OPERATING INSTRUCTIONS FOR CONTROLTRONIK

CONTROL KEYS DISPLAY LED’s

K1 Scroll parameter display A1a Over temperature cut out

K2 Start button A1b Motor overload cut out

K3 Stop button A1c Sense of rotation

K4 Increase parameter A1d Oil filter warning

K5 Decrease parameter A1e Air filter warning

K6 Reset button A1f Separator warning

A1g Automatic restart after power loss

A1h Remote control operation

A1o Power on

ADDITIONAL FUNCTIONS

B Display panel

SB2 Emergency stop

SL Dryer on / off switch

DP Dewpoint indicator

The above display will give all operating, warning and fault information during operation.

NOTE-When changing or setting any values in the Controltronic, you must wait until the new
value stops flashing before moving to the next item.
BASIC OPERATION
During normal operation the compressor shows the operating status and the current receiver
pressure.

When first switching on the display will light and scroll through its start procedure. If A1c
illuminates then the power should be switched off at the supply and two incoming phases should be
reversed, once the power is restored press K6 to re-set.

Press K2 to start the compressor, the display will show A 0.0 or C 0.0 depending on whether
automatic or continuous run has been chosen ( see menu 1 ). When the solenoid is energised to load
the compressor an LED will illuminate next to the A or C, the 0.0 will rise with the pressure in the
tank until the compressor offloads at its maximum pressure ( see menu 1 ) If after 5 minutes there is
no requirement for air then the compressor will shut down in “ auto shutdown “ and will
automatically re – start upon a requirement for air.

During any time the power is on to the compressor K1 can be used to scroll the following information

K1 x 1, Discharge air / oil temperature

K1 x 2, Total run hours

K1 x 3, Loaded hours

K1 x 4, Hours left to service

K1 x 5, Back to pressure display

To stop the compressor press K3 and the compressor will run for approximately 30 seconds
depending on setting ( see menu 10 )
The emergency stop SB2 will stop the compressor immediately.
The maintenance warning lights are pre – programmed and not adjustable, the following values are
programmed and after service should be re – set via menu 2.

ACTION 100 HRS 1000 HRS 2000 HRS 3000 HRS 4000 HRS
AIR FILTER # #
OIL FILTER # # # # #
SEPARATOR # #
OIL CHANGE #
Air filter needs check only and verify at 100Hr
When oil change is required display will show OIL cH
Procedure is repeated with the exception of 100Hr service.
Belt tension should be checked after the first 100 hours and every 1000 hours thereafter.
 CONTROL MENU’S

MENU 1 control menu

DANGER
Incorrect setting of the operating values can cause operational problems with the compressor.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 01 ( menu 01 )

PUSH Display Description Default

K1 x 1, Max pressure value Up to Max pressure of model 125

K1 x 2, Min pressure value Normally 15 PSI below max 110

K1 x 3, Bar or PSI Alternates display PSI

K1 x 4, Celsius or Fahrenheit Alternates display F

*K1 x 5, Condensate drain opening time Between 0.4 sec and 10 sec 5

*K1 x 6, Condensate drain interval Between 10 sec and 1800 sec 60

K1 x 7, Run on timer setting 0 = continuous / 2 – 240 minutes 15

K1 x 8, Return to Max pressure.

*Applies to GENESIS only, values are shown but are not functional on the SMART.

MENU 2 reset maintenance

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 02 ( menu 02 ) The above procedure will re –
set all service intervals that had reached zero hours.

For Software version E09 and above, the following procedure should be used.
Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use button K4 to change display to 02 (menu 2).

Use K4 to change the value to the default time (as set in menu 12), then use K1 to scroll to the
next item to be reset and repeat the procedure. This procedure must be carried out for each
maintenance indication (yellow light on the board).

Return to the normal display with K6. The maintenance periods can now be reset when the timer
is within 100 hours of zero.
MENU 3 auto restart
DANGER- DURING OPERATION IN AUTO RESTART MODE, THE
COMPRESSOR CAN START UP AUTOMATICALLY AT ANY TIME!

Prior to accessing this menu, Menu 35 must be entered to unlock the access.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 03 ( menu 03 )then press buttons K2 and K3
together.

K1 x 1, Display reads “ 0 “ (DEFAULT) Change with K4 from 10 – 240 sec

“0” = Auto re-start off.

10 – 240 = Duration of power loss sustained in seconds from which machine will re- start
automatically. If chosen then LED A1g will illuminate.

MENU 5 Remote control

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 05 ( menu 05 ) then press buttons K2 and K3
together.

K1 x 1, Remote control of Motor on / off or LoAd on / off

K1 x 2, Remote control Local / Remote

K1 x 3, Air temp reading tON Enable or tOFF disable

K1 x 4, rs485 + number Select rs485 (not available ye

MENU 10 Limit values

Danger-Incorrect setting of the limit values can cause severe damage to the compressor and
could void the warranty.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 10 (menu 10) then press buttons K2 and K3
together.

K1 x 1, TP 1 – 4 according to pressure of compressor TP 1 = 117 PSI

TP 2 = 146 PSI
TP 3 = 190 PSI
TP 4 = 219 PSI
Should any adjustments of the Factory limit values be required then these must be adjusted only
in TP 0, once adjustments are made then restore the machine to the correct pressure “ TP “, the
new settings will be incorporated. To make any changes to settings you must walk through all
steps and get back to TP0 prior to hitting K6 (reset) to exit the menu.
Possible settings in TP 0 are as follows:
PUSH DESCRIPTION RANGE DEFAULT
K1 x 1, Max pressure 44 to 233 PSI per order

K1 x 2, Centre temp for fan thermostat 0 – 230 deg F 169 F

K1 x 3, Delta T of fan switching 1 – 68 deg F 9F

K1 x 4, Fan on time after power off 10 – 120 sec’s 15

K1 x 5, Max temp cut out 0 – 257 deg C 230 F

K1 x 6, Fan status alarm FAN

K1 x 7, Star / Delta time 0 – 15 seconds N/A

K1 x 8, Soft stop timer 0 – 75 seconds 30

K1 x 9, Blow down time 0 – 240 seconds 10

K1 x 10, Base time h=hours s=seconds h

K1 x 11, Total hours

K1 x 12, Load hours

K1 x 13, Return to max pressure.

MENU 11 Digital inputs

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 11 ( menu 11) Then press buttons K2 and
K3 together.

K1 x 1, Input NR 1 = N/C emergency stop switch

K1 x 2, Input NR 2 = N/C phase monitor relay

K1 x 3, Input NR3 = N/C over pressure

K1 x 4, Input NR 4 = N/C motor temp

K1 x 5, Input NR 5 = N/O remote start/stop enable

K1 x 6, Input NR 6 = N/O remote start switch connection

K1 x 7, Input NR 7 = N/O air filter switch

MENU 12 Maintenance Interval Defaults (New with version E09)

Access to the menu is gained by holding buttons K4 and K5 together until all LED’s
illuminate and flash. Use button K4 to change display to 12 (menu 12) then press buttons
K2 and K3 together.

The following maintenance intervals can be programmed in this menu, these values will
take effect after the factory stored value has elapsed, (i.e.- the value programmed for the oil
filter change will take effect after the initial 100 hour interval programmed by the factory).

⇒ AFILT (air filter) 100 to 2000 hours (default is 2000)

K1 X 1 OFILT (oil filter) 100 to 2000 hours (default is 1000)
K1 X 2 OSEP (separator) 100 to 4000 hours (default is 2000)
K1 X 3 OILch (oil change) 100 to 8000 hours (default is 2000??)

When setting intervals, you must wait until the new value stops flashing before moving to
the next item.

MENU 20 Test menu

Prior to accessing this menu, Menu 35 must be entered to unlock the access.
* Caution- the machine will start during this test- it is imperative that direction of
rotation be checked prior using the MENU 20 tests.

Access to the menu is gained by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 20 ( menu 20 )then press buttons K2 and
K3 together.

Display will test all LED’s and “8” will cycle through display.

K5 x 1, Inputs test 0 = OK, 1= not OK

All 8 inputs should be looked at ( only number 5 should read 1 )

K5 x 9, Output tests ( tUSC 1)

K5 x 10, Line contactor (CAUTION-the machine will start)

K5 x 11, Star contactor

K5 x 12, Delta contactor

K5 x 13, Load solenoid

K5 x 14, Fan

K5 x 15, Drain valve

K5 x 16, Rotation test ( press start to test-this will jog the motor)

Exit by pressing K6 and then K3.

MENU 35 ABAC Codes

Access to this menu is by holding buttons K4 and K5 together until all display LED’s
illuminate and flash. Use K4 to change display to 35 ( menu 35 ) then press buttons K2 and
K3 together.
This will “ unlock “ the access to ABAC factory settings.

FAULT DISPLAYS

All faults should be rectified and then cleared with the re-set key K6

Display reads --- Fault with Temperature transducer

Display reads ----- Fault with Pressure transducer

Display reads PCO Machine has gone over pressure

All LED’s flashing Emergency stop depressed

A1c illuminated Reverse direction of rotation

A1o off Fuse blown or power loss

A1a flashing (slow) Warning machine running over temperature

A1a flashing (fast) Machine cut out on over temperature

A1b illuminated Machine cut out on motor overload

A1d illuminated Change oil filter warning

A1e illuminated Change air filter warning

A1f illuminated Change separator warning