Compressor Controller

MAM – 200

OPERATION MANUAL

Revision 1.0
04.08.2017

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 Notice
Please read all the operation manual before operating the set and keep this manual for further reference.

Installation of MAM—8** compressor controller can be performed only by professional technicians.

RC snubber must be connected to the two terminals of coil (such as AC contactor, valve, etc),which are controlled
by relay output.

Port connection shall be inspected carefully before power on.

PARAMETER is not allowed to be modified in running and stop delay status. Only user
parameter is allowed to be changed at running status

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 Contents
1. Basic Operations ......................................................................................................................................................... 4
1.1 Button Explanation .................................................................................................................................................. 4
1.2 Status Display and Operations ................................................................................................................................ 6
1.3 Operating Parmeter and Menu ............................................................................................................................... 7
1.4 Calendar .................................................................................................................................................................. 7
1.5 Custom parameter .................................................................................................................................................. 8
2 Controller Function and Technical Parameter ............................................................................................................ 13
3 Model and Specification ............................................................................................................................................. 14
4 Alarm Function ........................................................................................................................................................... 16
5 Controller Protection .................................................................................................................................................. 17
6 Troubleshooting .......................................................................................................................................................... 18
7 Sequence Mode Control and Network ....................................................................................................................... 20
7.1 Sequence Mode Control .................................................................................................................................... 20
7.2 Sequence Mode Setting ..................................................................................................................................... 21
7.2.1 Set as Master .................................................................................................................................................. 21
7.2.2. Set as Slave .................................................................................................................................................... 22
7.3 Start, Stop Sequence Control:............................................................................................................................ 22
7.4 Sequence Communication Receiving and Sending Message: ............................................................................ 22
7.5 Network ............................................................................................................................................................. 23
8 Copyright .................................................................................................................................................................... 24

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 1. Basic Operations
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 (No. 1) 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

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 Move down button / Decreasing button
 When viewing the menu, press this button to move downward the cursor
 When modifying data, press this button to decrease the data at current position

Move up button / Increasing 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

Shift button / Enter 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 sub menu 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 prevorious menu
 When the controller is at failure stop status, long press this button to reset

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 1.2 Status Display and Operations

The Display screen will show as below after powered on:

After 5 seconds the menu will switch as below:

Press to enter into selection menu:

RUN PARAMETER
CALENDAR
CUSTOMER PARAMETER
FACTORY PRAMETER

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 1.3 Operating Parmeter and Menu

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

HOST、FAN CURRENT
TOTAL RUN TIME
CURRENT RUN TIME
MAINTENANCE PARAMETER

Move the cursor to “HOST, FAN CURR”, press to switch to secondary menu:

CUR(A)：R S T
HOST： 56.1 56.2 56.0
FAN： 4.1 4.1 4.1

Press to return to the prevorious menu or main menu. If no operation at the current menu for 120seconds,
controller will automatically return to the main menu and turn off the back light simultaneously.

According to above method, use move down button , move up button , enter button ,

and return button to check TOTAL RUN TIME, THIS RUN TIME, VSD PARAMETER,
MAINTENANCE PARAMTER, FAULT RECORD, PROD DATE, SERIAL NUMBER, THIS FAULT and returnto previous
menu.

1.4 Calendar
Check and set time of controller

DATE AND TIME

2017 - 2 - 22
WEEK 0
12 H 46 M 59 S

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 1.5 Custom parameter
1.5.1 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:

Press or to move the cursor to “CUSTOMER PARAMETER”, then press to switch to secondary
menu

SET P、T
ON/OFF DELAY PRESET
OP. MODE PRESET
BLCK PARA PRESET

Move the cursor to “SET P, T”, press to switch to secondary menu:

LOADING P: 0.8MPa
UNLOADING P: 0.6MPa
FAN START T: 80℃
FAN STOP T： 70℃

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

ENTER PASSWORD
****

NOTE: Customer password can be set in CUSTOMER PARAMETER

and FACTORY PARAMETER is fixed as ____________

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 In this menu the first data bit of password blinking, press or to modify the first bit of password.

Press move the cursor to the next data bit, modify the second data bit of password in accordeance with the above.

Modify the the third and fourth data of password in sequence, press to confirm the input data and the menu will
switch to the following menu after verification.

The upper right corner with “*” BLOCK LOAD P: 0.8MPa *

indicates the system verification BLOCK UNLOAD P: 0.6MPa
of the password FAN START T: 80℃
FAN STOP T: 70℃

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 to confirm and save the data. Other CUSTOMER PARAMETER share the similar way for
modification.

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 1.5.2 Customer Parameter Table and Function

First Second
Preset Value Functions
Submenu Submenu
1. In AUTO LOADING status, compressor will load if pressure is below this
set data
LOADING P 0,65 MPa 2. In STANDBY mode, compressor will start if the pressure below this set
data
1. Compressor will unload automatically if air pressure is above this set
data
UNLOAD P 0,80 MPa 2.This data should be set above LOADING P, also should be set below UNLD
P LIM
Set P / T / VF FAN START 0080℃ Fan will start if AIR T is above this set data
FAN STOP 0070℃ Fan will start if AIR T is above this set data
Set AIR P for VSD compressor to keep running stable, when pressure is
VF WORKING 0,70MPa fluctuated around this data, controller will adjust operation frequency of
inverter to control the pressure close to this data
RATED POWER 015kW Set RATED POWER in order to calculate actual power
Set RATED SPEED at 50HZ in order to calculate the actual speed in variable
RATED SPEED 2600RPM frequency
Set the HOST START TIME. Record time when motor is activated, controller
HOST START TIME 0008s will not start overload protection during this time to avoid impulse starting
current stopping the motor.
Set the FAN START TIME. Record time when fan is activated, controller will
FAN START TIME 0003s not start overload protection during this time to avoid impulse starting
current stopping the fan
STAR DELAY TIME 0006S Interval time from star to delta
LOAD DELAY TIME 0002S Unloading in this set time after enter delta running
When unloading continuously, compressor will automatically stop and
SET TIME EMPTY DELAY TIME 0600S
enter to standby status if over this set time
For NORMAL STOP operation, compressor will stop after it continuously
STOP DELAY TIME 0010S unloading over this set time
Machine cannot be restarted before this set time (stop and over time load
START DELAY TIME 0100S free stop till this time)
Restrict PID calculations in case the frequency increasing too fast which
VSD UP SPEED 0100 cause motor speeding up too fast
Restrict PID calculations in case the frequency decreasing too fast which
VSD DN SPEED 0100 cause motor slowing down too fast
NEAR: only the button on the controller can turn on and turn off the
machine.
ON/OFF MODE Near / Far
FAR: both the button on the controller and
the remote-control button can turn on and turn off the machine;
Manual: Only when the pressure is above Unload P, compressor will
unload automatically. For any other case, the Load/Unload function can
Operation mode Auto/
LOAD MODE only be executed by pressing “load/unload” key.
preset Manual AUTOMATICAL: the load/unload function can be executed by the
fluctuation of AIR P automatically
Prohibited: communication function is not activated.
Computer
COMPUTER: compressor can communicate with computer or DCS as slave
COM MODE Block according to MODBUS-RTU.
Prohibited BLOCK: compressors can work in a net
COM ADRESS 0255 Communication address
1.When service as master in BLOCK, master
Blocking
Main/ controls slave; the COM ADD should be set as No.1
parameter BLOCK STATE 2.When service as slave in BLOCK, slave is
Slave
preset controlled by master
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 Alone/
BLOCK ON/OFF
Order
When master pressure is between BLOCK LOAD P and BLOCK UNLD P,
TURN TIME 99 Hours master determines slave to work alternatively after
working over this set time
BLOCK NUMBER 0016 Number of air compressors in block net

In BLOCK mode, one compressor will start or load when master AIR P is
BLOCK LOAD P *.**MPa below this set data

In BLOCK mode, one compressor will stop or unload when master AIR P is
BLOCK UNLOAD P *.**MPa above this set Data

In BLOCK mode, when master sends two commands continuously, second

BLOCK DELAY 200S command signal delays for this set data

Record total running time of OIL filter. If changing new oil filter, the data
OIL FILTER RESET 0000 HOURS
should be reset by manual operation.

Record total running time of O/A filter. If changing new O/A separator, the
O/A RESET 0000Hours data should be reset by manual operation.
Maintenance
parameter Record total running time of AIR filter. If changing new air filter, the data
AIR FILTER RESET 0000Hours should be reset by manual operation.
preset
Record total running time of LUB OIL. If changing new lubricating oil, the
LUB OIL RESET 0000Hours data should be reset by manual operation.
Record total running time of LUB GREASE. If changing new grease, the data
LUB GREASE RESET 0000Hours should be reset by manual operation.
1. Alarm prompt when total running time of oil filter is above the set data
OIL FILTER 9999Hours 2. Set this data to “0000”, alarm function for
oil filter running time is not activated
1. Alarm prompt when total running time of O/A separator is above the set
data.
O/A SEPARATOR 9999Hours 2. Set this data to “0000”, alarm function for O/A separator running time is
not activated
1. Alarm prompt when total running time of air filter is above the set data.
Max. life time
AIR FILTER 9999Hours 2. Set this data to “0000”, alarm function for air filter running time is not
preset activated
1. Alarm prompt when total running time of lubricant is above the set
data.
LUB. OIL 9999Hours 2. Set this data to “0000”, alarm function for lubricant running time is not
activated.
1. Alarm prompt when total running time of grease is above the set data.
LUB GREASE 9999Hours 2. Set this data to “0” , alarm function for grease running time is not
activated
Language
English Change the display language.
display
User password User could modify the user password by old user password or factory
**** password
modification

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 1.5.3 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 as below:

Menu Initial Value Functions

After the starting delay time, when the motor current is greater than 1.2 times of the set
HOST RATED CURRENT value and less than 4 times of the set value, the unit will jump as per overload feature.
FAN RATED CURRENT Same as above
PRE-ALARM T 105℃ Pre-alarm when the temperature reaches this set value
STOP T 110℃ Alarm when the air exhausting temperature reaches this set value.
STOP P 1.00MPa Alarm and stop the machine when the air supply temperature reaches this set value
UNLOAD P. UPPER LIMIT 0.80MPa The Unload Limit Pressure in the Customer Parameter must be set lower than this value.
LOAD TIME ****Hours Total load time
TOTAL TIME ****Hours Total run time
HISTORY FAULT RESET **** Input the history failure password to clear all the history failures.
When (the max. phase current / min. phase current) is greater than (1+set value), the
UNBALANCE SCOPE 0006 unbalance protection will stop the machine. If the set value is greater than 15, the
unbalance protection will be unavailable.
LACK PHASE PROTECTION 0005 Set the LACK PHASE TIME ≥20S, the Lack phase protection will be disabled
VF VF: Inverter will run
RUN MODE Commercial F: Star-delta will run
Commercial F

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 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:

Customer Password: factory set ____________

Permissions: Allows to modify all Customer Parameter
Factory Password: fixed ____________
Permissions: Allows user to modify all Parameter

2 Controller Function and Technical Parameter

 Phase sequence protection:

When compressor is at stop mode an detects open phase, response time <2ms

 Open phase protection

When any phase opens, the response time equals to set time: This fuinction is not activated when OPEN PHASE
PROTECTION time iss et over 20s

 Motor protection: This control unit has the following 5 basic protection functions to the motor and fan.
o Rotor lock protection: After the starting oft he motor, if the working current reaches 4 or 8 times oft he set
value, the protection activates. The activate time is less than 0,2s.
o Short.circuit protection: If the detected current reaches 8times or more above the set value, the protection
activates, the activate time is less then 0,2s
o Lack phase protection: Any oft the phase lack, the protection activates and theactivate time ist he setting
time
o Unbalance protection: The current difference between any of the two phases reaches the percentage of the
setting value, the protection activates and the activate time is less than 5s.
o Protection features of overload, please see following table for your reference. Multiple＝Iactual／Iset ,
response time is shown in following table according to overload multiples from 1.2 times an 3.0times.

Iact/Iset
≥1.2 ≥1.3 ≥1.5 ≥1.6 ≥2.0 ≥3.0
Time Para
response time (s) 60 48 24 8 5 1

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 3 Model and Specification
 Main controller model description
MAM - KY02 S (40) (B) (T)

T：RS—485 communication
B：Transformer; K：Pressure Switch
Matched Host Maximum nominal working current
S：Screw type Air compressor
02 type air compressor controller（LCD）
Products Series

 Power consumption table for corresponding motor

Parameter Adopted Host

Current Range
Spec. Motor Power Remarks Descriptions
（A）
（KW）
MAM—KY02S（20） 8～20 4～10
MAM—KY02S（40） 16～40 8～20 Fan has three levels of
MAM—KY02S（100） 30～100 15～50 current. Such as 0.2-2.5A,
MAM—KY02S（200） 80～200 40～100 1-5A and 4-10A,
MAM—KY02S（400） 160～400 80～200 determined by current of
motor.
MAM—KY02S（600/5) Connect to
100～600 50～300
CT

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  Electrical basic wiring installation

Attention: the magnetic coil must be connected to the surging absorber when wiring

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 4 Alarm Function

4.1 Monitor text

4.1.1 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 air filter exhausts

4.1.2 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

4.1.3 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. Set O/A max. time
The monitor displays O/A LIFE END when the run time of the O/A separator exhausts

4.1.4 Lubricating Oil Alarm

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

4.1.5 Grease Alarm

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

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 5 Controller Protection
5.1 Motor Protection
MAM-200 compressor controller provides short circuit, block, overload, lack phase and unbalance protection on
motor.

Electronic
Failure Display Reasons
Failure
Short circuit Display “MOTOR / FAN OVERLOAD” Short circuit or wrong current set

Current block Display “MOTOR / FAN BLOCK” Overload, bearing wear off or other mechanical failures

Overload Display “MOTOR / FAN OVERLOAD” Overload, bearing wear off or other mechanical failures

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

5.2 Protection of Air Temperature High

When AIR T is above the STOP DISC T, the controller will alarm and stop the machine.
This fault displays DISC T HIGH

5.3 Protection of Air Compressor Reversal

When the phase sequence of the power connected to the air compressor is not conforming to the set of the
controller, the local failure displays “Wrong phase sequence” and as a result the controller cannot start the motor.
It is needed to check and alternate any two of the phase sequence and investigate the motor rotation direction.

5.4 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

5.5 Protection of Sensor Failure

When the cable of the pressure sensor or the temperature sensor is broken, the controller will alarm and stop the
machine and the local failure displays “** sensor failure”.

5.6 Interlock Protection

The Motor is running and the air exhaust temperature reaches the fan starting temperature but the fan does not
run, the controller alarm, the local failure displays “FAN is stopped”.

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

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

MOTORS CURRENT
TOTAL RUN TIME:
CURRENT RUN TIME
MAINTENANCE

Press to move the cursor to “CURRENT FAULT”

HISTORY FAULT
PROD. DATE/NUM
CURRENT FAULT

Then press to reach the following failure cause:

Temperature sensor Failure

170℃

Check the temperature sensor to confirm if there is any line broken or damage.

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 User can reset the error according to the following information:
Failure Causes Measurement to take
AIR T HIGH Bad vent condition, Oil lacking etc. Check the vent condition and lubricant amount etc.

AIR T SENSOR FAULT Cable off or PT1OO damaged Checking the wiring and PT100

The pressure too high or the pressure

AIR P HIGH Check the pressure and the pressure sensor
sensor failure
Cable off, Sensor damaged or the cable
AIR P SENSOR FAULT Check the wiring and sensor transformer
connected reversed

LACK WATER Water Pressure switch damaged Check the water pressure switch

Power phase lacking or the Contactor

LACK PHASE Check the power and contactors
terminal damaged
Voltage too low, tubes blocked, bearing
Check the set data, Voltage, bearings, tubes and other
OVERLOAD wear off or other mechanical failure or mechanical system.
wrong set data etc.
Power unbalance, contactor damaged
UNBALANCE Check the power, contactors and the motor
or the internal open of the motor
Voltage too low, tubes blocked, bearing
Check the set data, Voltage, bearings, tubes and other
BLOCK wear off or other mechanical failure or mechanical system.
wrong set data etc.
Wrong cable connection, wrong set
SHORT CIRCUIT Checking the wiring and set the data correctly
data

WRONG PHASE SEQUENCE Reversed Phase sequence or phase off Check the wiring

Fan damaged, Contactor damaged, no

Fan stopped Check the wiring and control output
control output
Overload or Rotor locking Start time set too less than the star Reset the host starting time to be longer than star delta delay
during starting process delta time delay + load delay time

Main Contactor activate time

The emergency button loose Check the wiring
to time

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 7 Sequence Mode Control and Network

7.1 Sequence Mode Control

MAM-860 controller can operate with other MAM series compressor (with communication function). 16 pcs
compressors are allowed in the net at most. The cable connection for block mode is as below….

A B A B A B A B A B

Master 1 Slave 2 Slave 3 Slave 4 Slave 16

Compressors with net communication address 0001 is master, others are slave. Any one MAM-series compressors can
be set as master or slave

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 7.2 Sequence Mode Setting

7.2.1 Set as Master

Press or to move the cursor to “USER PARAMETER”, then press to switch to the menu below:

P, T SET
TIMER SET
OPERATION MODE
SEQ PARA. SET

Move the cursor to the “OPERATION MODE”, then press to switch to the menu below.

RUN MODE: REMOTE

LOAD MODE: AUTO Set “COM MODE” as SEQ
COM MODE: SEQ Set “COM ADD” as 0001
COM ADD： 0001

Return to the previous menu, move the cursor to “SEQ PARA SET” press to switch to the menu below.

SEQ STATE: HOST

TURN TIME: 0099H
SEQ NUMBER: 0016
SEQ LOAD： 1,36MPa

SEQ UNLOAD: 1,36MPa

SEQ DELAY: 200s

According to user requirement, set SEQ STATE as Host, set TURN TIME, SEQ NUMBER, SEQ LOAD, SEQ UNLOAD
and SEQ DELAY according to user´s need.

Attention: After setting, controller needs to be powered off and restarts to the settings!

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 7.2.2. Set as Slave
When MAM controller serves as slave, it is only necessary to set COM MODE as SEQ. Set COM ADD from 2 – 16
with sequence according to the quantity of compressors, and SEQ STATE as SLAVE.

7.3 Start, Stop Sequence Control:

Make sure sequence cables connect correctly and the parameter of compressors in net set correctly. Activate
master, master controls the compressors in net automatically according to the air pressure detected. Sequence
control stops at the same time when manually stop the master. So, master will no longer send command to
compressor in net.

AIR T: 78°C ◊
AIR P： 0.53MPa
NORMAL STOP 0S ◊: Blinking icon indicate
C16 REMOTE
master has active seq
mode function

7.4 Sequence Communication Receiving and Sending Message:

The message received and sent by RS485 can be displayed by the corresponding indication screen which is
convenient for customer to make sure if they have received and feedback data in SEQ MODE or COM MODE.
The method to switch to communication menu is as below:

Press or in main menu and select “RUN PARAMETER” and move down the cursor to communication

menu. Press to switch to the menu below:

RX: ----
TX: ----

When controller receives data, RX “—“ and “*” display alternately. When sends data, TX “—“ and “*” display
alternately. When controller is in SEQ mode or communicates with monitoring center, user can confirm the
establishment of communication through this menu.

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 7.5 Network
MAM-860 controller supports MODBUS RTU protocol and can serve as slave when connect with other equipment and
supports 03, 06, 16 MODBUS command.
 Communication baud rate: 9600BPS
 1 start bit
 8 data bits
 1 stop bit
 even parity

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 8 Copyright
This manual is protected by copyright and intended solely for internal use.
This manual must not be made available to third parties, duplicated in any manner or form – whether in whole or in part –
and the content must not be used and/or communicated, except for internal purposes, without the written consent of the
manufacturer. Violation of the copyright will result in legal action for damages. We reserve the right to assert further claims.

Tolpec GmbH
Wertstrasse 44
D- 73240 Wendlingen
Telephone: +49 (0)7022 789 604-0
E-mail: contact@tolpec.com

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