"AIR CONTROL 2"

1. General:

The control unit consists of the following functional blocks:

a) Microprocessor logic (with EEPROM memory for data back-up) for all control, monitoring
and display functions;

b) Keyboard with 5 keys for switching the compressor on and off, and for entering recommended
and limit settings;

c) Customized LCD display for showing the current actual and recommended parameters and the
operating status, plus faults/warnings;

d) Analogue processing of network pressure, compressor temperature and air flow;

e) Digital inputs and outputs for selecting a compressor;

f) Serial interface (RS485) for selecting a frequency converter;

Air Control 2 / V 1.16 Page 1 of 32 24/10/2007

2. Hardware description:

2.1) Micro-processor logic:

Microprocessor controller with Watchdog,
Power failure detection (mains failure > 30 ms),
64 kbyte Flash EPROM,
256 byte EEPROM (for data backup),
4 kbytes RAM.

2.2) Keyboard:
5 keys,
Customised finish.

2.3) Display:
LCD with display area approx. 75mm* 50mm:
- 7-segment A => 3-digit, 7-segment display (top left);
- 7-segment B => 3-digit, 7-segment display (top right);
- 7-segment C => 1½--digit, 7-segment display (left centre);
- 7-segment D => 5-digit, 7-segment display (down);
- symbols for units: oC, oF, oK, bar, psi and MPa;
- symbols also for: fault, warning, motor, solenoid valve,
heating, fan, remote operation, restart, automatic (mode),
BLCO (GLW [Baseload Selection] mode);

1 LED (red);

2.4) Pressure sensor:

The sensor (0-16 bar) is on the board

2.5) Analogue inputs:

1 x temperature sensor input (KTY 11-7);
1 x 2nd temperature sensor input (present on "new" Air Control 2 only)
1 x fan current monitoring (0-16 A)

Air Control 2 / V 1.16 Page 2 of 32 24/10/2007

2.6) Digital inputs:
1 ×12V DC PTC temperature sensor input;
1 x input for air flow monitoring (only possible on Air Control-2);
5 additional inputs for option cards (only possible on Air Control-2)

2.7) Digital outputs:

3 x relay outputs, closers
1 x relay output, selector

2.8) Networking (Option)

1 x additional RS485 interface

2.9) Power supplies, terminals, casing

Power supply 230V AC (50/60 Hz);

2.10 Wiring:
1 Signal + (A) ) [Frequency Converter: R+]
2 Signal – (B) ) 1st RS485 interface [FU: R+]
3 Earth ) (Frequency converter)
4 NC )
5 Common ) group fault (potential-free)
6 NO )

7 Common ) Heating selection

8 NO ) (potential-free)

9 Mains phase )
10 N ) 230V~ mains feed
11 Equipotential )

12 Motor phase )
13 N ) Fan motor selection
14 Equipotential )

15 Valve phase )
16 N) Solenoid valve selections
17 Equipotential )

18 Earth )
19 Signal - (B) ) Option: 2nd RS485 interface
20 Signal + (A) ) [Viewing/GLW]

Air Control 2 / V 1.16 Page 3 of 32 24/10/2007

 21 PTC sensor voltage (12V DC) )
22 PTC input ) Motor temperature

23 KTY input ) Compressor temperature

24 KTY earth )

25 KTY 2 input ) heating temperature

26 KTY 2 earth )

27 Sensor voltage (24 V DC) )

28 Digital input “DE 1” ) Fan OK (1=OK)

29 Sensor voltage (24 V DC) )

30 Digital input “DE 2” ) Remote on/off (1=On)

31 Sensor voltage (24 V DC) )

32 Digital input “DE 3” ) Remote load/idle (1=load)

33 Sensor voltage (24 V DC) )

34 Digital input “DE 4” ) GLW OK (1=OK)

35 Sensor voltage (24 V DC) ) Temp. restriction,

36 Digital input “DE 5” ) heating (1=OK)

37 Sensor voltage (24 V DC) )

38 Digital input “DE 6” ) Dryer OK (1=OK)

Attention: Terminals 28 to 38 only exist on the “new” Air Control-2, whereby

terminals 18 to 20(!) and 29 to 38 are to be found on the option board!

The inputs on the FU control will not be processed if an option board is

available!!!

Air Control 2 / V 1.16 Page 4 of 32 24/10/2007

 Terminal assignment on the "new" Air Control-2

20 Schnittstelle 2
19 RS485
18

38
Optionsmodul 37 DE 6 (Trockner ok)
steckbar 36 steckbares
35 DE 5 (Temp.Begrenz.)) I/O Erweterungs-
34 modul
33 DE 4 (GLW ok)
32 DE 3 (Fern Last/Leer)
31
30
29 DE 2 (Fern Ein/Aus)

DE 1 (Lüfter ok) 28 28
27 DE 1 (Lüfter ok)
27
KTY 2 (Heizung) 26 26 Grundplatine
25 25 KTY 2 (Heizung)

17

24
10

12

13

14
15
16

21
22
23
11
1
2
3

4
5
6

7
8

KTY 1 (Verdichter
Netzeinspeisung
Sammelstörung

(Schlauch 6mm)
Schnittstelle 1

temp.)
(potentialfrei)

(potentialfrei)

Magnetventil

Drucksensor
Lüftermotor
(Frequenz-
umrichter)

Anschluß
Heizung
RS485

PTC

Air Control 2 / V 1.16 Page 5 of 32 24/10/2007

 Terminal assignment on the "old" Air Control-2

X91

X90

Steckplatz für
op tio nale Schnittste lle
(RS-48 5)

X82
Anschluß
Drucksensor
(Schla uch 6x1 mm)
X80

X1 X2 X3 X4 X5 X6 X7 X8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Air Control 2 / V 1.16 Page 6 of 32 24/10/2007

3. Software description:

3.1) Key assignment:

If a key is assigned to multiple use, then the next position is selected each time it is pressed.

, : Editing recommended/limit settings/codes

ENTER : Taking the edited value into the current variable;

* Default display => display/editing of:

7-segment C 7-segment D Parameters

[ 1] [ ##.#] Lower pressure threshold (3.5-15.0 bar)
[ 2] [ ##.#] Upper pressure threshold (3.5-15.0 bar)
[ 3] [ ##.#] Safety pressure (display only)
[ 4] [ 05.0] Minimum compressor temperature (display only)
[ 5] [ 110] Maximum compressor temperature (display only)
[ 6] [#####] Total runtime
[ 7] [#####] Runtime on load
[ 8] [#####] Remaining air filter time (display only)
[ 9] [#####] Remaining time oil/oil filter (display only)
[10] [#####] Remaining oil separator time (display only)
[11] [#####] Remaining lubrication time (display only)
[12] [#####] Remaining compressor time (display only)

0 (1) If compressor ON:

Switch off compressor;
(2) After a fault has occurred:
Clearing the fault report (= RESET key)
(3) Key pressed longer than 3 seconds:
Enter the code (only possible if system OFF);

<red LED> : flashes for warning/service message, steady light for fault;

I : Switch on compressor;

Settings which you call up in the default display via the "ENTER" key can only be changed if the
CODE 0011 is entered beforehand. Without this code, these values can only be displayed.

Air Control 2 / V 1.16 Page 7 of 32 24/10/2007

3.2) Other parameter inputs:

3.2.1) Mode: (refer also to: Item. 3.5.2)

Enter code 0002 => 7-segment A,B 000 002

1
7-segment C # 1 = Mode
7-segment D

0 = AUTOMATIC
1 = LOAD/NO LOAD
2 = OPTIONAL
AUTOMATIC (II)

The following 2 parameters only then appear if

OPTIONAL AUTOMATIC mode has been activated.

ENTER => 7-segment A,B 000 002

2
7-segment C 2=
#.# max. Pressure drop
7-segment D Ran ge: 0 - 9.9 bar

max. pressure drop after selecting No Load

ENTER => 7-segment A,B 000 002

7-segment C 3 3= max. no. of cycles
##
7-segment D Ran ge: 1 - 55

maximum permissible cycles, compressor motor

- If AUTOMATIC mode is selected, then this is displayed using the Automatic

symbol.

- If OPTIONAL AUTOMATIC mode is selected, then this is also marked by the II

symbol under the temperature indicator.

Air Control 2 / V 1.16 Page 8 of 32 24/10/2007

3.2.2) Automatic restart after a power cut: (refer also to: item 3.5.10)

enter code 0003 => 7-segment A,B 000 003

1
7-segment C #
7-segment D

0 = Restart OFF
1 = Restart ON

If restart has been activated, this is shown using the Restart symbol.

3.2.3) Local operation or remote control:

Enter code 0008 => 7-segment A,B 000 008

1
7-segment C #
7-segment D

0 = Local operation (ON/OFF only via the keyboard)

1 = Remote control (ON via the optional RS485 interface, if Local keyed;
or “S1” input of the FU control
or "DE 2” input of options board
(OFF via the optional RS485 interface,
or “S1” input of the FU control
or "DE 2” input of options board
or via the 0 key)

If remote control has been switched in and the systems is keyed (via the I key), then this is
indicated by the Remote symbol

If the system is switched off using the 0 key, then the Remote symbol in the LCD is
extinguished once more.

ATTENTION: The parameters must be assigned for the“S” input

on the FU control if they are to be processed by the “Air Control 2”!

The FU control inputs are only processed if there is no option board is

present!

Air Control 2 / V 1.16 Page 9 of 32 24/10/2007

3.2.4) GLW mode (system works as GLW slave):

Enter code 0018 => 7-segment A,B 000 018

7-segment C 1
#
7-segment D

0 = not GLW mode, i.e. Load/No load via local

pressure sensor

1 = GLW mode, Load/No load via the optional RS485

interface
or input “S2” on FU control
or input “DE 3” on option board

If GLW mode has been activated and the GLW OK signal from the GLW higher control unit (via
RS485 or via input S4 on the Fu control or input “DE 4” on the option board) is present, then this
is indicated by the BLCO symbol in the LCD

In GLW mode, the local pressure sensor is used purely for monitoring the safety pressure
(P_ALLOWED).

If the data exchange via the interface is interrupted for more than 20 seconds and signal “GLW-
OK” from input “S4” on the FU control or from input “DE 4” on the option board, then the
control unit switches back to Local mode.
The BLCO symbol in this case is again extinguished in the LCD.

Attention! Inputs “S2” and “S4” must be configured correspondingly on the FU

control if they are to be processed by the Ai4rControl-2!
Input “S4” is available from plant type “SOLO-11” for Air Control-2. For
types “SOLO-6/7” this input is permanently configured to “0”!

The inputs from the FU control will only be processed if no option boards
are present!

Air Control 2 / V 1.16 Page 10 of 32 24/10/2007

3.2.5) Editing the recommended service interval settings:

a) Air filter:
Enter code 0041 => 7-segment A,B 000 041
1
7-segment C
#####h
7-segment D

b) Oil/oil filter:
Enter code 0042 => 7-segment A,B 000 042
1
7-segment C #####h
7-segment D

c) Oil separator:
Enter code 0043 => 7-segment A,B 000 043
7-segment C 1
#####h
7-segment D

d) Motor lubrication:
Enter code 0044 => 7-segment A,B 000 044
7-segment C 1
7-segment D #####h

e) Compressor:
Enter code 0045 => 7-segment A,B 000 045
7-segment C 1
#####h
7-segment CD

You can use the arrow keys in steps of 500 to select the relevant recommended value,
and then accept with the ENTER key (range: 0-20,000 hours).

If you accept a recommended setting with the ENTER key, then the relevant
interval (remaining time) is also started afresh with the recommended setting.

Air Control 2 / V 1.16 Page 11 of 32 24/10/2007

3.2.6) No Load time/Shutdown time:

Enter code 0051 => 7-segment A,B 000 051

7-segment C 1 1 = No load time
####s
7-segment D Range: 10-1200 seconds

ENTER => 7-segment A,B 000 051

7-segment C 2 2 = Shutdown time
###s
7-segment D Range: 0-120 seconds

ENTER => 7-segment A,B 000 051

7-segment C 3 3 = Run-up time
##s
7-segment D Range: 1 - 60 seconds

The Run-up Time is used to delay Frequency Converter ON until the load valve is selected.

Set the relevant recommended value with the arrow keys and then confirm with the ENTER key.

3.2.7) Pressure measurement correction setting:

Enter code 0105 => 7-segment A,B 000 105

7-segment C 1
##.#
7-segment D

Now use the arrow keys to enter a setting of -0.5 to +0.5.

Air Control 2 / V 1.16 Page 12 of 32 24/10/2007

3.2.8) Supplementary heating/Upper temperature threshold

Enter code 0015 => 7-segment A,B 000 015

7-segment C 1 1 = Mode
#
7-segment D

Mode: 0 = no supplementary heating ) Cycle see

1 = Supplementary heating ) heading 3.5.7

ENTER => 7-segment A,B 000 015

7-segment C 2 2 = Upper threshold
##
7-segment D temperature.Range: 5 – 80°C

This temperature is only used for switching the supplementary heating on and off if Mode = 1 and
the compressor is in operation. (refer also to heading 3.5.7)

If the additional heating is deactivated (Mode = 0) then the KTY sensor

(heating temperature / only available on “new” Air Control 2!) will no longer be
monitored for line faults.
In this case, the 1st KRY sensor (compressor temperature ) will be used for the control of
relay outputs for the additional heating system.

Air Control 2 / V 1.16 Page 13 of 32 24/10/2007

3.2.9) Fan current monitoring:

Enter code 0005 => 7-segment A,B 000 005

7-segment C 1 1 = max. fan current
##.# A
7-segment D Range: 0.1 - 10.0A

ENTER => 7-segment A,B 000 005

7-segment C 2 2 = Delay
##s
7-segment D Range: 0 - 99 seconds

ENTER => 7-segment A,B 000 005

7-segment C 3
##.# A
3 = min. fan current
7-segment D Range: 0.0 - 10.0A

The fan is switched on and off using the compressor motor.

After the fan has been switched on, the set delay time (0-99 seconds) elapses before the fan
current is monitored at the set threshold.

If the fan current is higher than the set maximum fan current (or input DE 1 / fan OK, terminals
27 + 28) are open after this delay time has elapsed, then the compressor is switched off with fault
[7] "HiCur".

If the fan current is lower than the set minimum fan current after this delay time has elapsed,
then the compressor is switched off with fault [8] "LoCur".

Air Control 2 / V 1.16 Page 14 of 32 24/10/2007

3.2.10) Convert temperature display unit:

Enter code 0090 => 7-segment A,B 000 090

1
7-segment C #
7-segment D

0 = Pressure display in [bar]

1 = Pressure display in [MPa]
2 = Pressure display in [psi]

3.2.11) Convert temperature display unit:

Enter code 0095 => 7-segment A,B 000 095

1
7-segment C #
7-segment D

0 = Temperature display in [°C]

1 = Temperature display in [°F]
2 = Temperature display in [°K]

Air Control 2 / V 1.16 Page 15 of 32 24/10/2007

3.2.12) Set system address: (PC connection/viewing/GLW)

Enter code 9950 => 7-segment A,B 009 950

7-segment C 1
##
1 = Address
7-segment D

00 = The optional RS485 interface is switched off.

01..16 = The system is (e.g. from the PC) contacted via the relevant
address.

N.B.: You must ensure that a separate address is set for each connected system.
The relevant interface module (RS485) must also be available in the control unit.

ENTER => 7-segment A,B 009 950

2
7-segment C # 2 = Mode
7-segment D

0 = Data can be read from the control unit via the interface, and the
settings in the control unit can also be changed.
1 = Only data from the control unit can be read via the interface.

ENTER => 7-segment A,B 009 950

3
7-segment C # 3 = Baud speed
7-segment D

0 = 4800 bauds (default setting)

1 = 9600 bauds
2 = 19200 bauds

CAUTION: You must ensure that the same baud rate

(transfer speed) is set for each connected system.

Air Control 2 / V 1.16 Page 16 of 32 24/10/2007

3.2.13) Fault memory:

a) Display fault memory:

Enter code 0030 ...

7-segment A,B => Err ### Item: 01 – 20

7-segment C => ##
#####h
Fault/warning number
7-segment D => Total runtime when
the fault/warning occurred

If the symbol [warning triangle] is included, then this entry is a

warning/service.
If the symbol [tool] is included, then this entry is a
fault.

If the relevant item is unassigned, then the following display appears:

7-segment A,B => Err ###

-
7-segment C => -----
7-segment D =>

Use the arrow keys to scroll through the 20 items in the

Item 1 always contains the most recent fault.

Individual items in the fault memory are stored in the EEPROM memory,
and are therefore still available after a power cut.

b) Clear fault memory:

Enter code 0130 ... The fault memory is cleared.

Air Control 2 / V 1.16 Page 17 of 32 24/10/2007

3.2.14) Digital input/output test:

Enter code 9980 => 7-segment A,B 009 980

7-segment C 1 1 = PTC input
7-segment D # (0 = off / 1 = On)

ENTER => 7-segment A,B 009 980

7-segment C 2 2 = Input 1 Fan OK
7-segment D # (0 = off / 1 = on)

ENTER => 7-segment A,B 009 980

7-segment C 3 3 = Input 2, Option card
#
7-segment D (0 = off / 1 = on)

ENTER => 7-segment A,B 009 980

7-segment C 7 7 = Input 2 , Option card
7-segment D # (0 = off / 1 = on)

ENTER => 7-segment A,B 009 980

7-segment C 8 8 = Output 1
7-segment D # (0 = off / 1 = on)

ENTER => 7-segment A,B 009 980

11
7-segment C # 11 = Output 4
7-segment D (0 = off / 1 = on)

Input 1 “Fan OK” only exists on the “new” Air Control-2.

Inputs 2 to 6 (option card) only exist if the corresponding
option card is installed (only possible on “new” Air Control-2).

With the output signals, you can use the arrow keys to switch
the relevant output ON- ( key) or OFF (key).

Press the ENTER key to switch to the next stage on each occasion
(in this situation, the outputs are always switched off initially).
You return to the default display after the final stage.

Air Control 2 / V 1.16 Page 18 of 32 24/10/2007

3.2.15) Control settings for selecting the frequency converter:

Enter code 0075 => 7-segment A,B 000 075

7-segment B 1
##.#
7-segment C Speed lowering from:

This presets the pressure from which the maximum recommended setting for the FU is limited.
(Range: 5.0 to 13.0 bars//default setting: 5.0 bars on the “Solo 15”: 8.0 bars )

ENTER => 7-segment A,B 000 075

7-segment C 2
##.#
7-segment D Speed lowering to:

This presets the pressure from which the maximum recommended setting for the FU is
no longer limited. (Range: 5.0 to 13.0 bar//default setting: 13.0 bar)

ENTER => 7-segment A,B 000 075

7-segment C 3
#
7-segment D Speed lowering to:

This presets the current at which the maximum recommended setting is lowered furthest.
(Range: 3 to 15 mA//default setting: 12 mA//20mA = FU 100%)

ENTER => 7-segment A,B 000 075

4
7-segment C ###
7-segment D Percentage recommended
value:

This presets the recommended value within the current governed pressure range. (Range: 0 to
100% //default setting: 50%)

Example: 0% => recommended value = lower pressure threshold;

50% => recommended value = (lower pressure threshold + upper
pressure threshold)/2;
100% => recommended value = upper pressure threshold;

Air Control 2 / V 1.16 Page 19 of 32 24/10/2007

 ENTER => 7-segment A,B 000 075
7-segment C 5
###
7-segment D Control factor:

This sets the control factor (P proportion of the controller).

(Range: 1 to 999//default setting: 110)

ENTER => 7-segment A,B 000 075

7-segment C 6
####s
7-segment D Adjustment time:

The adjustment time is set here (I proportion of the controller at 0 => no I proportion) .
(Range: 0 to 9999 seconds//default setting: 8 seconds).

ENTER => 7-segment A,B 000 075

7-segment C 7
###
7-segment D max. recommended value

Here you can define the maximum recommended value that may be sent to the FU.
(Range: 50 to 100% //default setting: 100%)

ENTER => 7-segment A,B 000 075

8
7-segment C ###
7-segment D min. control range

Here you can define the minimum value as a percentage for the speed of the inverter machine
(= idle speed). The value configured here must match the value configured for the frequency
converter! (Range: 0 % to 100%)

Air Control 2 / V 1.16 Page 20 of 32 24/10/2007

3.2.16) Set system type, pressure range and quantity delivered:

Enter code 0060 => 7-segment A,B 000 060

7-segment C 1
#####
7-segment D

System type: Solo 6/7/11/15

Dependent on the system type selected here, the following parameters: Run-up time, maximum
number of cycles (ABO), No load time, speed reduction by (mA), mA) “speed reduction (bar)”,
min. control range (%) and the servicing intervals are preset with the backing table values.

ENTER => 7-segment A,B 000 060

7-segment C 2
##.#
7-segment D

Pressure range: 7.0 - 15.0 bar

The upper pressure threshold is preset to the value chosen here and the lower pressure threshold
is preset to 2.0 bar.
The pressure range set here is also used as the upper limit when editing the lower and upper
pressure threshold settings (refer to: Item 3.1/ENTER key).

ENTER => 7-segment A,B 000 060

3
7-segment C ##.#
7-segment D

Pressure range: 7.0 - 15.0 bar

Max quantity delivered 0 – 9999 m³/h

The maximum quantity delivered for the compressor is specified here (in m³/h !)

Air Control 2 / V 1.16 Page 21 of 32 24/10/2007

3.2.17) Set “with dryer” option:

Enter code 0080 => 7-segment A,B 000 080

7-segment C 1
#####
7-segment D

Range: 0 = without / 1 = with dryer

If the value “1” (i.e. “with dryer”) is programmed, then a fault message will be triggered if signal
"dryer OK" on input "S3" of the FU control is missing.

If an option board is installed then a fault message will be triggered if the signal “Dryer OK”
(DE 6) is missing.

Caution: Input “S3” must be configured to the FU control if it is to be controlled by

the “Air Control-2”. This input is available only from plant type “SOLO-
11” up for Air Control-2. For types “SOLO-6/7” this input is permanently
configured to “1”!

The inputs from the FU control will only be processed if no option boards
are available!

Air Control 2 / V 1.16 Page 22 of 32 24/10/2007

3.3) Depiction on the LCD of the operating/display unit:

Top: - left: 7-segment pressure indicator ("7-segment A");

Symbols for: MPa, psi, bar;
- right: 7-segment temperature indicator ("7-segment B");
Symbols for: °C/°F/°K
Centre: - 7-segment display ("7-segment C");
Symbols for: fault, warning/servicing, automatic, remote, restart,
motor, solenoid valve, heating, fan;

Bottom: - 7-segment display ("7-segment D");

- Symbols for: BLCO, hours, minutes, seconds;

3.3.1) Default display:

7-segment A: - current network pressure "10.2 bar"

7-segment B: - current compressor temperature "52 °C"

7-segment C: - no display (no Load mode, no fault/warning);

- number of the active fault (if tool on);
- number of the active warning/servicing message (if warning triangle on);

7-segment D: a) if fault/warning: fault/warning text (abbreviation, 5 characters);

b) no fault/warning: running shutdown or tracking time;
or current setting [0-100%] for frequency
converter (in Load mode);

3.3.2) Input code:

In the default display, press the 0 key for approx. 3 seconds ...

7-segment A,B: cod

7-segment C:
####
7-segment D:

Now use the arrow keys to enter the relevant code.

Press the ENTER key to accept the code or the 0 key to reject the input.

Air Control 2 / V 1.16 Page 23 of 32 24/10/2007

3.4) Processing faults/warnings:

3.4.1) Fault: The Tool symbol flashes and the relevant number is shown
flashing in the "7-segment C" field.

7-Segm.C 7-Segm.D
[ 1] [Por ] "Incorrect setting" (Change recommended pressure settings)
[ 2] [EPROm] "EEPROM?" (Change all settings)
[ 3] [Lo AC] "Low voltage" (only if detection is activated/refer to: item 3.6)
[ 4] [No AC] "Power cut" (only if Automatic Restart is not set)
[ 5] [DEFEC] "Incor.compens.setting" (Check for repairs/compensation)
[ 6] [mot t] "Motor temperature" (PTC )
[ 7] [hiCur] "Fan current too high" Fan current > max. fan current )_ and delay
[ 8] [LoCur] "Fan current too low" Fan current < min. fan current ) cycled
[ 9] [SE t ] "Temp.sensor def." (monitoring: KTY sensor 1 compressor temp.)
[10] [SE P ] "Press.sensor def." (monitoring: pressure sensor)
[11] [hi t ] "Compr.temp.too high" (Temperature > max. compression temperature)
[12] [hi P ] "Network pres.too high" (Network pressure > Safety pressure)
[13] [FU ] "FU fault" Frequency converter does not respond or registers a fault
[14] [dryEr] “Dryer fault” Signal “dryer OK” missing
[15] [SE t2] “Heating temp.sens.fault” (Monitoring: KTY sensor 2 / heating temperature)

If any of these faults appear, then this leads to the compressor switching off.
The red LED stays on until the fault has been cleared. The fault can only be cleared with the 0 key if
its cause has been rectified in the interim.

3.4.2) Warning/Servicing: The Warning Triangle symbol flashes and the relevant
number is shown flashing in the "7-segment C" field.

7-Segm.C 7-Segm.D
[ 2] [hi t ] "Compr.temperature up" (Temperature > max. compression temperature - 5°C )
[ 3] [hi P ] "Network pressure up" (pressure > [safety pressure - 0.3 bar])
[ 4] [Cold ] "Comp. temp. too low" (temperature < +1°C)
[ 5] [oilHE] "Oillevel/Heating" „Heating activated“, and no signal on „DE 5“

[11] [m Air] "Air filter servicing" (Time to service < 100 hours)
[12] [mOilF] "Oil/oil filter servicing" (Time to service < 100 hours)
[13] [m SEP] "Oil separator servicing" (Time to service < 100 hours)
[14] [m mot] "Lubrication servicing" (Time to service < 100 hours)
[15] [m Com] "Compressor servicing" (Time to service < 100 hours)

The compressor is not switched off if a warning or servicing message is displayed.

The red light flashes until the reason for the warning is eliminated or until the relevant servicing
interval has been cleared. Normally, a fault/warning is indicated immediately.
However, if the user has pressed the ENTER key, to enter recommended or limit settings, then
the fault/warning is displayed only when the user has switched back to the default display.

Air Control 2 / V 1.16 Page 24 of 32 24/10/2007

3.5) Information on the programme:

3.5.1) Modes:

a) the compressor is switched off:

- the Motor and Solenoid Valve symbols are off (LCD)

b) the compressor is switched on, but the current pressure is still higher than the lower
pressure threshold (run-up guard).
- the Motor and Solenoid valve symbols are off
- the text “run” =is flashing in the lower 7-segment indicator

c) The compressor is switched on, but the compressor temperature (or heating temperature if
operated “with heating”) is still less than +1°C
- the Motor and Solenoid valve symbols are off
- the temperature unit symbol is flashing (LCD: °C/°F/K)
- the text “cold” =is flashing in the lower 7-segment indicator

d) The compressor is in operation, but the load valve is switched off, i.e. the compressor is not
compressing. (run-up phase or no load)
- the Motor symbol is on
- the Load Valve symbol is off

If the compressor is in the "Automatic" operating mode, or "Automatic Opt." and the idling
time is active, this is shown in the lower 7-segment display.*

e) The compressor is in operation and the load valve is switched on,

i.e. the compressor is compressing. (Load)
- the Motor symbol is on
- the Load Valve symbol is on
- the current setting for the frequency converter is shown in the bottom line
(7-Segm.D) ("Fu ###" // ### = 0-100%)

Air Control 2 / V 1.16 Page 25 of 32 24/10/2007

 3.5.1) Modes: (refer also to: item 3.2.1)

a) AUTOMATIC mode:

After reaching the upper pressure threshold, the system moves to NO LOAD for the duration of
the tracking time (see: 3.2.6).
After the no load time has elapsed, the motor switches off.
After switching off, the text run flashes => ready for a new start-up.
As soon as the pressure is again less than the lower pressure threshold, the system restarts.

b) LOAD/NO LOAD mode:

The compressor alternates between Load and No Load modes, i.e. it tracks with no time
restriction.

c) OPTIONAL AUTOMATIC mode: (refer also to: Item 3.2.1)

The symbol II (to the right below the temperature display) and the Automatic symbol are
selected as the coding for OPTIONAL AUTOMATIC MODE.

Whenever the system alternates between Load and No Load modes, then after 10 and 40
seconds respectively, the network pressure is memorised.
If the pressure drop thus calculates is above the threshold (ABO PRESSURE DIFFERENCE),
then the system remains in No Load mode for the "long" tracking time (Item 3.2.6/NO LOAD
CYCLE) and, if not, then switches off after a "short" tracking time (45 seconds).

Each time the compressor motor starts up, an internal counter (number of switches) is
incremented by 1. As soon as this counter reaches the preset maximum number of cycles
(MAX. CYCLES), the motor no longer switches off after the tracking time has elapsed, but
remains in No Load mode until the counter is again below the relevant threshold [MAX.
CYCLES].

After one complete cycle (tSP = 3600 seconds/max. cycles) the counter is decremented by 1
again.

Air Control 2 / V 1.16 Page 26 of 32 24/10/2007

3.5.3) Switch on process:

If the current network pressure is above the set pressure threshold when the compressor is
switched on, then the text run flashes. Only when the network pressure falls below the threshold
does the compressor start.
If the compressor temperature (or heating temperature if operated “with heating”) when
switching on is below +1°C, then the temperature unit (°C/°F/°K) flashes, as does the text
“Cold”.
If the temperature then rises to at least +1°C, then the compressor starts up. (refer to item 3.5.7)

3.5.4) Switch-off process:

If you switch the compressor of using the 0 key (or the optional RS485 interface, then it switches
first into No Load mode. The remaining No Load cycle time is shown in the lower 7-segment
indicator.
The shutdown time is used as the time here (see item 3.2.6).
Only after this time has elapsed does the system switch off completely.

3.5.5) Shutdown time:

(see: item 3.5.10/automatic restart)

3.5.6) Safety pressure: ("P_ZUL")

The safety pressure is the set pressure range + 0.8 bar.

(For pressure range, refer to: Item 3.2.16)

Example: Pressure range = 10 bar => "P_allowed" = 10.8 bar

If the pressure exceeds the "P_allowed – 0.3 bar", then a warning is registered.
If the pressure exceeds the "P_allowed" threshold, then the compressor is switched off and a fault
message is displayed.

Air Control 2 / V 1.16 Page 27 of 32 24/10/2007

3.5.7) Supplementary heating function: (refer also to: 3.2.8 + 3.2.9)

a) "no heating"

If the heating temperature falls below the threshold [min. compressor temperature], the
Supplementary Heating output is switched on.
As soon as the heating temperature rises above the threshold [minimum compression
temperature + 2°C], the output is switched off once more.

b) "heating"/compressor is OFF/master switch is ON

If the heating temperature falls below the threshold [minimum compression temperature],
then the Supplementary Heating output is switched on.
As soon as the heating temperature rises above the threshold [minimum compression
temperature + 2°C], the output is switched off again.

c) "heating"/compressor is ON

If the heating temperature is below the - 3°C switch-off temperature threshold

(refer to item 3.2.8), then the Supplementary Heating output is switched on.
As soon as the upper temperature threshold has been reached, or if the compressor is switched
off, then the output switches off again.

If the function “heating” is activated, and the signal “temp.restriction” (“DE 5”) is missing,
then warning [5] (“oilleval/heating”) will be displayed.

The “new” Air Control-2 must have its own KTY filter fitted for heating temperature (b + c).
The “old” Air Control-2 always uses the compressor temperature!

In general, the compressor can only be started when the compressor temperature (or heating
temperature if operated “with heating”) has reached at least the threshold of +1°C.

If the supplementary heating output is switched on, then this is shown in the LCD using the
corresponding symbol.

Air Control 2 / V 1.16 Page 28 of 32 24/10/2007

3.5.8) Servicing intervals:

(Actual values, refer to: 3.1/recommended values refer to: 3.2.5)

a) Servicing requirement

The relevant intervals are enumerated below.

As soon as any of these intervals is less than 100 hours, the relevant message appears and the
red light flashes (=> Servicing).
To clear this message, first enter the code 0021 and then press the 0 key. This resets the relevant
interval to the recommended setting once more.

b) 1. Servicing for Oil/Oil Filter:

After the first service, the recommended value for the Oil/Oil Filter servicing interval is
changed automatically from 500 hours to 2000 hours.

3.5.9) System data default settings:

Enter CODE 0088 => all variable parameters are set to fixed default settings.

(N.B.: data that has been set previously by hand will be overwritten).

3.5.10) Sequence on Automatic Restart

If automatic restart after a power cut has been programmed, then the time which has been preset
in the "Shutdown time" (refer to item 3.2.6) will run after power has been restored. The Restart
symbol flashes while this time runs.

If the system was in operation before the power cut, then it will restart after this time has elapsed,
but will otherwise remain in STOP mode.
If Restart is activated, the Power Cut fault [4] will not be reported after power has been restored.

Air Control 2 / V 1.16 Page 29 of 32 24/10/2007

3.6) Codes used in the program:

0002 => Selection: AUTOMATIC, LOAD/NO LOAD, OPTIONAL AUTOMATIC mode

(+ supplementary settings for OPTIONAL AUTOMATIC mode)

0003 => Selection: automatic restart (Y/N) + time

0005 => Selection: Fan current monitoring settings

0008 => Selection: Local operation or remote control

0011 => Release: Release editing of recommended/limit settings which are called up via the
INFO key

0015 => Selection: Supplementary heating settings

0018 => Selection: GLW mode (0/1) [1 => System is GLW slave]

0021 => Call-up: Release COMPRESSOR SERVICING clearance

You then clear with the 0 key)

0030 => Call up: Show fault memory

0041 => Call up: Editing the Air Filter servicing interval
0042 => Call up: Editing the Oil/Oil Filter servicing interval
0043 => Call up: Editing the Oil separator servicing interval
0044 => Call up: Editing the Motor Lubrication servicing interval
0045 => Call up: Editing the Compressor servicing interval

0051 => Call up: Edit No Load, Shutdown time,

0060 => Call up: Select system, pressure range and quantity delivered (refer to: Item 3.2.16).
0062 => Call up: Only select the pressure range (e.g. following a software update)
0069 => Call up: Only enter quantity delivered (e.g. following a software update)

0075 => Call up: Set the parameters for selecting the frequency converter;
(see: Item 3.2.15)

0080 => Call up: Program option “with dryer” (see section 3.2.17)

Air Control 2 / V 1.16 Page 30 of 32 24/10/2007

 0088 => Call up: System data default settings (variable parameters)

0090 => Call up: Convert pressure indicator unit

0095 => Call-up: Convert temperature indicator unit

0105 => Call-up: Define pressure measurement correction factor

0130 => Call-up: Erase fault memory

9900 => Release: Initializing (then press the 0 key.)

- Set runtime/load time to 0;
- Servicing intervals => recommended values;
- Erase fault memory;
N.B.: (only designed for 1 start-up.)

9919 => Release: Edit operating/load hours

Next, call up the relevant settings using the INFO key

9929 => Release: Edit operating/load hours ...

The operating/load hours can be edited in steps of 1000 hrs.

9950 => Call-up Set system address, interface mode, and baud speed [PC link]

9970 => Call-up Set the behavior when power is restored after a "Low Voltage" warning

9980 => Call-up Test of inputs/outputs

9999 => Call-up Show current program version

13.0 AC2 Air Control-2 ( standard: 13 bar )

P 1.16 Ö “OLD”
Software version 1.16

10.0 AC2 Air Control-2 ( version: 10bar )

2 Ö “NEW”
P 1.16
Software version 1.16

Air Control 2 / V 1.16 Page 31 of 32 24/10/2007

3.7) Fault in the control unit programming memory

After switching the mains on, if an error in the programming memory (Flash EPROM) has been
detected, the following message then appears in the lower 7-segment indicator:

"FLASH" => In this case, the program must be reloaded into the control unit.

3.8) Transferring a new program to the control unit;

- Switch off the power supply to the control unit;

- Press the ▲ and 0 keys simultaneously and switch on the power supply again at the same
time

- FLASH now appears in the indicator.

=> The relevant program (hexadecimal file) can now be transferred to the control unit.

To do this, connect the control unit via an RS232/RS485 interface adapter

via the first interface (= FU connection) with the relevant PC (PC software setting:
19200 bauds).

3.9) Frequency converter settings:

- You set the following FU interface parameters

* Recommended setting scaling: 0.1%

* control unit and recommended value: MemoBus

* Slave address: 1
* Baud speed: 9600
* Parity: even
* Pause when sending: 10 ms
* RTS control: active

Air Control 2 / V 1.16 Page 32 of 32 24/10/2007