SCHULZ COMPRESSORS 434379 Controll III Electronic Interface Instruction Manual
- May 21, 2024
- SCHULZ COMPRESSORS
Table of Contents
SCHULZ COMPRESSORS 434379 Controll III Electronic Interface
Product Information
The Electronic Interface is designed to provide the user with key information regarding compressor control, monitoring of measured quantities, protection of several compressor components, and maintenance information. The interface has a bright display and seven keys on its front panel and can be modified according to the actual compressor usage needs easily and safely. The interface also has several indication LEDs, including stop button, start/stop configuration, relief, down/decrease, up/increase, to the side/enter, and return.
Navigation in Menus
The interface display has indication LEDs that turn on after powering up the interface and when the compressor is running. The LED will flash when an alarm is active, and it will remain fully on when an error is active. After powering up, the display will show the SCHULZ COMPRESSORS screen. After five seconds, the main menu will be displayed. The main menu has two menu screen levels – menu operacao (operation) and menu usuario (user). In the menu press to modify the parameter that is being displayed on the screen. To enter the menu, you will need to enter a password.
Product Usage Instructions
- Read the entire manual before making any changes to the interface parameters.
- If you have any questions, contact the nearest SCHULZ CUSTOMER SERVICE CENTER.
- To navigate in menus, use the keys on the interface’s front panel.
- Press or to position the cursor on MENU OPERACAO (OPERATION). Press the button to enter the menu.
- In the menu press to modify the parameter that is being displayed on the screen. Enter the password to make any changes.
- After the screen displays the information, press. The load pressure value will begin to flash. Press or to change the value. When finished, press to confirm and save. The interface will beep.
- We recommend that parameters are changed only by an authorized Schulz Technical Service Agent.
Introduction
Introduction
The purpose of the Electronic Interface is to provide the user with key information regarding compressor control, monitoring of measured quantities, protection of several compressor components and maintenance information. The parameters in the Electronic Interface can be modified according to the actual compressor usage needs, simply and safely.
warning: Before making any changes to the interface parameters, read the entire manual. If you have any questions, please contact the nearest SCHULZ CUSTOMER SERVICE CENTER.
Electronic Interface
The interface has on its front panel a bright display and seven keys, as indicated in the figure below:
Keyboard
NAVIGATION IN MENUS
Indication LEDs
- turned on after the interface is powered up;
- turned on when the compressor is running;
- led will flash when an alarm is active; led will remain fully on when an error is active.
Status and Operations
The interface display will show the following conditions after power up:
After 5 seconds the main menu will be displayed.
Press the button for the main menu to show the screen below:
Press to go to the menu selection screen:
Operating Parameters
Press or to position the cursor on MENU OPERACAO (OPERATION). Press the button to enter the menu.
By pressing the button continuously you can check the following parameters:
- Main motor current (*);
- Fan motor current (*);
- Total operating time;
- Load time;
- Operating time since the last time the machine was started;
- Load time since the last time the machine was started;
- Hours for exchanging the oil filter;
- Separator element;
- Air filter;
- Oil;
- Motor grease;
- Re-tighten the belt;
- The last five errors;
- Product serial number;
- Communication network status (if used).
(*) Current sensors not available with the product. Without the sensors, the current displayed by the interface will be 0.0A (zero amps).
User Parameters
-
Press or to position the cursor on the MENU USUARIO (USER). Press the Enter button to enter the menu.
-
In the menu press to modify the parameter that is being displayed on the screen. You will need to enter a password.
A screen will be displayed to enter the password. The first digit of the password will flash. Press or to change the value. Then press to move the cursor to the next digit. Change it as done previously. Follow the same procedure to change the third and fourth digits of the password. Then press to confirm. We recommend that parameters are changed only by an authorized Schulz Technical Service Agent.
- After the screen displays the information above, press . The load pressure value will begin to flash. Press or to change the value. When finished, press to confirm and save. The interface will beep.
Functions of User Parameters (acess passaword: 9999)
Table 5.1
Parameters| Default Value| Function
(LOAD PRES)| . Bar| Load pressure value
(RELIEF PRES)| . Bar| Relief pressure value
(TEMP FAN ON)| ****
***ºC
| ****
Fan enabling temperature. If the value is set to 120 °C, the function is disabled
(TEMP FAN OFF)| *ºC| Fan disabling temperature
** (MOTOR PROTECTION DELAY)| ****
0008S
| When the interface is being used to perform the overload control of the main motor, this time is necessary to prevent the protection from being activated when the motor starts. This time must be greater than the star/delta time plus the load delay time.
(FAN DELAY TIME)
| ****
0006S
| When the interface is being used to perform the overload control of the fan
motor, this time is necessary to prevent the protection from being activated
when the motor starts.
(Y!J T ME)| ****
0006S
| Star/delta time. Used in the main motor activation. Note: for compressors
with direct start this time will be equal to zero.
(LOAD DELAY)| ****
0002S
| Load delay time. Time the compressor will remain in relief after the motor is started.
(RELIEF TIME)
| ****
0020M
| ****
Relief time. After this time, the compressor will go into standby mode and the motor will restart after the pressure reaches the load pressure.
(STOPPAGE TIME)
| ****
0010S
| Stoppage time. Time the compressor will remain in relief before turning off
the main motor when the button is pressed.
(RESTART TIME)| ****
0100S
| Restart time. The machine cannot be restarted before this time, after a stoppage event has occurred.
PART
| ****
LOCAL/ REMOTE
| When the remote mode is selected, both local and remote activation buttons will be active to turn the machine on and off.
When in local mode only the local activation buttons can perform this function.
(LOAD MODE)
| ****
AUTO/ MANUAL
| 1. When set to MANU: only when the pressure is above the relief pressure will the compressor automatically enter in relief. In all other cases the load/ relief function will only be performed by the button.
2. When set to AUTO, the load/relief function can be performed automatically by fluctuation of the network pressure.
(COMMUNICATION)
| ****
PROHIBITED/ COMPUTER/ SEQUENCE
| 1. When PROHIBITED is selected, the communication functions are disabled.
2. When COMPUTER is selected, Control III will function as a slave and will be able to communicate with a computer or other controller.
3. When set to SEQUENCE, the interface will be the master of a compressor network.
---|---|---
(NETWORK ADRESS)| ****
0255
| ****
Network Adress
(SEQ STATUS)
| ****
MASTER/ SLAVE
| 1. When the interface is configured as the network master.
2.When the interface is configured as a slave on a network controlled by another master.
(ROTATION TIME)
| ****
0099H
| Rotation time. When the pressure of the master compressor is betwe- en the
load and relief pressure, the master will perform the rotation of the slave
compressors at the time set in this parameter.
(NO. OF COMPRESSORS)| ****
0000
| ****
Number of compressors in the network.
(SEQ LOAD PRESSURE)| ****
6.5 Bar
| ****
In the network, a compressor will be activated or enter in load mode when the pressure is lower than the set value.
(SEQ RELIEF PRES- SURE)| ****
7.5 Bar
| In the network, a compressor will stop or enter in relief mode when the
pressure is above the set value.
(OIL FILTER RESET)| ****
0000H
| Time to exchange the oil filter. After exchanging the filter, the time must
be reset manually.
(SEP ELEM RESET)| ****
0000H
| Time for exchanging the air/oil separator element. After exchanging the
element, the time must be reset manually.
(AIR FILTER RESET)| ****
0000H
| Time to exchange the air filter. After exchanging the filter, the time must
be reset manually.
(OIL RESET)| ****
0000H
| Time for oil exchange. After changing the oil, the time must be reset
manually.
(MOTOR GREASE RESET)| ****
0000H
| Time to reapply grease on the motor. After reapplying grease on the motor
bearings, the time must be manually reset.
(BELT RESET)| ****
0000H
| Time to check belt tensioning. After tensioning the belt, the time must be manually reset.
(OIL FILTER SETUP)
| ****
9999H
| 1. Set the value at which the oil filter exchange indication alarm will occur.
2. Set the value to “0” to disable the oil filter exchange indication alarm.
(SEP ELEM SETUP)
| ****
9999H
| 1. Set the value at which the separator element exchange indication alarm will occur.
2. Set the value to “0” to disable the separator element exchange in- dication alarm.
(OIL SETUP)| ****
9999H
| 1. Set the value at which the oil change indication alarm will occur.
2. Set the value to “0” to disable the oil change indication alarm.
---|---|---
(MOTOR GREASE SETUP)| ****
9999H
| 1. Set the value at which the motor bearing grease indi- cation alarm will occur.
2.Set the value to “0” to disable the motor bearing grease indication alarm.
(BELT SETUP)| ****
9999H
| 1. Set the value at which the belt re-tension indication alarm will occur.
2. Set the value to “0” to disable the belt re-tension indication alarm.
(LANGUAGE)| Portuguese/Spanish or
Spanish/English
| ****
Select the language according to your preference.
(USER PASSWORD)| ****
| Parameter used by the user to change the access password.
Factory Parameters
The factory parameters can be unlocked and modified by a special password in the same way as the user parameters. The table below provides a detailed explanation of each of the parameters. We recommend that parameters are changed only by an authorized Schulz Technical Service Agent.
Table 6.1
Parameters| Default Value| Function
(MOTOR CURRENT)| MAXIMUM OVERLOAD VALUE / 1,2| When the main motor current is
1.2 times higher than the set value, the compressor will be shut down due to
overload on the main motor.
(FAN CURRENT)| MAXIMUM OVERLOAD VALUE / 1,2| When the motor fan current is
1.2 times greater than the set value, the compressor will be switched off due
to overloading the fan motor.
(ALARM TEMP)|
105ºC
| When the unload temperature of the compressor unit reaches the adjusted
value the interface will alarm, but the compressor will continue to operate.
(OVERHEATING)|
110ºC
| When the unload temperature of the compressor unit reaches the adjusted value, the interface will present an error and the compressor will shut down due to overheating.
(STOPPAGE PRESS)
|
According to the compressor
|
When the compressor unload pressure reaches the set value, the compressor will shut off due to overpressure.
(MAX RELIEF PRES)|
According to the compressor
| This is the maximum relief pressure of the machine. The relief pressure in
the User Menu cannot be greater than was is set in this parameter.
(TOTAL HOURS)| ****Hours| Modifies the total operating time.
(LOAD TIME IN HOURS)|
****Hours
|
Modifies the load time.
(RESET FAILURES)|
|
Resets the failure records.
---|---|---
(UNBALANCED CURR)|
0006
| Current Unbalance: Imax-Imin >=adjustment*Imin/10
If the set value is greater than 15 the current unbalance protec- tion will be disabled.
(PHASE FAILURE DELAY)|
005.0
| Phase failure protection: if one of the power phases fails for a longer time
than settings, the phase failure protection will be activated and an error
will turn off the compressor. Phase failure protection must be enabled.
(MANUFACTU- RING DATE)|
**--**
|
Compressor manufacturing date
(SERIAL NUMBER)|
|
Compressor serial number
(PHASE PROTECTION)|
OFF/ON
| ON: Enables failure protection and phase sequence OFF: Disables failure
protection and phase sequence.
(NETWORK FRE- QUENCY)|
50HZ/60HZ
|
Sets the compressor operating frequency
(SEQ MODE)| COMPATIBLE/ ADVANCED| Not used
(HIGH VOLTAGE)|
****V
| 1. If the interface detects a voltage greater than the adjusted value, the compressor will shut off due to overvoltage.
2. Set this value to “0” to disable the function.
(LOW VOLTAGE)|
****V
| 1. If the interface detects a voltage less than the adjusted value, the compressor will shut off due to undervoltage.
2. Set this value to “0” to disable the function.
(LOW TEMP PROT)|
-5ºC
| 1. When the compressor is off, the product will not start if the temperature is lower than the set value.
2. If the compressor is running and the temperature is below the set value, the compressor will shut down and an error in the temperature sensor will be triggered.
(MAX OPER TIME)|
0000H
| 1. When the total compressor operating time is greater than the value set in this parameter the compressor will shut down and an error will be displayed.
2. If the value is set to “0000”, the function is deactivated.
(LONG ALARM FAILURE)|
0000H
| If the interface detects that an oil filter, separator, air filter, oil,
grease or belt alarm has a longer time than the time set in this parameter,
the product will shut down and an error will be triggered.
(COMMUNICATION ON/OFF)|
ON/OFF
| 1. When set to ON: user can configure Modbus network data
2. When set to OFF: user cannot configure Modbus ne- twork data.
Note: Network configuration can only be performed with the compressor turned off.
---|---|---
(CHANGE PAS- SWORD)|
|
Parameter to change the factory password
(PRESSURE UNIT)| BAR/MPA/PSI| Selection of pressure unit
(TEMP UNIT)| °C/°F| Selection of temperature unit
Calibration Parameters
Calibration parameters are used to modify Control III data. A password is required to access the menu.
- To check the calibration parameters, go to MENU CALIBRATION (CALIBRATION), press and enter the access password.
- We recommend that parameters are changed only by an authorized Schulz Technical Service Agent.
Table 7.1
PARAMETER| Initial Value| Functions
MOTOR
A
|
(TARGET)
|
0000
| Enter the current value of the current. The interface will divide the value
entered by the value being measured at the moment to calculate the
coefficient.
COEF| 1.000| To calibrate the value of the motor current, enter the
appropriate coefficient.
MOTOR A
|
**.A
| The interface displays a sample of the current value. It is a read-only value, it cannot be modified.
MOTOR
B
|
(TARGET)
|
0000
| Enter the current value of the current. The interface will divide the value
entered by the value being measured at the moment to calculate the
coefficient.
COEF| 1.000| To calibrate the value of the motor current, enter the
appropriate coefficient.
MOTOR B
|
**.A
| The interface displays a sample of the current value. It is a read-only value, it cannot be modified.
MOTOR
C
| (TARGET)|
0000
| Enter the current value of the current. The interface will divide the value
entered by the value being measured at the moment to calculate the
coefficient.
COEF| 1.000| To calibrate the value of the motor current, enter the
appropriate coefficient.
MOTOR C
|
**.A
| The interface displays a sample of the current value. It is a read-only
value, it cannot be modified.
VENT(FAN)
A
|
ALVO (TARGET)
|
0000
| Enter the current value of the current. The interface will divide the value
entered by the value being measured at the moment to calculate the
coefficient.
---|---|---|---
COEF| 1.000| To calibrate the value of the motor current, enter the
appropriate coefficient.
VENT A
|
**.A
| The interface displays a sample of the current value. It is a read-only
value, it cannot be modified.
VENT(FAN)
B
| ALVO (TARGET)|
0000
| The interface displays a sample of the current value. It is a read-only
value, it cannot be modified.
COEF| 1.000| To calibrate the value of the motor current, enter the
appropriate coefficient.
VENT B
|
**.A
| The interface displays a sample of the current value. It is a read-only
value, it cannot be modified.
VENT(FAN)
C
|
ALVO (TARGET)
|
0000
| Enter the current value of the current. The interface will divide the value
entered by the value being measured at the moment to calculate the
coefficient.
COEF| 1.000| To calibrate the value of the motor current, enter the
appropriate coefficient.
VENT C
|
**.A
| The interface displays a sample of the current value. It is a read-only value, it cannot be modified.
CONTROL PRINCIPLES
Local Start (Y- start)
The interface will power the contactors K1, K2 and K3 in the correct sequence for starting the main motor. During the start procedure, the product will remain in relief.
Automatic load mode
After the start procedure the compressor will start the control solenoid valve and the compressor will enter load mode and the pressure in the air network will increase. When the network pressure reaches the relief pressure value, the control solenoid valve will be de-energized, and the compressor will enter relief mode. If the pressure decreases to the load pressure value, the solenoid valve will be triggered again, and the compressor will enter load mode. If the product remains in relief for a longer period than the set relief time, the motor will stop automatically. A new start procedure will automatically start when the air supply pressure reaches a lower value than the load pressure.
Manual load mode
After the start process, the compressor will only operate in relief mode and will only enter load mode if the button is pressed. When in load mode, if the relief pressure value is reached, the compressor will automatically enter relief mode.
Local Shutdown
To turn off the compressor, press the button . The product will enter relief mode during the stopping time. Next, the main motor and fan will shut down. The compressor can only be restarted after the restart time has elapsed.
Remote start and stoppage
Remote start and stoppage work basically the same way as local commands. The difference is that they can be performed through a digital input. When the digital input is closed the compressor will initiate a start process and when the input is open a stoppage process will be started. When set as remote start/stoppage, local commands are still enabled.
Temperature Control by Fan
When the unload temperature is higher than the value set in the parameter “temperatura liga ventilador” (turn on fan temperature), the compressor fan will be activated. When the unload temperature is less than the value set in the parameter “temperatura de desligamento do ventilador” (fan shutoff temperature), the compressor fan will shut off automatically.
Errors and Alarms
Control III may have several failures that are classified as alarms or errors. Alarms are less severe failures or alerts that the interface displays to the user to avoid damage to the compressor. Errors are failures that do not allow the compressor to continue in operation, due to risks to staff safety or extreme damage to the equipment. Below is the list of major failures that can be detected by Control III.
| Message | Failure Category | Description |
|---|---|---|
| (EMERG STOP) | Error | Immediate stop button pressed |
| (EXCHANGE OIL FILTER) |
Alarm
|
Replace oil filter
(EXCHANGE BELT)| Alarm| Replace belt
(EX- CHANGE AIR FILTER)| Alarm| Replace air filter
(EXCHANGE SEP ELEM)|
Alarm
|
Replace oil/air separator element
(EXCHANGE OIL)| Alarm| Replace lubricating oil
(EXCHANGE MOTOR GREASE)|
Alarm
|
Replace motor grease (where applicable)
(PHASE SEQ)| Error| Incorrect phase sequence of supply voltage
(UNBALANCED CURR)|
Error
|
Electrical current between unbalanced power phases
(C PHASE FAILURE)|
Error
|
Phase failure
(LONG ALARM)| Error| Alarm without correction for a very long time.
(HIGH TEMP)| Alarm| High compresor temperature
(TEMP SENSOR)| Error| Temperature sensor reading failure
(PHASE SEQ PRT)| Error| Phase sequence protection
(VOLT PRT)| Error| Voltage protection (high or low)
(HIGH TEMP)| Error| Overtemperature
(BLO- CKED OIL FILTER)| Alarm| Blocked oil filter
(PARAMETER ERROR)|
Alarm
|
Incompatible value in a parameter
(OVERLOAD)| Error| Overload on main motor or fan
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