Operation Manual MAM-200

USER MANUAL
Screw Compressor Manual
MAM-200

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 Operation Manual MAM-200

1. Basic Operation
1.1. Button explanation
1.2. Status Display and Operations
1.3. Calendar
1.4. Customer Parameter
1.5. Factory Parameter
1.6. Operating Authorization and Password
2. Controller Function and Technical Parameter
3. Model and Specification
3.1. Main Controller Model Description
3.2. Monitor Description
3.3. Power Consumption Table for Corresponding Motor
4. Installation
4.1. Mechanical Installation
4.2. Electrical Wiring Installation
5. Alarm Function
5.1. Monitor text
5.2. Controller Indicator
6. Controller Protection
6.1. Motor Protection
6.2. Protection for Air Temperature High
6.3. Protction of Air Compressor Reversal
6.4. Protection of Air Pressure High
6.5. Protection of Sensor Failure
7. Troubleshooting
7.1. This Fault Review
7.2. Common Failres and Causes
8. Electronic Diagram

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 Operation Manual MAM-200

1. Basic Operation
1.1 Button explanation

Start Button
· When compressor is at stop status, press this button to start the compressor
· When compressor is set as main (No.1) in block mode, press this button to start the
compressor and activate block mode function at the same time

Stop Button
· When the compressor is at running status, press this button to stop the compressor
· When compressor is set as main (No1) in block mode, press this button to stop compressor
and block mode as well

Loading / Unloading Button

· When the compressor is at running status, press this button to load or unload

Set Button
· When the compressor is at setting mode, press this button after modification to confirm
and save the modified data
· Press this button after input password to verify the password

Move down button / Decreasing button

· When viewing the menu, press this button to move upward the cursor
· When modifying data, press this button to increase the data at current position

Move up button / Increasing button

· When viewing the menu, press this button to move downward the cursor

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 Operation Manual MAM-200

· When modifying data, press this button to decrease the data at current position

Shift button / Reset button

· When modifying data, press this button to move to the next data bit
· When select menu, press this button to switch to sub menu. If no submenu available, the
controller will shift to data setting mode

Return button / Reset button

· When modifying data, press this button to exist data setting mode
· When viewing the menu, press this button to return to previous menu
· When the controller is at failure stop status, long press this button to reset

1.2 Status Display and Operations

The display screen will show as below after powered on:

WELCOME USING

SCREW COMPRESSOR

After 5 seconds the menu will switch as below:

AIR T: 20°C FR T: 97°C

AIR P: 0,60MPa BR T: 95°C

STATE: NORMAL STOP

ADD 001

Press to enter into Selection Menu:

RUN PARAMETER

CALENDAR

CUSTOMER PARAMETER

FACTORY PARAMETER

Check RUN PARAMETER

Press to move the cursor to “RUN PARAMETER”, then press to switch to
secondary menu:

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 Operation Manual MAM-200

MOTORS CURRENT
CUR(A): R S T
COIL; ROTORS T
HOST: 00,0 00,0 00,0
TOTAL RUN TIME
FAN: 4,1 4,1 4,1
THIS RUN TIME

Press to switch to the menu below:

CUR (A): R S T

HOST: 00.0 00.0 00.0

FAN: 4.1 4.1 4.1

No black cursor appears in the last menu. Press “enter” to return to the previous menu or to the
main menu. If no operation at the current menu for a few seconds, controller will automatically
return to the main menu.
Use “Move down” button, “Move up” button, “Enter button” and “Return button” to check COIL,
ROTORS T, TOTAL RUN TIME, THIS RUN TIME, MAINTENANCE PARAMETER, HISTORY FAULT,
PRODUCTION DATE, NUM, THIS FAULT and return to previous menu.

1.3 Calendar
Check and set time for controller

DATE AND TIME

2004-2-22

W0
12 : 46 : 59

1.4 Customer Parameter

1.4.1 Customer Parameter View and Modification:

Customer Parameter and Factory Parameter are not allowed to be modified in running and stop
delay status.

When modifying Customer Parameter please refer to run parameter modification method. The
modification process of LOADING P is showing as an example below:

Move the cursor to “CUSTOMER PARAMETER”, press “ENTER” to switch to the following menu:

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 Operation Manual MAM-200

SET P; T

SET TIME

OPERATION MODE

BLOCKING MODE

Then press to the following menu

LOADING P: 00,65MPa

UNLOADING P: 00.80MPa

FAN START T: 0080°C

FAN STOP T: 0070°C

User can check the CUSTOMER PARAMETER in this menu or press to switch to the following
menu which requires an enter password.

ENTER PASSWORD

****

Note: Customer password can be set in CUSTOMER PARAMETER and FACTORY PARAMETER is
fixed as ________

In this menu the first data bit of password started blinking, press or to modify the
first bit of password. Press move the cursor to the next data bit, modif the second data of
password. In accordance with the above, modify the third and fourth data of password in
sequence, press “S” to confirm the input data and the menu will switch to the following menu
after verification:

LOADING P: 00,65MPa*

The upper right corner with “*” indicates UNLOADING P: 00.85MPa

the system verification of the password
FAN START T: 0080°C

FAN STOP T: 0070°C

In the menu above press , the first data of LOADING P start to blink, user can press or
to modify the present data in accordance with the above method. Press to move to
next data bit and modify the target data in sequence. When finished press “S” to confirm and save
the data. Other CUSTOMER PARAMETER share the similar way for modification.

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 Operation Manual MAM-200

1.4.2 Customer Parameter Table and Function

First menu Second menu Preset Data Function

LOADING P 0,65 MPa 1 .In AUTO LOADING status, compressor will load if pressure is below this set data
SET P, T 2. In STANDBY mode, compressor will start if the pressure is below this set data
UNLOADING P 0,80MPa Compressor will unload automatically if air pressure is above this set data
This data should be set above LOADING P, also should be set below ULD LIM P
FAN START 80°C Fan will start if AIR T is above this set data
FAN STOP T 70°C Fan will stop if AIR T is below this set data
Set the HOST START TIME, record time when HOST is activated, controller will not
SET TIME HOST TIME: START 0008 Sec start overload protection during this time to avoid stopping the motor by impulse
starting current
Set the FAN START TIME, record time when fan is activated, controller will not start
FAN TIME: START 0006 Sec overload protection during this time to avoid stopping the fan by impulse starting
current
OTHER 0001 Sec Fixed as 1 S
LOAD TIME. DELAY 0002 Sec Unloading in this set time after enter delta running
EMPTY TIME: DELAY 0020 M When unloading continuously, compressor will automatically stop and enter to standby
status if over this set time
STOP TIME: DELAY 0010 Sec For NORMAL STOP operation, compressor will stop after it continuously unloading over
this set time
START TIME: DELAY 0100 Sec Machine can be restarted only over this set time at any case (after NORMAL STOP,
STANDBY or FAILURE STOP)
OTHER: 0000 Sec Standby
DRAIN TIME: OPEN 0002 Sec Continuously drain time in auto mode
DRAIN TIME: CLOSE 0010 M Interval drain time in auto mode
ON/OFF MODE NEAR/FAR 1. When set as NEAR, only the button on the controller can turn on and turn off the
machine
2. When set as REMOTE mode, both the button on the controller and the remote
control button can turn on and turn off the machine
LOAD MODE AUTO/MANU 1. When set as MANU, only when the pressure is above UNLOAD P, compressor will
unload automatically. For any other case, the Load/Unload function can only be
OPERATION MODE executed by pressing load/unload key.
2. When set as AUTO, the loading/unloading function can be executed by the
fluctuation of AIR P automatically
COM MODE PROHIBIT / COMPUTER / 1. When set as PROHIBIT, the communication function is invalid
BLOCK 2. When set as COMP, compressor can communicate with computer or DCS as slave
according to MODBUS-RTU.
3. When set as BLOCK, compressor can work in net
COM ADD 0001 Set the communication ADD in block mode or when communicate with monitoring
center. This ADD is unique for every controller in net
BLOCK STATE MAIN / SLAVE 1. When service as main in BLOCK. Main controls slave, the COM ADD should be set as
No.1
2. When service as slave in BLOCK, slave is controlled by main
BLOCK ON/OFF ORDER / ALONE Standby
TURN TIME 9999H When main pressure is between BLOCK LOAD P and BLOCK UNLOAD P, motor
BLOCKING MODE determine slave work, alternatively over this set time
BLOCK NUMBER 0016 Number of air compressors in block net
BLOCK LOAD P 2.00MPa In BLOCK mode, one compressor will start or load when pressure is below this set data
BLOCK UNLOAD P 2.00MPa In BLOCK mode, one compressor will stop or unload when pressure is above this set
data
BLOCK DELAY 0000S In BLOCK mode, when main sends two commands continuously, second command
signal delays for this set data
OIL RESET 0000H Record oil filter run time. If changing new oil filter, the data should be reset by manual
operation
O/A RESET 0000H Record O/A separator total run time. If changing new O/A separator, the data should
be reset by manual operation
CLR LIFE TIME AIR RESET 0000H Record air filter total run time. If changing new air filter, the data should be reset by
manual operation.
LUB RESET 0000H Record lubricating oil total run time. If changing new lubricating oil, the data should be
reset by manual operation
GREASE RESET 0000H Record grease total run time. If changing new grease, the data should be reset by
manual operation
OIL 9999H 1. Alarm prompt when total run time of oil filter is over the data set
2. Set this data to “0” to invalidate the oil filter alarm function
O/A 9999H 1. Alarm prompt when total run time of O/A separator is over set data
2. Set this data to “0” to invalidate the O/A separator alarm function
MAX LIFE TIME AIR 9999H 1. Alarm prompt when total run time of air filter is over the set data.
2. Set this data to “=” to invalidate this alarm function of air filter
LUBE 9999H 1. Alarm prompt when total run time of lubricating oil is over set data.
2. Set this data to “=” to invalidate this alarm function of air lube.
GREASE 9999H 1. Alarm prompt when total run time of grease is over set data.
2. Set this data to “=” to invalidate this alarm function of grease.
LANGUAGE SEL CHINESE/ENGLISH CHINESE Chinese display when set to CN
English display when set to EN
NEW USER **** User could modify the user password by old user password or factory password
PASSWORD

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 Operation Manual MAM-200

1.5 Factory Parameter

The view and modification of factory parameter requires a factory password- The
modification step is same as customer parameter modification. Main function is a s below:

PARAMETER Initial Data Function

HOST RATED CURR Maximum host overload data/1.2 When the current of host is more than 1.2 times and less than 4 times of the set
data, the unit will shut down according to overload feature
FAN RATED CURR Maximum fan overload data/1.2 When the current of fan is more than 1.2 times and less than 4 times of the set data,
the unit will shut down according to overload feature
PRE-ALARM T 105°C Alarm prompt when actual AIR T is over the set data
AIR STOP T 110°C Alarm and stop when actual AIR T is over the set data
STOP P 1.00MPa Alarm and stop when actual AIR P is above this set data
UNLOAD LIM P 0.80MPa The UNLOAD P in CUSTOMER PARA must be set no higher than this set
data
CLR LOAD TIME 000000H Modify the LOAD TIME
CLR TOTAL TIME 000000H Modify the TOTAL RUN TIME
CLR FAULT RECORD 0000 Input the password “8888” and press “set” button to clear all the history
failure record
UNBALANCE SCOPE 0006 MAX-MIN >=SET*MIN/10, respond time is 5s
If the set data ≥ 15, the unbalance protection will be invalid.
LACK PHASE STOP 000.5S If LACK PASE protection ≥ 20 seconds, LACK PHASE protection is invalid
ROTOR STOP 0160°C Alarm and stop when the rotor temperature is higher than this set data
PROD TIME ****-**-** Production date
PROD NUM ******** Production serial no.
COIL STOP T 160°C Alarm and stop when the coil temperature is higher than this set data
WARM START T 0060°C In stop mode, when coil temperature is lower than this set data, heater
relay will close
WARM STOP T 0080°C In stop mode, when coil temperature is higher than this set data, heater
relay will open
COM SET PARA ENABLE/DISABLE Set controller parameter through DCS center

1.6 Operating Authorization and Password

Controller provides multiple passwords and access management. According to different

levels of passwords, controller provides different levels of operating authorization. Details
are as following:
1.6.1 CUSTOMER PASSWORD: factory set ___________
Permissions: Allows to modify all CUSTOMER PARAMETER
1.6.2 FACTORY PASSWORD: fixed____________
Permissions: Allows users to modify all CUSTOMER PARA and FACTORY PARA.

2 Controller Function and Technical Parameter

2.1 Digital input and output: 9 points of Digital input; 10 points of digital relay output
2.2 Analog input: 6 points of Pt100 temperature input, 1 point of 4 ̴20mA pressure signal
input, 11 group of three phases current inputs (CT provided)

2.3 Input voltage of phases: 380V

2.4 Compressor working power supply: 220V, 50Hz, 20VA

2.5 Measurement:
2.5.1 AIR T: ‐20 ̴ 178°C; Accuracy: ± 1°C
2.5.2 Run time:0 ̴999999H
2.5.3 Current: 0 ̴ 999.9A
2.5.4 Pressure: 0 ̴ 1.60MPa, Accuracy: 0.01MPa
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 Operation Manual MAM-200

2.6 Phase sequence protection: When compressor is at stop mode and detects wrong phase,
respond time ≤ 2s

2.7 Motor protection: This controller has 5 basic protection function for motor and fan.
2.7.1 Block protection: After start. When operation current is equal to 4-8 times the set
current, respond time ≤ 0.2sec
2.7.2 Short circuit protection: When operation current is equal to 8 times the set current,
respond time ≤ 0.2sec
2.7.3 Phase lack protection: When any lack, the respond time equals to set time
2.7.4 Unbalance protection: When MAX-MIN ≥ SET*MIN/10, respond time is 5sec
2.7.5 Protection features of overload (time unit: second), see following table;
multiple = Iactual / Iset motor operates with delay time according to overload multiples
and operation time shown in following table when motor working current is higher
or equal to the set current from 1.2 times and 3.0 times

Iactual/Iset

Time Parameter ≥ 1,2 ≥ 1,3 ≥ 1,5 ≥1,6 ≥2,0 ≥ 3,0

Response time (sec) 60 48 24 8 5 1

2.8 Temperature protection: When actual temperature measured is higher than

temperature set; response time ≤ 2sec

2.9 Contact capacity of output relay: 250V, 5A: Contact endurance: 500.000 times

2.10 Current error is less than 1,0%

2.11 RS-485 connection

3. Model and Specification

3.1 Main Controller Model Description

MAM-KY16S (B) MAM … Series

KY16 … 16 compressor controller
S … Screw air compressor
(B) … Pressure converter
3.2 Monitor Description

MAM-200 (B) (T) MAM … Series

200 … 200 Monitor
(B) … B: Pressure Transmitter
(T) … T. Communication function

3.3 Power consumption table for corresponding motor

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 Operation Manual MAM-200

Parameter Current Corresponding Remark Description

range Main motor
Specification (A) Power (kW)
KY16(S) (20) 8 ~ 20 ≤ 11
KY16(S) (40) 16 ~ 40 11-18.5 Fan has three levels of current
KY16(S) (100) 100 22-45 Such as 0.2-2.5A, 1-5A and
KY16(S) (200) 200 55-90 4-10A, determined by current
KY16(S) (400) 400 110 of motor
KY16(S) (600/5) 600/5 200-250 With CT

4. Installation

4.1 Mechanical Installation

4.1.1 Current transformer installation

The CT shall be installed at a place where the current of motor cable van be
measured, thus controller can be set according on motor nameplate, the detailed
dimensions are show as below:

4.1.2 Controller Installation

A certain room should be left around controller for wiring. The specific dimension is
shown as below:

1. Indicator (IN)

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 Operation Manual MAM-200

The corresponding digital input terminal of 00, 01, 02, 03, 04, 05, 07 is 26, 25, 24, 23, 22,
21, 20, 19, 18
2. Indicator (OUT)
The corresponding digital output terminal of 00, 01, 02, 03, 04, 05, 06, 07, 08. 09 is 39,
40, 41, 42, 43, 46, 47, 49, 50, 51
3. Power Indicator: PWR indicator
4. Run indicator: RUN indicator
5. Error Indicator: ERR indicator

4.1.3 Panel function and installation

MAM 200 monitor in control cabinet

4.2 Electrical Wiring Installation

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 Operation Manual MAM-200

Monitor control cable:

There are six connection cable and a communication cable which are used for display connection
RS-485 communication, 24V power supply. For detail please refer to the silk print in monitor

Controller cable terminal:

Communication cable is used to connect monitor and controller:

1, 2, 3 N/A 4, 5, 6 Terminal for fan CT2 input 7, 9 Input terminal for AIR T
8, 9 Input terminal for front rotor 10, 12 Inut terminal for AIR P 11 N/A
temperature
13, 15 Input terminal for rear rotor 14, 15 Input terminal for COIL 1 temperature 15, 16 Input terminal for COIL2 temperature
temperature
17, 15 Input terminal for COIL 3 18 High voltage ready 19 “Remote” on
temperature
20 “Remote” off 21 Differential pressure switch 22 Differential pressure switch for oil/air
for air filter separator
23 Differential pressure switch 24 Lack water 25 High voltage cabinet error
for oil filter
26 Emergency stop 27 24V output 28 24V output
29, Input terminal for phase 30, 31 N/A 33, 34 N/A
32,35 sequence
29, Input terminal for phase 30, 31 N/A 33, 34 N/A
32,35 sequence
36, 37, N/A 39 Output signal, start high 40 Output signal, stop high
38
41 High voltage pre-heater 42 Control valve 43 Control fan
on/off
44 Common terminal for output 45 N/A 46 Operation ready
control
47 Dryer 48 N/A 49 Run indicator
53 N/A 54 Terminal for ground 55, 56 220V power supply
connection

Note: 39 terminal: start high voltage cabinet. When turn on, it will close for 5sec and then open
40 terminal: stop high voltage cabinet. When turn off, it will close for 5sec and then open
Electromagnetism coil shall be connected nearest with RC snubber during wiring

5. Alarm Function
5.1 Monitor text

5.1.1 Air Filter Alarm

1. Use switching signal to detect Alarm

The monitor displays AIR FILTER BLOCK by checking air filter differential pressure switch
2. Set air filter max time
The monitor displays AIR LIFE END when the run time of the air filter exhausts

5.1.2 Oil Filter Alarm

1. Use switching signal to detect Alarm

The monitor displays OIL FILTER BLOCK by checking oil filter differential pressure switch
2. Set OIL filter max time
The monitor displays OIL LIFE END when the run time of the oil filter exhausts
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5.1.3 O/A Alarm

1. Use switching signal to detect Alarm

The monitor displays O/A BLOCK by checking O/A filter differential pressure switch
2. Seat O/A max time
The monitor displays O/A LIFE END when the run time of the O/A exhausts

5.1.4 Lubricating oil Alarm

1. Use switching signal to detect Alarm

The monitor displays LUBE LIFE END when run time of lubricating oil exhausts

5.1.5 Grease Alarm

1. Use switching signal to detect Alarm

The monitor displays GREASE LIFE END when run time of the grease exhausts

5.2 Controller Indicator

Indicator Meaning and function Indicator status

Power Controller power on PWR indicator on
Run Controller run RUN indicator on
Error Failure and stop ERR indicator blink
Digital input Terminal 26 ̴ 18 digital input IN00-08 corresponding indicator on.
Indicator will not be illuminated if input
has no function
Digital output Terminal 39, 40, 41, 42, 43, 46, 47, 49, 50, OUT00-09 corresponding indicator on
51 digital output
Data storage Data and time set PWR blink once

6. Controller Protection

6.1 Motor protection

MAM-KY16S compressor controller provide short circuit “block, overload, lack

phase, unbalance protection on motor”.

Electronic failure Failure display Reason

Short circuit Display “MOTOR / FAN OVER LOAD” Short circuit or wrong current set
Current Block Display “MOTOR / FAN BLOCK” Overload, bearing wear and other
mechanical failure
Overload Display “MOTOR / FAN OVERLOAD” Overload, bearing wear and other
mechanical failure
Lack phase Display “MOTOR / FAN LACK PHASE” Power supply, contactor and open phase of
motor
Unbalance Display “MOTOR / FAN UNBALANCE” Poor contact of contactor, inside open-loop
of motor

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6.2 Protection of Air Temperature High

When AIR T is above the AIR STOP T, the controller will send out the alarm to shut
down the machine and this fault displays AIR T HIGH.

6.3 Protection of Air Compressor Reversal

When compressor stops and three phases sequence is not in order, this fault displays
PHASE REVERSAL and the controller cannot start the motor. Change the position of
any arbitrary two-phase power lines and check the rotation of motor.

6.4 Protection of Air Pressure High

When the AIR P is above the STOP P, the controller will send out the alarm to shut
down the machine and this fault displays AIR P HIGH.

6.5 Protection of Sensor Failure

When pressure sensor is disconnected, the controller will send out the alarm to shut
down the machine and this fault displays **SENSOR FAULT.

7. Troubleshooting
7.1 This Fault Review

Failure stop caused by the external parts of controllers may be removed by checking
this fault or history fault, method is shown as below.

Move the cursor to RUN PARA menu, then secondary menu will show:

MOTORS CURRENT

COIL; ROTORS T

TOTAL RUN TIME

THIS RUN TIME

Press

MANTENANCE PARAMETER

HISTORY FAULT

PRODUCTION DATE; NUM

THIS FAULT

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Move cursor to THIS FAULT and switch to the following error menu:

STOP: T SENSOR FAULT

170°C

User can reset the error according to the following information:

Failure Reason Solution

AIR T HIGH Band vent condition, Oil shortage etc. Check the vent condition and
lubricant amount etc.
AIR T SENSOR FAULT Cable of PT100 failure Check the wiring and PT100
AIR P HIGH Pressure too high or the pressure Check the wiring and the pressure
sensor failure sensor
AIR P SENSOR FAULT Cable off, Sensor failure or sensor Check the wiring and pressure
cable reversal transmitter
LACK WATER Water pressure switch failure Check water pressure switch
LACK PHASE Power lack phase or the contactor Check the power and contactors
terminal failure
OVERLOAD Voltage too low, tubes block, Check the set data, voltage,
bearing wear off or other bearings, tubes and other
mechanical failure or wrong set mechanical system
data etc.
UNBALANCE Power unbalance, contactor failure Check the power, contactor and
or the internal open loop of the the motor
motor
BLOCK Voltage too low, tubes block, Check the set data, voltage,
bearing wear off or other bearings, tubes and other
mechanical failure or wrong set mechanical system
data etc.
SHORT CIRCUIT Wrong cable connection, wrong set Check the cable, set the data
data
PHASE REVERSAL Reversed phase sequence or open Check the wiring
phase
Overload and block during start MAIN start time set too less tha the Reset the main start time to be
START DELATA delay time longer than STAR DELTA delay + 2
seconds
Main contactor shakes frequently The emergency button loose, Check the wiring; if the coil of
controller reset by interference contactor connect with RC snubber
or not

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8. Electronic Diagram

Stand: 20.12.2016

TOLPEC GmbH
Kelterstrasse 59
DE-72669 Unterensingen
Tel.: +49 2054 8710150
e-mail: [email protected]
www.tolpec.com
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