setting 7,11Oil change setting/info 7,9,11,14Oil filter setting/info 7,9,11,14

Onload info 14Onload hours info 9,14Operation without timer setting 8,12Operation with timers setting 8,12

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

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

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

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

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


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*** W ***Warning : auto restart info 15Warning auto restart by timer info 6,15,18Warning, high temperature alarm 15Warning : remote restart info 6,15

Water cooling info 10,13Water flow fault fault 17


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Export Department U.K. Operation France

Phone : 33 (0) 3 44 52 67 31 Fax : 33 (0) 3 44 52 67 35

Zone industrielle – BP 804194 rue Émile ZolaF-60114 Méru Cedex

Great Britain

Phone : (01709) 87 69 20Fax : (01709) 87 62 34

Worthington Creyssensac Air Compressor

Products LtdUnit 4 Silverwood Court, Fairfield ParkManvers, Rotherham

South Yorkshire S63 SDB

Worthington - CreyssensacZone industrielle - BP 80419 - 4 rue Émile Zola - 60114 Méru Cedex

http://www.airwco.com

worthington instruction book pci07 en

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