Detroit Screw Compressor Manual A4 NEW
SCREW COMPRESSORCONTROLLER OPERATING MANUALMAM SERIES AIR SCREW CONTROLLER AND PROTECTION SYSTEMS FORDETROIT DT/DB-SERIES INTEGRATED AIR SCREW COMPRESSORSWITH MAM-6070/6080/6090 PLC SYSTEMS
Reliable Machinery from the Experts.NOTICE Please read instruction manual before use. Installation of MAM controllers should only be performed by a professional technician. Installation of the MAM controller needs to take into consideration heat dissipation and electromagnetic interference. Wiring must be installed according to regulations for high and low current to reduce electromagnetic interference. Surge arrestors must be used with inductive loads, such as AC contactors, on the output control of relay. Inspect port connections carefully before powering on. In order for the unit to resist signal noise, it is imperative that the MAM controller be earthed correctly. T he motors’ rated current – MAM overload auto stop current – must be set according to the rated current indicated onmotor name plate overload current multiplication factor of 1.2.FEATURES Multiple run modes optional. Colour touch screen, with control buttons. Supports real time power consumption and accumulative power consumption measurement and display. Scheduled on/off function and scheduled pressure function optional. High-speed and accurate frequency control for VSD models. Interfaces with all inverters supporting MODBUS RTU protocol. Phase lack, current overload, current imbalance, high voltage, low voltage and motor protection. High level of integration, high reliability and high efficiency.2www.detroitcompressors.co.za
Reliable Machinery from the Experts.CONTENTS1. Basic operation .51.1Button explanation .51.2Indicator explanation .61.3Status display and operation .61.4Run parameters .71.5User parameters .91.6Factory parameters .111.7Calibration parameters .131.8Block parameters .151.9Hardware parameters .151.10Maintenance parameters .161.11Inverter set .171.12Touch calibration .181.13Scheduled P .191.14Scheduled on-off .191.15History record .191.16Motor VSD .201.17Fan VSD .231.18Date .241.19Operation authorization and passwords .252. Controller Function and Technical Parameter .262.1Ambient temperature .262.2Digital input & output .262.3Analog input & output .262.4Input voltage of phases .262.5High voltage, low voltage protection .262.6Controller power supply .262.7Measurement .262.8Phase anti-reversal protection .262.9Motor protection .262.10Temperature protection .272.11Contact capacity of output relay .272.12Current error reporting is less than 1.0% .272.13RS485 communication port .272.14Remote controlling the compressor .273www.detroitcompressors.co.za
Reliable Machinery from the Experts.Contents (Cont).3. Model and Specification .273.1Model explanation .273.2Power specification sheet for corresponding motor .274. Installation .284.1CT Installation .284.2Controller installation - MAM-6070 / MAM-6080 / MAM-6090 .295. Alarm functions .345.1Air filter alarm .345.2Oil filter alarm .345.3O/A separator alarm .345.4Lubricant alarm .345.5Grease alarm .345.6Discharge high temperature alarm .346. Controller protection .356.1Motor protection .356.2Protection of discharge temperature high .356.3Protection of air compressor (anti-reverse rotation) .356.4Protection of air compressor against open phase (dropped phase) .356.5Protection of air pressure high .356.6Protection of sensor fault .357. Troubleshooting .368. Block control and network communication .378.1Block control .378.2Network communication .389. Inverter control .389.1485 Communication control .3810. Schematic Wiring Diagram.4010.1DT/DB Fixed speed modules with 6070 controller.4010.2DT/DB Fixed speed single-stage with MAM-6080 controller.4710.3DT/DB Variable speed single-stage with MAM-6080 controller.4810.4DT/DB Variable speed two-stage with MAM-6090 controller.4911. Appendix Output Mode Introduction.52www.detroitcompressors.co.za4
Reliable Machinery from the Experts.1. Basic Operation1.1 Button ExplanationStart Button:Press this button to start the compressor. When compressor is set as master (No.1) in array mode, press this button to start thecompressor and activate block mode function at the same time.Stop Button:Press this button to stop the compressor. When compressor is set as master (No.1) in array mode, press this button to stopcompressor and block function as well.Set Button; Load / Unload Button:When the compressor is running, press this button to load or unload. When modifying data in a textbox, press this button tosave data. When the cursor is at any page icon, press to execute the corresponding function.Return Button / Reset Button:When the controller is alarming in stop status, press this button for 5 seconds to reset. When modifying data, press this buttonto exit data setting mode. When viewing the menu, press this button to return to previous menu.Scroll Left Button:When checking data in a textbox, press this button to enter data modifying mode; data starts to blink from right to left. Whenmodifying data in a textbox, press this button to move the cursor to the left. When modifying data in data set and display icon,press this button to modify and save the data. When cursor is on a page icon, press to move to the previous icon.Move Right Button / Enter Button:When checking data in a textbox, press this button to enter data modifying mode; data starts to blink from left to right. Whenmodifying data in textbox, press this button to move the cursor to the right. When modifying data in data set and display icon,press this button to modify and save the data. When cursor is on a page icon, press to move to the next icon.Move Down Button / Decrease Button:When checking data, press this button to move the cursor downward to the next icon. When modifying data in a textbox, pressthis button to decrease the current value. When the current page is on Run Parameters, press this button to scroll to the nextpage.Move Up Button / Increasing button:When checking data, press this button to move the cursor downward to the previous icon. When modifying data in a textbox,press this button to increase the current data value.textboxdata set and display iconpage icon5www.detroitcompressors.co.za
Reliable Machinery from the Experts.1.2 Indicator ExplanationPower:Indicator illuminates when the controller is powered on.Run:Indicator illuminates when the motor is running.Alarm:Indicator blinks when the controller alarms. Indicator illuminates when the compressor is alarming and stopped. Indicator is offafter the error is cleared and reset.1.3 Status Display and OperationThe display screen will appear after powering on:After 5 seconds, the menu will appear as shown here:6www.detroitcompressors.co.za
Reliable Machinery from the Experts.1.4 Run ParametersSelect “RUN PARAMETER” to check the relative data and settings below:MenuPreset DataFunctionOIL FILTER0020HRecord total running time of the oil filter.O/A SEPARATOR0020HRecord total running time of the O/Aseparator.AIR FILTER0020HRecord total running time of the air filter.LUBE0020HRecord total running time of lubricant.GREASE0020HRecord total running time of grease.MOTOR CURRENTA: 000.0AB: 000.0AC: 000.0ADisplays motor current.FAN CURRENTA: 000.0AB: 000.0AC: 000.0ADisplays fan current.THIS Runtime0000:00:00Record compressor’s current runtime.THIS LOAD TIME0000:00:00Record compressor’s current load time.INPUT STATE1 2 3 4 5 6 7 8 9 101: In accordance with No.5 digital input state;2: In accordance with No.6 digital input state;3: In accordance with No.7 digital input state;4: In accordance with No.8 digital input state;5: In accordance with No.9 digital input state;6: In accordance with No.10 digital input state;Red dot input state means the terminal is connected;orange dot input state means the terminal is disconnected.OUTPUT STATE1 2 3 4 5 6 7 8 9 101: In accordance with No.17 digital output state;2: In accordance with No.16 digital output state;3: In accordance with No.15 digital output state;4: In accordance with No.14 digital output state;5: In accordance with No.13 digital output state;6: In accordance with No.12 digital output state;Red dot input state means the terminal is connected;orange dot input state means the terminal is disconnected.MOTOR RATEDSPEED0000 RPMDisplay of motor RPM based on thecalculation of the motor’s frequencyreading.MOTOR RATEDPOWER000.0 HzDisplays the output frequency of the motorinverter.7www.detroitcompressors.co.za
Reliable Machinery from the Experts.1.4 Run Parameters (cont).MOTOR OUTPUTCURRENT000.0 ADisplays the output current of the motorinverter.MOTOR OUTPUTVOLTAGE000.0 VDisplays the output voltage of the motorinverter.MOTOR OUTPUTPOWER000.0 KwDisplays the real time output power of themotor inverter.MOTOR THIS POWER 0000000.0Kw.HCONSUMPTIONDisplays the accumulative powerconsumption based on the motor inverterreal time output power.MOTORTOTAL POWERCONSUMPTION0000000.0Kw.HDisplays the accumulative total powerconsumption based on the motor inverterreal time output power.MOTOR STATEDESCRIPTION0000Displays in the motor status area, basedon the running status register data outputfrom the motor inverter.ERRORDESCRIPTION0000Displays in the controller error reportssection, based on the running error registerdata output from the motor inverter.WRITE FREQUENCY000.0Displays the motor frequency based on PIDcalculation.FAN SPEED0000 RPMDisplays fan real time speed based on thefan frequency reading.FAN OUTPUTFREQUENCY000.0 HzDisplays the output frequency of the faninverter.FAN OUTPUTCURRENT000.0 ADisplays the output current of the faninverter.FAN OUTPUTVOLTAGE000.0 VDisplays output voltage of the fan inverter.FAN OUTPUTPOWER000.0 KwDisplays the real time output power basedon the fan inverter.FAN THIS POWERCONSUMPTION000000.00Kw.HDisplays the accumulative powerconsumption based on the fan inverter realtime output power data.FAN TOTAL POWERCONSUMPTION000000.00Kw.HDisplays the accumulative total powerconsumption based on the fan inverter realtime output power.FAN STATEDESCRIPTION0000Displays in the fan status section, based onthe running state register data reading fromfan the inverter.ERRORDESCRIPTION0000Displays in the controller error area basedon the running error register data read fromfan inverter.WRITE FREQUENCY000.0Displays the frequency based on the PIDcalculation.8www.detroitcompressors.co.za
Reliable Machinery from the Experts.1.5 User ParametersUser parameters store relevant data. User password is required for modification of parameters1Touch operation (highlighted in yellow):When the cursor is here, you can revise the parameter by clickingthe data box directly if the password has been verified alreadyIf the password has not been verified yet, a password verificationbox will prompt you. Button operation shows as below:2 While in data checking mode, press left or right button toenter data modification mode; While in data checking mode, press up or down buttonto move the cursor to next icon; While in data modification mode, press up or down buttonto revise current data; While in data modification mode, press left or right buttonto move the cursor to next data bit.21When the cursor is on the page icon, press “S” to execute thecorresponding function.MAIN FUNCTIONS BELOWMenuPreset DataFunctionLOAD P (MPa)00.651. In AUTO load mode, the compressor willload if air pressure is below this set data.2. In STANDBY mode, the compressor willstart if the pressure is below this set data.UNLOAD P (MPa)00.801. The compressor will unload automaticallyif the air pressure is above this set data.2.This data should be set above LOAD P,also it should be set below UNLD P LIM.FAN START T (oC)0080Fan will start if DISC T is above this set data.FAN STOP T ( C)0070Fan will stop if DISC T is below this set data.MOTOR STARTDELAY (s)0008Set the MOTOR START TIME. Record timewhen motor is activated, the controllerwill not start overload protection duringthis time to avoid impulse starting currentstopping the motor.FAN START DELAY(s)0003Set the FAN START TIME. Record time whenfan is activated, the controller will not startoverload protection during this time toavoid impulse starting current stopping thefan.owww.detroitcompressors.co.za9
Reliable Machinery from the Experts.MenuPreset DataFunctionSTAR DELAY (s)0006Interval time from star start to delta runstate.LOAD DELAY (s)0002Unloaded in this set time after enteringdelta run state.STANDBY DELAY (s)0600When unloaded for this time continuously,the compressor will automatically stop andenter standby.STOP DELAY (s)0010For NORMAL STOP operation, thecompressor will stop after it continuouslyunloads for this set time.RESTART DELAY (s)0100Machine can start only after this set timeelapses (after normal stop, standby or alarmand stop).DRAIN OPEN TIME(s)0002Auto drain control, continuous drain time.DRAIN CLOSE TIME(m)0060Auto drain control, continuous draininterval time.SOFT START DELAY(s)0006Controller starts LOAD DELAY TIME afterSOFT-START DELAY (this data is onlyavailable in SOFT START mode)LOAD MODEMANUAL/AUTOMATICMANUAL: Only when the pressure reachedUNLD P, the compressor will unloadautomatically. For any other case, the Load/Unload function can only be executed bypressing the Load/Unload function button.AUTOMATIC: Load/Unload functionsare executed by the fluctuation of AIR Pautomatically.START MODELOCAL/REMOTELOCAL: Only the button on the controllercan turn on / off the machine.REMOTE: Both the button on the controllerand the remote control button can turn on /off the machine.Note: When one input terminal is set asREMOTE START ENABLE, the start mode iscontrolled by hardware status. It is remotewhen terminal is closed; it is local whenterminal is open.RUN MODEPF/MOTOR VSD/FAN VSD/MOTORFAN VSD/SOFTSTARTChoose the corresponding compressorrun mode according to the customerrequirement and choose the correspondingschematic diagram for reference.COM ADD0001Set the communication address toCOMPUTER or BLOCK mode. This address isunique for every controller in the network.BACKLIGHTADJUSTMENT0001Adjust the backlight; the higher the data,the brighter the display (from level 1 tolevel 4).10www.detroitcompressors.co.za
Reliable Machinery from the Experts.MenuPreset DataFunctionCOM MODECOMPUTER/BLOCK/DISABLEDisable: Communication function is notactivated.Computer: Compressor can communicatewith computer or DCS as slave according toMODBUS-RTU. Baud rate: 9600; data format:8N1; parity bit: even parity check.Block: Compressors can work in a network.PRESSURE UNITMPa/PSI/BARMPa: Pressure unit displays as MPa.PSI: Pressure unit displays as PSI.BAR: Pressure unit displays as BAR.TEMPERATUREUNITOLANGUAGECHINESE/ENGLISH English: displays in EnglishChinese: displays in ChineseUSER PASSWORD****C / oFC temperature unit displays as oC.F temperature unit is displays as oF.OOUsers can modify the user password byusing the current user password or thefactory password.1.6 Factory ParameterFactory parameters are used to store relevant data. Factory password is required for checking and modification. The modificationof factory parameters are the same as customer parameters.MAIN FUNCTIONS BELOWMenuPreset DataFunctionMOTOR RATEDCURRENTMAXIMUMMOTOROVERLOAD DATA/1.2When the motor current is more than 1.2times the set limit, the unit will stop onoverload protection (see table2.1.1).FAN RATEDCURRENTMAXIMUM FANOVERLOADDATA/1.2When the fan motor current is more than1.2 times the set limit, the unit will stop onoverload protection.ALARM DISC T0105When the discharge temperature reachesthis limit, the compressor will alarm.STOP DISC T0110When the discharge temperature reachesthis set limit, compressor will alarm andstop.T 2 ALARM0105When T2 reaches this set limit, thecompressor will alarm.T 2 STOP0110When T2 reaches set limit, the compressorwill alarm and stop.STOP P (MPa)00.90When pressure reaches this set limit, thecompressor will alarm and stop.STOP P 2 (MPa)01.00When P2 reaches this set limit, thecompressor will alarm and stop.11www.detroitcompressors.co.za
Reliable Machinery from the Experts.MenuPreset DataFunctionUNLD P LIM (MPa)00.85This data is the maximum UNLD P. TheUNLD P in the customer parameter must beset no higher than this data.CURRENTUNBALANCE0006When MAX -MIN CURRENT (1 SETDATA*MIN CURRENT/10), the unbalancedprotection function is activated, thecompressor will alarm and stop, reportingMOTOR CURR UNBAL. If the set data 15,the unbalanced protection will not beactivated.OPEN PHASEPROT (s)002.0If OPEN PHASE protection 20 seconds,OPEN PHASE protection is not activatedFAULT RECORDRESET****Input ”8888”and press “set“ button to clearall the history fault records.ALARM LONG STOP(h)0000When the controller detects oil filter / airfilter / O/A separator / lubricant / greaserunning over the max time (if the alarm isset) the compressor will alarm and stop.MAX Runtime (h)00001. When the compressor is in a stoppedstate and the TOTAL Runtime is over thisMAX TIME setting, the compressor willalarm and stop, reporting USER MISTAKE.2. Set the data to ‘0000’ to disable thisfunction.FACTORYPASSWORD 2Set a FACTORY PASSWORD which can bemodified.HIGH VOLTAGE (V)0410When voltage is detected higher thanHIGH VOLTAGE, the controller will alarmand stop. When set as 0000, HIGH VOLTAGEprotection function disabled.LOW VOLTAGE (V)0350When voltage is detected lower than LOWVOLTAGE, the controller will alarm and stop.When set as 0000, LOW VOLTAGE protectionfunction disabled.VSD COM OVERTIME 002.0(s)Record time when the controller sentfirst data; if controller fails to receive thefeedback from the inverter within this settime, the controller will send the commandagain.VSD COMINTERRUPT (s)0020If the controller fails to receive feedbackfrom the inverter for the set time, the VSDCOM is interrupted.VSD COM RESTORE0015After VSD COM is interrupted, and thecontroller receives the correct data morethan the set times, VSD COM is regarded asrestored.12www.detroitcompressors.co.za
Reliable Machinery from the Experts.MenuPreset DataFunctionSCHEDULEDON/OFFDISABLE/ENABLEENABLE: SCHEDULED ON/OFF is activated.DISABLE: SCHEDULED ON/OFF isdeactivated.SET P SECTIONDISABLE/ENABLEENABLE: S SET P SECTION is valid. DISABLE:SET P SECTION is invalid.TOTAL RUNTIME (h)000100.00Total runtime regardless of loaded orunloaded running time.TOTAL LOAD TIME(h)000095.00Total runtime in the loaded state.1.7 Calibration ParametersCalibration parameters are used to store relevant calibration data. Calibration password is required for checking and modification.MAIN FUNCTIONS BELOWMenuPreset DataMOTOR A COEF1.000MOTOR B COEF1.000MOTOR C COEF1.000FAN A COEF1.000FAN B COEF1.000FAN C COEF1.000T 1 COEF1.000T 2 COEF1.000T 3 COEF1.000T 4 COEF1.000T 5 COEF1.000T 6 COEF1.000FunctionInput the coefficient to calibrate current.Controller displays current samplecurrent*coefficient.The range of coefficient: 0.800-2.000Input the coefficient when calibratingdischarge temperature. Controllerdisplay temperature sampletemperature*coefficient.The range of coefficient: 0.800-2.000Note: This parameter is reserved in MAM6080P 1 COEF1.000Input the coefficient to calibrate airpressure. Controller displays pressure sample pressure*coefficient. The range ofcoefficient: 0.800-2.000P 2 COEF1.000Note: This parameter is reserved in MAM608013www.detroitcompressors.co.za
Reliable Machinery from the Experts.MenuPreset DataFunctionP COEF1.000Input the coefficient to calibrate airpressure. Controller display pressure sample pressure*coefficient. The range ofcoefficient: 0.800-2.000PWM1 COEF1.000PWM2 COEF1.000T 1 ZERO0002T 2 ZERO0002T 3 ZERO0002T 4 ZERO0002T 5 ZERO0002T 6 ZERO0002Note: This parameter is reserved in MAM6080Calibrate controller temperature to zero.Calibrate temperature to -20OC whencontroller pressure sensor terminalconnects the resistance in accordance with-20OC. For the calibration of temperature,it is required to calibrate T to zero first andthen calibrate the coeffi
calculation. FAN SPEED 0000 RPM Displays fan real time speed based on the fan frequency reading. FAN OUTPUT FREQUENCY 000.0 Hz Displays the output frequency of the fan inverter. FAN OUTPUT CURRENT 000.0 A Displays the output current of the fan inverter. FAN OUTPUT VOLTAGE 000.0 V Displays output voltage of the fan inverter. FAN OUTPUT POWER
I4 Compressor 2 ready I5 Compressor 3 ready I6 Compressor 4 ready I7 MOS activated Q1 Turn on compressor 1 Q2 Turn on compressor 2 Q3 Turn on compressor 3 Q4 Turn on compressor 4 Q6 Turn off compressor 1 Q2 Turn off compressor 2 Q7 Turn off compressor 3 Q8 Turn off compr
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The high stage screw compressor is with economizer, but the low stage (Booster) compressor is without economizer. Compressor used for this Option-2: Low Stage (Booster): Screw Compressor without Economizer High Stage: Screw Compressor with Economizer The calculation and selection procedures are almost the same as for the System
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