Manual

AIR CONTROL 1
 1 Plant main switch The unit‘s main switch that is installed externally connects or
disconnects the unit to and from the power supply.

The compressor main switch must be switched off for all service or in-
stallation work and protected from illicit or accidental switching on (e.g.
affix a warning sign to the main switch forbidding its being turned on)!
DANGER

2 Emergency OFF The system may be stopped with EMERGENCY OFF in the case of a real
emergency!

Stop the motor in case of danger: press key.

Make sure that the shut-down system is sufficiently protected against

recommissioning!
Enable the system only when the cause of danger has been profession-
ally removed and a securely operating state is achieved.
DANGER

Enable system:
1. switch main switch off and on.
2. press key to acknowledge the malfunction.
3. press key to switch the system on again.
2
3 Air Control 1 7KHRSHUDWLQJGLVSOD\GHVNRI$LU&RQWURO
• displays the compressor states / operating data
• switches on and off compressed air generation
• is used for compressor parameterizing.

0RGL¿FDWLRQRISDUDPHWHUYDOXHV

&RQ¿UPDWLRQRISDUDPHWHUFKDQJHV

Display additional operating data.

Switch on compressor.
Integrated green LED
%OLQNLQJ FRPSUHVVRULVQRWUXQQLQJFDQDWDQ\WLPH
be automatically started up.
Lighted: Compressor is running.
3

Compressor shut down.

Signals a current warning/malfunction with the inte-

grated red LED.
 3.1 Basic display $IWHUVZLWFKLQJRQWKHPDLQVZLWFKRUGXULQJQRUPDORSHUDWLRQ
Air Control 1 will inform you about the compressor state.

Current pressure

Warning present (see Chapter 5.4.5)

Motor is running

Compressor compresses air

Fault is present (see Chapter 5.4.6)

RESTART Automatic restart after power supply is activated

AUTOMATIC Operating mode Automatic or Automatic optional

REMOTE - Flashing: Generation of compressed air ON/

4 OFF by remote switch
- Continuous: Generation of compressed air con-
trolled by higher-level control

Current compressor temperature

Instead of the current compressor temperature you can also have the cur-
UHQWFRROLQJÀXLGWHPSHUDWXUHGLVSOD\HG3UHVVNH\ . For viewing further
RSHUDWLQJGDWDVHH&KDSWHU3
3.2 ON/OFF switching of Switching ON: press NH\ .
compressed air generation The compressor is ready and can start up automatically at any time.

The compressor starts up only when

• the current line pressure falls below the start pressure and
• the compressor temperature is at least 1 °C.

Switching OFF: press NH\ .

)RU WKH GXUDWLRQ RI WKH RII WLPH WKH FRPSUHVVRU VZLWFKHV WR WKH RIIORDG
state and afterwards off.

'XULQJWKHVZLWFKLQJRIISURFHVVWKHXQLW¿UVWFKDQJHVRYHUWRWKH³RIIORDG´
PRGHPRWRUUXQQLQJEXWFRPSUHVVRUGRHVQRWFRPSUHVVDLUDÀDVKLQJ
point appears in the display) for the duration of the “off time” (45 s). Only
then is the unit switched off (motor stops).

3.3 Viewing additional opera- Press the INFONH\UHSHDWHGO\WRYLHZWKHIROORZLQJRSHUDWLQJGDWDLQWKH

operatiing data order below.

Operating data

1x Start pressure in bar. The compressor starts up as soon as the line

pressure falls below this value.
2x Stop pressure in bar. The unit changes over to the off-load mode as
soon as the line pressure increases above this value.
3x Safety pressure in bar (= stop pressure + 0.8 bar). When this safety
SUHVVXUHLVUHDFKHGWKHFRPSUHVVRUVKXWVGRZQDQGDQHUURUPHV-
sage is output.
4x min. permissible compressor temperature 5
5x max. permissible compressor temperature
6x Total running hours
7x On-load hours
 [ 5HPDLQLQJVHUYLFHOLIHRIDLU¿OWHU
 [ 5HPDLQLQJVHUYLFHOLIHRIFRROLQJÀXLGDQGFRROLQJÀXLG¿OWHU
[ 5HPDLQLQJVHUYLFHOLIHRI¿QHVHSDUDWRU
11x Remaining service life of motor lubrication
12x Time remaining until compressor must be serviced

Display of faults/warnings is deactivated!

As long as the operating data above are viewed, no fault messages
or warning can be output. This screen should therefore be exited as
NOTICE soon as possible.
 3.4 Menu system All basic settings of the system can be viewed in the menu system. If the
Unit parameterisation 3.4.1 PRGL¿FDWLRQVKDYHQRLQÀXHQFHRQRSHUDWLRQDOVDIHW\WKH\PD\EHPRGL¿HG
Basic parameterisation 3.4.2 by means of a code entry.
Available code numbers
3.4.3 to 3.4.13

3.4.1 Unit parameterisation ThHXQLWFDQRQO\EHSDUDPHWHULVHGZKHQWKHJHQHUDWLRQRIFRPSUHVVHG

air is switched off. See Chapter 3.2.

3DUDPHWHUVDOORZWKHXQLWWREHDGMXVWHGWR\RXUVSHFL¿FUHTXLUHPHQWV7R
WKLVHQG$LU&RQWUROPXVWEHVZLWFKHGWRWKHSDUDPHWHULVDWLRQPRGH
The individual parameters can be selected with a code and then changed.
A description of available code numbers can be found in Chapters 3.4.3
to 3.4.13.

Paremeterisation procedure:
 3UHVVNH\ until the message “cod” appears in the display. Air Control
1 is now at the main level of the parameterisation mode.

Code
ÀDVKLQJ

 1RZVHOHFWWKHUHTXLUHGFRGHE\PHDQVRINH\V and .

3. Press ENTERWRDFWLYDWHWKHFRGH$LU&RQWUROFKDQJHVWRWKH¿UVW
sub-level.
6

With some codes, several parameters can be entered one after the other.
In these cases, simply press key ENTER to select the subsequent param-
eter.

 8VHNH\V and to change the current setting of the selected code
according to your requirements.
 3UHVVNH\ENTERWRWDNHRYHUWKHQHZVHWWLQJVRUSUHVVNH\ to leave
the setting unchanged and return to the next higher level.
3.4.2 Basic parameterisation ThHXQLWFDQRQO\EHSDUDPHWHULVHGZKHQWKHJHQHUDWLRQRIFRPSUHVVHG
air is switched off. See Chapter 3.2.

The basic parameterisation prepares the unit for operation.

 3UHVVNH\ until the message “cod” appears in the display.

 6HOHFWFRGHE\PHDQVRINH\V and DQGSUHVVNH\ENTER.
 3UHVVNH\INFO.

&RGHÀDVKLQJ

Air Control 1 now shows the start pressure. The compressor compresses
air as soon as the line pressure falls below this value. Possible adjust-
ment range: 3.5 to maximum pressure of the unit.
 $GMXVWWKHUHTXLUHGVWDUWSUHVVXUHXVLQJNH\V and FRQ¿UPWKH
VHWWLQJE\SUHVVLQJNH\ENTER.
 3UHVVNH\INFO.

6WDUWSUHVVXUHÀDVKLQJ

Air Control 1 shows the stop pressure. The compressor changes over
to off-load operation as soon as the line pressure exceeds this value.
Possible adjustment range: 3.5 to maximum pressure of the unit.
The stop pressure must be higher than the start pressure!
 6HOHFWWKHUHTXLUHGSDUDPHWHUYDOXHXVLQJNH\V and DQGFRQ¿UP 7
WKHVHWWLQJE\SUHVVLQJNH\ENTER.
 3UHVVNH\ to complete the basic parameterisation.

6WRSSUHVVXUHÀDVKLQJ
 3.4.3 Code 2: Operating mode Determines how the unit is to respond when the start or stop pressure
is reached. Both limit values are set during basic parameterisation (see
Chapter 3.4.2).

0: Automatic.
The symbol “Automatic“ appears in the display.
The motor starts up and the compressor compresses air (= on-load
RSHUDWLRQDVVRRQDVWKHOLQHSUHVVXUHIDOOVEHORZWKHVWDUWSUHVVXUH
7KH XQLW FKDQJHV RYHU WR RIIORDG RSHUDWLRQ PRWRU UXQQLQJ EXW WKH
FRPSUHVVRUGRHVQRWFRPSUHVVDLUDVVRRQDVWKHOLQHSUHVVXUHH[-
FHHGVWKHVWRSSUHVVXUH$VVRRQDVWKHRIIORDGSKDVHVWDUWVWKHRII
WLPHHODSVHVIRUWKHSDUDPHWHULVDWLRQVHH&RGH&KDSWHU3
The motor stops after the off time.
1: On-/off-load
The symbol “Automatic“ is not shown in the display.
 ,QFRQWUDVWWRWKHDXWRPDWLFRSHUDWLQJPRGHWKHPRWRUQHYHUVWRSVUXQ-
ning. The compressor compresses air as soon as the line pressure falls
below the start pressure. The unit changes over to off-load operation
PRWRULVUXQQLQJEXWWKHFRPSUHVVRUGRHVQRWFRPSUHVVDLUDVVRRQ
as the line pressure rises above the stop pressure.
2: Automatic optional
The symbol “Automatic“ and an additional dot before the temperature
are shown in the display.
 6LPLODUWRWKHDXWRPDWLFPRGH+HUHWKHXVHUKDVDQLQÀXHQFHRQKRZ
RIWHQWKHPRWRUVWRSV7RWKLVHQGWKHSDUDPHWHUV³PD[LPXPSUHVVXUH
loss” (adjustment range 0.0 to 9.9 bar) and “max. number of motor starts”
(adjustment range 1 to 55 cycles/hour) are queried additionally.

Function “Max. pressure loss“:

 :KHQ WKH XQLW FKDQJHV RYHU IURP RQORDG WR RIIORDG RSHUDWLRQ$LU
Control 1 saves the current line pressure after 10 and after 40 seconds.
If the pressure loss thus established is higher than the “Max. pressure
ORVV´WKHPRWRUVKXWVGRZQDIWHUWKHRIIWLPHKDVHODSVHGSDUDPHWHUL-
VDWLRQZLWKFRGHVHH&KDSWHU3RWKHUZLVHDIWHUWKH³RII´WLPH
(45 s).

Function “Max. number of motor starts“:

 7KH PRWRU LV QRW VZLWFKHG RII DIWHU WKH ³RII´ WLPH HODSVHG ZKHQ WKH
number of starting cycles of the compressor exceeds the “Max. number
of motor starts”.
8
3.4.4 Code 3: Automatic re- Determines whether the generation of compressed air is to restart automati-
start after power failure cally after a mains power failure.

0: Automatic restart: OFF

The generation of pressure remains deactivated after a power failure.
The fault message “power fail” is output.
1: Automatic restart: ON
 :KHQ WKLV IXQFWLRQ LV DFWLYDWHG WKH GLVSOD\ VKRZV WKH V\PERO ³UH-
start“.
If the generation of pressure was activated before the power failure
RFFXUHGWKHXQLWUHVWDUWVDXWRPDWLFDOO\DIWHUWKH³RII´WLPH,QWKLVFDVH
the fault message “power fail” is not output. If the generation of pressure
ZDVGHDFWLYDWHGEHIRUHWKHSRZHUIDLOXUHLWUHPDLQVGHDFWLYDWHG

3.4.5 Code 8: Local control, 'HWHUPLQHVKRZWKHJHQHUDWLRQRISUHVVXUHLVWREHVZLWFKHGRQDQGRII

remote control, LLC-OK
0: Local control
The generation of compressed air can only be switched on or off from
the control panel of Air Control 1.
1: Remote control
The generation of compressed air can be switched on only by way of a
positive edge (24 VDC) at terminal 23 and switched off only by means of
DORZOHYHO9DWWHUPLQDORUE\SUHVVLQJNH\ . This functionality
LVVLJQDOOHGRQWKHGLVSOD\RI$LU&RQWUROE\DÀDVKLQJWH[W³5HPRWH³
If the NH\LVORFDOO\RSHUDWHGRQWKHXQLWWKHXQLWVZLWFKHVRIIDIWHU
VHFRQGVDQGIRUVDIHW\UHDVRQVFDQRQO\EHUHVWDUWHGE\UHPRWH
control after the NH\ZDVRSHUDWHGORFDOO\DFNQRZOHGJHPHQW7KLV
also applies to a start via PLANT CONTROL V/T.
2: LLC-OK
The input at terminal 23 is used to signal the readiness for operation
of an external control. The external control can only be switch between
on-load and off-load operation when a high level (24 VDC) is applied
VHHFRGHYDOXH&KDSWHU3:KHQDORZOHYHOLVDSSOLHG
LLC operation is automatically switched off and the internal pressure
sensor used.

3.4.6 Code 11: Start and stop 'HWHUPLQDWLRQRIWKHVWDUWDQGVWRSSUHVVXUHVIRUWKHSURFHGXUHVHH&KDS-

pressure ter 3.4.2
 3.4.7 Code 18: Lead leg con- Determines whether the changeover between on-load and off-load opera-
trol (LLC) tion is to be controlled by the internal pressure senor or by a higher-level
control.

0: Changing over between on-load/off-load operation by internal pres-

sure sensor
1: Changing over between on-load/off-load operation by external
control (e.g. PLC)
On-load operation when a high level (24 VDC) is applied to terminal 22.
Off-load operation when a low level (0 V) is applied to terminal 22. This
functionality is signaled by the text “remote” that appears continuously
in the display of Air Control 1.

3.4.8 Code 21: Maintenance ,VXVHGIRUDFNQRZOHGJLQJDPDLQWHQDQFHZDUQLQJFXUUHQWO\SUHVHQW)RU

acknowledgement WKHPHDQLQJRIPDLQWDLQHQFHQXPEHUVDQGDFNQRZOHGJHPHQWRIZDUQLQJV
see Chapter 3.5.

Possible damage to the unit!

Required maintenance work is signalled in the form of warnings.
Acknowledge these warning only, when the required maintenance has
actually been carried out!
NOTICE
If the unit is not serviced, its service life and reliability are reduced.
Please note that damage resulting from improper handling is not cov-
ered by the warranty!
Use only genuine spare parts.

10
3.4.9 Code 51: Off-load, off, The relevant times can be entered successively at operating levels 0 to 2.
star/delta time

0: Off-load time
Adjustment range: 10 - 1200 s. Operation in conjunction with Code
2 (operating mode). Is used in the operating modes “Automatic” and
“Automatic optional”.
1: Off time
Adjustment range: 0 - 60 s. The factory setting of 45 s should be retained.
'XULQJWKHRIIWLPHWKHPRWRULVUXQQLQJLQWKHLGOHPRGHQRFRPSUHVVHG
air is generated. The off time elapses
  ZKHQNH\ is pressed for switching off
- according to the Automatic optional mode
 :KHQWKHIXQFWLRQ³$XWRPDWLFUHVWDUWDIWHUSRZHUIDLOXUH´LVVHOHFWHG
the start-up of the motor is delayed for the set time of standstill.
2: Star/delta time
Adjustment range: 3 - 30 s. Determines after which time changing over is
WRWDNHSODFHIURPVWDUWRGHOWDFLUFXLWZKHQWKHPRWRULVVZLWFKHGRQ

3.4.10 Code 65: Condensate ,VXVHGIRUDGMXVWLQJWKHLPSXOVHDQGEUHDNWLPHVRIWKHFRQGHQVDWHYDO-

valve ve.
0: Impulse time
Duty cycle of the condensate valve
1: Break time
Off time of the condensat valve

11
 3.4.11 Code 90: Unit for pres- Determines the unit for the pressure indication:
sure indication
0: bar
1: MPa
2: psi

3.4.12 Code 95: Unit for tempe- Determines the unit for the temperature indication:
rature indication
0: Degree Celsius (°C)
1: Degree Fahrenheit (°F)
2: Kelvin (K)

3.4.13 Code 9999: Software Indicates the software version of Air Control 1.
version

12
3.5 Warnings / maintenance $ZDUQLQJLVSUHVHQWZKHQWKHUHGOLJKWLVEOLQNLQJ
work The compressor is not switched off.

The following is displayed:

Maintenence number
ÀDVKLQJ

Symbol for warnings

ÀDVKLQJ

Meaning of maintenance numbers:

2 ([FHVVLYH¿QDOFRPSUHVVLRQWHPSHUDWXUH
3 Excessive line pressure
11 5HPDLQLQJWLPHXQWLODLU¿OWHULVWREHVHUYLFHGK
12 5HPDLQLQJWLPHXQWLOFRROLQJÀXLGFRROLQJÀXLG¿OWHULVWREHVHUYLFHG
K
13 5HPDLQLQJWLPHXQWLO¿QHVHSDUDWRULVWREHVHUYLFHGK
14 5HPDLQLQJWLPHXQWLOPRWRULVWREHOXEULFDWHGK
15 5HPDLQLQJWLPHXQWLOFRPSUHVVRULVWREHVHUYLFHGK

Damage to the system is possible!

Necessary service work appears in the form of warnings.
$FNQRZOHGJHWKHVHZDUQLQJVRQO\ZKHQWKHGH¿QHGVHUYLFHZRUNKDV
NOTICE actually been carried out!
Service work not carried out degrades the service life reliability of the
system. Please note that damage caused by improper usage is not 13
covered by the warranty!
Only original spare parts may be used.

$FNQRZOHGJHPDLQWHQDQFHZRUN
 3UHVVNH\ (ca. 3 sec.) until the message “cod“ appears in the dis-
play.
 6HOHFW&RGHXVLQJNH\V and .
3. Press ENTERWKHQ .
 3.6 Malfunctions Malfunction has occurred when the red light is permanently on.

The compressor is stopped automatically.

The following is shown in the display:

Symbol of malfunction
ÀDVKLQJ

Fault number
ÀDVKLQJ

Fault text
DOWHUQDWHVZLWKWKH¿QDO
compression temperature

Meaning of fault numbers and texts:

1 Par Incorrect pressure setpoints
2 EPROM Incorrect setting parameters
3 Lo AC Undervoltage
4 No AC Power failure
5 OEFEC Air Control 1 defective
6 Emerg EMERGENCY OFF actuated
7 Rotat Wrong direction of rotation
8 Mot t Excessive motor temperature
9 Hi cur Overcurrent
10 Hi P Overpressure
11 'LI3  'LIIHUHQWLDOSUHVVXUHRI¿QHVHSDUDWRU
12 6HW  6HQVRUIRU¿QDOFRPSUHVVLRQWHPSHUDWXUH
13 6HRLO  6HQVRUIRUFRROLQJÀXLGWHPSHUDWXUH
14 Se P Pressure sensor
15 +LW  ([FHVVLYH¿QDOFRPSUHVVLRQWHPSHUDWXUH
14 16 Hi P Excessive line pressure

0DOIXQFWLRQVFDQRQO\EHDFNQRZOHGJHGZKHQWKHFDXVHKDVEHHQSURIHV-
sionally repaired. Troubleshooting and repair should be done exclusively
E\TXDOL¿HGSHUVRQQHO

$FNQRZOHGJHIDXOWPHVVDJHV
 SUHVVNH\ .
 SUHVVNH\ in order to restart the compressed air generation.
D
ALUP-Kompressoren GmbH
Tel.: +49/7024/802-0
Fax: +49/7024/802-106
Internet: www.alup.com
E-mail: [email protected]
Adolf-Ehmann-Str. 2
73257 Köngen
DEUTSCHLAND

A
AGRE-Kompressoren GmbH
Tel.: +43/7252/52341-0
Fax: +43/7252/52133
Internet: www.agre.at
E-mail: [email protected]
Werkstraße 2
4451 Garsten-St. Ulrich
ÖSTERREICH

NL
ALUP-Kompressoren B.V.
Tel.: +31/30/2809000
Fax: +31/30/2895675
Internet: www.alup.nl
E-mail: [email protected]
Biezenwade 8-10
3439 NW Nieuwegein
NEDERLANDS

HU
ALUP Magyarország Kft.
Tel.: +36/36/423444
Fax: +36/36/516340
Internet: www.alup.hu
E-mail: [email protected]
Manual_AirControl 1_gb_01_2007

Szálloda u. 5
3300 Eger
MAGYARORSZÁG

BG
ALUP-Kompressoren Bulgaria OOD.
Tel.: +359/2/528032
Fax: +359/2/528032
E-mail: [email protected]
Tsar Asen Str. 63
1000 Sofia
BULGARIA