KT Controller Manual - M45-75

Ingersoll-Rand
KT-GL-09B Controller
Operation Manual
25 Oct. 2011
P/N：24122400.A
Contents
1. Product information ....................................................................................................................................... 0
1.1 Electrical features ..................................................................................................................................... 0
1.2 Basic operation panel................................................................................................................................ 0
1.3 Conroller‟s ports ....................................................................................................................................... 1
1.4 Dimensional diagrams .............................................................................................................................. 1
1.5 Electrical diagrams ................................................................................................................................... 3
1.6 Description of terminals ........................................................................................................................... 4
2、Operation and displays ................................................................................................................................. 7
2.1 Flowcharts of operation interfaces ........................................................................................................... 7
2.2 How to operate on LC display interface ................................................................................................... 8
2.2.1 Interface skip .................................................................................................................................... 8
2.2.2 Parameter checking & modifying methods ........................................................................................ 8
2.3 Initialized interface ................................................................................................................................. 10
2.4 Main page ............................................................................................................................................... 10
2.5 Menu pages ............................................................................................................................................. 10
2.6 Fault record ............................................................................................................................................. 11
2.7 Current time ............................................................................................................................................ 12
2.8 Parameter setting .................................................................................................................................... 12
2.9 Browsing of common parameters ........................................................................................................... 12
2.10Major fault alarm display ...................................................................................................................... 13
3、Parameter lists & description ..................................................................................................................... 13
3.1 Parameters under directory “Control setting”(table 3.1) ..................................................................... 13
3.2 Parameters under directory “Running parameter”(table 3.2) .............................................................. 15
3.3 Parameters under directory “User‟s parameter”(table 3.3).................................................................. 16
3.4 Parameters under directory “Element calibration”(table 3.4) ............................................................. 19
4、Control principles....................................................................................................................................... 19
4.1 Main machine control modes ................................................................................................................. 19
4.1.1 Local control .................................................................................................................................... 19
4.1.2 Remote control ................................................................................................................................. 20
4.1.3 Communicated remote control ....................................................................................................... 20
4.2 Fan control .............................................................................................................................................. 20
5、 Air compressor working states & fault status .......................................................................................... 20
5.1 Working states ........................................................................................................................................ 20
5.2 Minor fault warnings .............................................................................................................................. 21
5.3 Major fault shutdown.............................................................................................................................. 22
Appendix 1：Serial communication protocol ................................................................................................. 24
Appendix 2： ................................................................................................................................................... 26
1、Product information
1.1 Electrical features
Working electric source： AC24V(-5%/+5%), 30W。
Working ambient temperature：0-50℃。
1.2 Basic operation panel
7 Thank you for your using

8 Ingersoll-Rand compressor 6
9 KT―GL―09B
10 CPN: 19067875 VER.:BG-V100
1 2 3 4
1、 Start key：to start air compressor when in main screen。Used for “confirm” key when in special running mode。
2、 Manually enforced loading：Press this key when in unloaded status to enter “Locally loading” and compressor starts to
load。
3、 Manually enforced unloading；Press this key when in loaded status to enter “Locally unloading” and compressor starts
to unload。
4、 Stop key：Press this key in any page to stop compressor。
5、 LC interface function key：to perform a respective operation depending on hint displayed in an interface。
6、 LC arrow key：used to scroll pages up or down，or to modify a parameter value。
7、 Power on indicator lamp：it is lighting when controller power supply is normal；
8、 Running indicator lamp：it is lighting when air compressor is operating normally.
9、 Alarm indicator lamp：it is flashing when the system gives out a warning，and is lighting constantly when a major failure
alarm occurs。
10、Remote control indicator lamp：the system is set to normally lighting when in remote control。
Note：
The above picture shows the initialized page, which includes the following：
KT-GL-09B 控制器操作说明
Controller type“KT―GL―09B”、part number“CPN: 19067875”、and software version “VER:BG-V100”。
1.3 Controller’s ports

·Power input port：
101-103: AC24V input。
·D/I digital quantitative signal input ports（17 in total）
：
303-314, 201-206：201 is a COM port，a DC24V power is connected from an outside electric source through 301、
302。
·A/I analog quantitative signal input port（13 in total）
：
701-709，1001-1009：6 route PT100 temperature sensor input port。
710-715，1010-1015：6 route 4-20mA pressure sensor input port。
401-402：1 route PTC signal。
·D/O digital quantitative signal output port：
501-507：10A 220V。
601-612：8A 220V, separately output。
·A/O analog quantitative signal output port（2 routes in total）：
901-904：4-20mA。
·RS485 communication port（2 routes in total）
：
RS485communication ports：801-803，1101-1103。
1.4 Dimension diagrams
1
2
1.5 Electrical diagram:
3
( Please attention to the actual schematic electrical wiring that on behind the door of control box )
1.6 Description of terminals
No. Function defined Note

101 POWER-IN
24VAC
102 POWER-IN
103

201 Common terminal
202 Emergency stop Normally close/ DI
203 reserved Normally open/ DI
301 24VDC+in
302 24VDC-in
303 M contact feedback Normally open/ DI
304 S-D contact feedback Normally open/ DI
305 Main motor overload Normally close/ DI
306 Fan motor overload Normally close/ DI
307 Temperature switch Normally open/ DI
308 Remote loading enable Normally open/ DI
309 Remote load/unload Normally open/ DI
310 Remote stop Normally close/ DI
311 Remote start Normally open/ DI
312 Oil filter Normally open/ DI
313 Fine oil separator Normally open/ DI
314 Air filter Normally open/ DI

401
PTC resistor in
402

501 Main motor contactor signal Normally open/ DO
502 star-delta contactor signal Normally open/ DO
503 Fan motor contactor signal Normally open/ DO
504 Loader valve signal Normally open/ DO
505 Regulator valve signal Normally open/ DO
4
506 Draining valve signal Normally open/ DO

507 Common terminal Normally open/ DO
601 Normally open/ DO
Running signal
Alarm signal
Remote control signal
PORO signal
Warning signal
Front bearing hi-temperature alarm signal

701 A/E disch. Temp. T1 sensor terminal（＋）
Pｔ100
702 A/E disch. Temp. T1 sensor terminal（－）
Temp. sensor
703 GND
704 Package disch. Temp. T2 sensor terminal（＋）
Pｔ100
705 Package disch. Temp. T2 sensor terminal（－）
Temp. sensor
706 GND
707 A/E Injection temp. T3 sensor terminal（＋）
Pｔ100
708 A/E Injection temp. T3 sensor terminal（－）
Temp. sensor（option）
709 GND
710 Package disch. press. P1 sensor terminal（＋24V） 4～20mA current
711 Package disch. press. P1 sensor terminal Press. sensor
712 Sump press. P2 sensor terminal（＋24V） 4～20mA current
713 Sump press. P2 sensor terminal Press. sensor
714 Vacuum P3 sensor terminal（＋24V） 4～20mA current
715 Vacuum P3 sensor terminal Press. sensor

801 RS485+
802 RS485-
803 GND
Analog output terminals

901 Package pressure PWM 4～20mA
902 GND Current output
903 A/E temperature PWM 4～20mA
5
904 GND Current output

1001 Front bearing temp.T4 sensor terminal（＋）
Pｔ100
1002 Front bearing temp.T4 sensor terminal（－）
Temp. sensor
1003 GND
1004 T5 temp. sensor terminal（＋）
Pｔ100
1005 T5 temp. sensor terminal（－）
Temp. sensor
1006 GND
1007 T6 temp. sensor terminal（＋）
Pｔ100
1008 T6 temp. sensor terminal（－）
Temp. sensor
1009 GND
1010 P4 press. sensor terminal 4～20mA current
1011 P4 press. sensor terminal（+24V） Pressure sensor

1101 RS485+
1102 RS485-
1103 GND
6
△pack press. △a/e disch.temp. △sump press. △pack.disch.temp. △fr.brg.temp.
Curr.state Factory parameters（for Mfgr.only）
△run time △ambt.temp. △inlet vacuum △P4 △P5 △P6
☆saved as factory values ☆
△A/E inje.temp. △T5 △T6 △air filter time △air filter surplus rated press.☆press. difference
Main menu △oil filter time △oil filter surplus △oil sep. time △oil sep. surplus △load time warning
☆trial function ☆trial time
☆oil inje. Temp. enable ☆air
inlet vacuum enable
☆PTC fault enable ☆PTC hi-temp.
Fault record Comm..para Para setting N enable
Current time
☆run time change ☆airfilter
参数
change setting
2、Operations & displays
Enter code ☆P4 enable ☆P5 enable

Read only
☆P6 enable ☆fr. Bearing
Fault list 1~15 Sys. Curr.date/time
Cannot be changed Y temp. enable
2.1 Flowchart of operation interfaces
☆T5 enable ☆T6 enable

Para. setting ☆T5、T6 alarm ☆T2 enable
△package press.
△pack.disch.temp.
△A/E disch.temp.
7
△sump press. Control setting Run para. User’s para Elemt. Calr.
△fr.brg.temp.
△A/E inje.temp.
△air inlet vacuum
△P4 P5 P6
□local/remote contl □unloaded press. ■pressure unit □pack press slope □pack press zero
△T5 T6
■control mode □loaded press. □language select □sump press slope□sump press zero
△ambient temp.
□sleeping function ■load delay □date change □inlet vac slope□inlet vac zero
△fault occur.time
□sleeping time ■unload delay □time change □pack temp.slope □pack temp. zero
□PORO □stop delay □oil filter use □A/E temp. slope □A/E temp. zero
□PORO warning time □stop restart time reset □inj. Temp. slope □inj.temp. zero
familiarized with these interfaces and to find out any content he/she requires.
△：user’s parameter，read only □lag machine add. ■drain valve □oil sep. use time □analog qty 1 slope□analog qty1 zero
□：users para.，can be changed when stopping □baud rate interval reset □analog qty2 slope □analog qty2 zero
■：operator para.，can be changed when running □oil filter time ■drain valve open □air filter use □e-source volt slope□e-source vol
Or stopping □oil separator time ■fan motor start time reset zero
□air filter time temp. □user code change □P4 slope □P4 zero
■fan motor stop □factory values □P5 slope □P5zero
temp. restore □P6slope □P6zero
□Y-start time □fr.brg.temp.slope□fr.brg.temp.zero
□fr.brg.alarm □T5 slope □T5 zero
□T6 slope □T6 zero
This flowchart shows contents displayed in the controller‟s main interfaces to facilitate users to be
2.2 How to operate on LC display interface

2.2.1 Interface skip
What displayed in three cells on the last line of the interface displayed is respectively corresponding to three function
keys on the control panel. Follow hint displayed and press a corresponding key, you can perform a corresponding
interface skip or otherwise a functional operation.
In upper right corner of an interface, for most pages, there is an arrow, which may indicate in three different directions：
“↓”、
“↑”、
“↕”. Direction of the arrow indicates that by pressing“▽”or“△”key on the control panel you can turn pages.
When changing a parameter，the press key in the upper right corner will disappear，at this point you can press“▽”
or“△”key to change value of parameter.
0.56 Mpa -run param.- ↓

32℃ unloaded press. 0.71Mpa
shutdown loaded press. 0.60Mpa
return set
Fig. 2.2.1
2.2.2 Parameter checking & modifying methods
To quickly browse common parameters：enter“Common parameters)” from the main menu page to view parameter(s)
（read only）.
You must enter “Parameter setting” whenever a parameter setting is required to be modified, after entering it you can
change value of such parameter by methods introduced below:
Parameter is classified into two categories: numerical parameter and functional parameter. In the following paragraph
setting of“Unloaded pressure”and“loaded pressure”under directory “Run parameter”，and “Local/remote control”
and“Control mode”under directory “Control parameter” will be taken for example to describe methods of modifying
parameter of both categories.
①、How to change a numerical parameter
Input a code“1010”to enter menu page“Parameter setting”and select “Run parameter”，then press “Select” key to
enter “Control parameter setting” page (Fig. 2.2.2).
0.56 Mpa -run param.- ↓

return set
Fig. 2.2.2
Equally，press“▽” or “△”key to select other parameters，and when the second line is displayed inversely，press
again“▽” or“△”key to turn into the next parameter setting page.
select “loaded pressure” and press“Set” key，then parameter on this line will enter a changeable status，and value of
this parameter will flash starting from the last digit，while the press key hint changes to a state as shown in fig. 2.2.3.
8
0.56 Mpa -run param.-

return move left confirm
Fig. 2.2.3
Each time the key“move left” is pressed, flashing position of the parameter value will move left by one digit. Once the
first digit is reached and press the key“move left” again，the flashing position will return to the last digit. Press up/down key
on the control panel when a certain digit is flashing, it will add to or reduce from this flashing value by one.
Once the parameter has been modified press key“confirm” to save the new value and then quit modification status. If
you want to cancel such change, just press key “cancel”，and the original value remains unchanged，and quit the
modification status.
②、How to change a functional parameter
Input code 1010 to enter the menu page“parameter setting”, select “control parameter”，and then press key “Select” to
enter the page“control parameter” (fig. 2.2.4).
0.56 Mpa -control setting- ↓

32℃ local/remote local
shutdown control mode ON-OFF
return set
Fig. 2.2.4
Equally, press key “Set”，“ON-OFF” will flash，while the press key hint changes to a state as shown in fig.2.2.5.
0.56 Mpa - control setting -

32℃ local/remote local
shutdown control mode ON-OFF
return confirm
Fig. 2.2.5
At this point by pressing up or down key you can change “local” to “remote control” or “communicated remote control ”，
(Fig. 2.2.6，Fig. 2.2.7)。
0.56 Mpa - control setting - 0.56 Mpa - control setting -

32℃ local/remote remote 32℃ local/remote commun.
shutdown control mode ON-OFF shutdown control mode ON-OFF
return confirm return confirm
Fig. 2.2.6 Fig. 2.2.7
When press key “confirm”，parameter value will change to the currently displayed value and quit the modification
9
mode；if press key “cancel”，original parameter will remain unchanged，and quit the modification mode.
2.3 Initialized interface

Once the controller is energized，a power on indicator lamp will light and system comes into an initialized page
（Fig.2.3.1）. 8 seconds later it comes into the system main page.
The initialized page shows such contents as controller type，part number CPN，and software version VER..
Thank you for your using

Ingersoll-Rand compressor
KT―GL―09B
Fig. 2.3.1
CPN: 19067875 VER.:BG-V100
2.4 Main page
Having entered the main page，by pressing up or down key you can scroll through pages to check all the status
parameters.
running pack. press. 0.67 Mpa ↓ 1 3
ON-OFF A/E disch.temp. 50 ℃ 2 4
Running PORO local control 5 6 7
menu 8
Fig. 2.4.1 Fig. 2.4.2
By contrasting fig.2.4.2 with fig. 2.4.1，numbers in fig. 2.4.2 are corresponding to text in the same position in fig. 2.4.1.
Position 1：operation states of air compressor : standby、running、ready to start
。
Position 2：Current control modes（ON-OFF/ACS/MOD）
Position 3、4：such readings as current pressure、temperature、machine run hours. Operator can scroll through pages
to take other readings by using up or down key.
Position 5：compressor‟s current status（including loading、unloading、shutdown、sleeping，and minor fault warning

etc.）
Position 6：when machine auto restart（PORO）is enabled，text“PORO”will be displayed，otherwise leaving blank
Position 7：system‟s current control mode is indicated on the right of this line（local/remote/communication）。A
flashing“communicated remote control” indicates an abnormal communication.
Position 8：displays in 3 cells are corresponding to 3 LC functional keys on control panel, select the operation you
require according to the hint.
All the status parameters which can be displayed on the main page, see the flowchart in section 2.1.
2.5 Menu pages

In any of the main pages you can press “menu” key to enter a menu page (Fig. 2.5.1), which includes：common
parameters, parameter setting, fault record and current time, 4 items in total.
0.56 Mpa -main menu-

32℃ comm.. param. Para. setting
shutdown fault record curr. time
return 10 select
Fig. 2.5.1
That portion hilighted in black background in the above figure is the selected item, and you can select different options
in sequence by pressing scroll key.
Press “Select” key while you have selected a certain item, the corresponding option can be entered.
2.6 Fault record
“Fault record” is used to display system status message(s) recorded at the time when a major failure occurred. The
display will be as showed in fig. 2.6.1. below if there no current fault record exists.
0.56 Mpa -fault record-

32℃ fault alarm record
shutdown no major fault record
return
Fig. 2.6.1
The display will be as shown in fig.2.6.2. below should there be one fault alarm record:
0.56 Mpa -fault record-

32℃ fault alarm record
shutdown M starter fault
return record
Fig. 2.6.2
The display will be as shown in fig. 2.6.3，and fig. 2.6.4 below should there be a multi fault alarm record:
0.56 Mpa -fault record- ↓ 0.56 Mpa -fault record- ↓

32℃ fault alarm record 1 32℃ fault alarm record 2
shutdown M starter fault 停机 Fan overload shutdown
return record return record
Fig. 2.6.3 Fig. 2.6.4
A maximum of 15 pieces of record can be recorded, and only a maximum of 5 major fault alarms can be recorded
between a shutdown and the next machine restart. It will display only but not record any major fault alarm if there are
more than 5. A new fault can be recorded 5second after a machine restart.
When an alarm record occurs you can press “record” key to check the compressor system status at the time when this
fault occurred，as shown in fig. 2.6.5。
0.56 Mpa -fault record- ↓

32℃ pack. press. 0.56Mpa
shutdown pack. disch. temp. 34 ℃
. return
Fig. 2.6.5
11
Press Scroll key to view more messages. Currently recorded system status refers to flowchart in section 2.1.
Press “return” key to return to the upper level.
2.7 Current time

Under “current time” directory a real-time date and time are displayed (Fig. 2.7.1)。How to change current time refers
to section 3.3.
0.56 Mpa -current time- ↓

32℃ date 29 07 2009
shutdown time 00:00:00
return
Fig. 2.7.1
2.8 Parameter setting
When you select directory “parameter setting” from the main menu page, and press “select” key，a code input window
。
will appear（Fig. 2.8.1）
Code setting is in two grades，including a user‟s code（default：1010，changeable）and a factory code（9195）.
0.56 Mpa -code input-

32℃ key value:0000
shutdown code:0000
return move left confirm
Fig. 2.8.1
Note：the” key value” here will be used for code upgrading.
After inputting a correct code you get into the directory “parameter setting”, under which there are four sub options：
。Equally，by pressing “select” key
control setting，run parameter，user‟s parameter，and element calibration（Fig. 2.8.2）
you will input a selected sub option.
0.56 Mpa -param. setting-

32℃ control setting run param.
shutdown user param. Element calib.
return select
Fig. 2.8.2
For method of parameter checking & changing refer to section 2.2.2.
2.9 Browsing of common parameters

In the position of “common parameter” a part of common parameter settings under the system current status will be
displayed. Parameters displayed here can only be viewed, but not be changed.
12
2.10Display of major fault alarm
When a major system fault occurs，it will directly skips into the major fault alarm page (Fig. 2.10.1).
0.56 Mpa maj. Fault alarm ！

32℃ emergency stop
Alarm
return confirm
Fig. 2.10.1
Once having entered the major fault alarm page, you can quit it only after removing cause of the major fault, or by
punching the emergency stop button and then pressing “confirm)” key twice within 1 second.
After the cause of such major fault is removed，press “confirm” key twice within 1 second to quit the alarm page, and
cancel the alarm output signal at the same time.
3、Parameter lists and descriptions

3.1 Parameters under directory “Control setting” (Table 3.1)
Table 3.1
Factory
parameter unit Parameter range note
value
local/remote control —— local，remote，communication local
Control mode —— ON-OFF,ACS,Modulation ON-OFF ☆
Sleeping function —— ON/OFF ON Sleeping On/Off
Sleeping time Min 2~60 6
PORO —— ON/OFF OFF PORO On/Off
PORO warning time Sec 10~100 20
Lag machine add. —— 1~24 1
1200,1800,2400,4800,
Baud rate bps 7200,9600,14400, 9600
19200,38400,57600
Oil filter time h 100~9000 2000 O.F Alarm time
Oil sep. time h 100~9000 2000 O.S Alarm time
Air filter time h 100~9000 2000 A.F Alarm time
Note：“☆” indicates that this parameter can be changed when in running.
 Local/remote control
This parameter is used to set a method of controlling equipment, including local control，remote control，and
communicated control.
Local control：to control equipment operation by operating on local machine.
Remote control：to control equipment operation through opening/closing quantitative input terminal(s).
Communication control：through communication port(s) on the equipment，to use an upper monitor to control equipment
13
operation.
 Control modes
Control modes used on this machine are：ON-OFF、MODULATION、ACS。
ON-OFF mode：air compressor‟s regular loading and unloading operation mode；
As an auxiliary function added to on-off control，MODULATION and ACS will enable a regulation valve function,
which makes compressor‟s output pressure tend to be stable，and more closely satisfy customers‟ pragmatic needs for air
capacity.
MODULATION action logic is as shown in the table below：
Regulation valve
Modulation function setting System status
Output state
Shutdown state OFF

Disable
Running state OFF
enable Other states OFF
Successive loaded operation exceeds10 sec. ON
ACS action logic is as shown in the table below：
Regulation valve
ACS function setting System status
Output state
Shutdown state OFF
Disable
Running state OFF
shutdown 、unloaded、sleeping OFF
Run time=<10Min Run state OFF
Load/unload cycles less
than 3 within any 3 OFF
enable min.of operation
Run time>10Min Load/unload cycles
more than 3 within any
3 min.of operation，&in
ON
a loaded state
Successive ACS operation exceeds 1hour OFF
 Sleeping function、sleeping time
When “Sleeping function” is set to ON, equipment „s sleeping /stopping function will be enabled. When the
equipment starts to unload while keeping this unloaded state till a set “Sleeping time” , then a sleeping/stopping state will be
entered.
Note：
14
1、When a locally unloading method is used to enter sleeping status，you must press Locally loading key
while pressure is lower than wakening pressure, and only by doing so the air compressor can be re-started；
2、When a remote enforced unloading method is used to enter sleeping status，you must implement a
remote loading while pressure is lower than wakening pressure, and only by doing so the air compressor can be
re-started；
3、When a communication unloading method is used to enter sleeping status, you must use a remote
loading command to re-start the air compressor；
 PORO、PORO warning time
When“PORO”is set to“ON”，PORO function is enabled，while the operator needs to skip current screen to the main page
once the setting is completed, and he/she will see a hint“please confirm)” in the interface，press “Start” key at this time
and then PORO function can be used.
After this function has been enabled，should equipment have a power-off during its running and then power-on again，
it will automatically enter a start process after a“PORO warning time”.
The machine will not automatically restart after it is re-energized, if equipment had a normal stop before power-off.
After occurring a major fault alarm，you need to enter the main page to confirm, and then PORO function can be further
used.
 Lag machine address
The lag machine address when equipment is used as a lag machine in an interlocked control status.
 Baud rate
Baud rate of RS485communication port.
 Oil filter time，oil separator time，air filter time
Set alarm time for oil filter time, oil separator time and air filter time separately. When its use time reaches the set time,
equipment will give out a warning.
3.2 Parameters under directory “Run parameter” (Table3.2)

Table 3.2
parameter unit Parameter range Factory setting Note

Unloaded pressure Mpa 0.5~（rated press.+0.02） 0.75
Loaded pressure Mpa 0.45~（unloaded press.-0.05） 0.65
Load delay Sec 0~10 2 ☆
Unload delay Sec 0~10 2 ☆
Stop delay Sec 10~60 20
Stop/restart Sec 10~600 20
15
Drain valve interval Sec 90~300 120 ☆

Drain valve open Sec 0~10 0 ☆
Fan motor start ℃ 75~85 80 ☆
Fan motor stop ℃ 65~75 70 ☆
Y-start time Sec 6~15 10
Front bearing alarm ℃ 80~130 105
Note：“☆” indicates that this parameter can be modified when running.
 Unloaded pressure
When a machine is running with its discharge pressure is greater than or equal to the unloaded pressure setting, and
unload delay setting is time up, then equipment will come into unloaded status.
 Loaded pressure
 When a machine is running with its discharge pressure is lower than or equal to the loaded pressure setting, and load
delay setting is time up, then equipment will come into loaded status.
 Load delay
To prevent situation of frequent loading from occurring，equipment needs a delay process before it enters a loaded
status. User may set it based upon its requirement. It can be set in a range of 0~10s.
 Unload delay
 To prevent situation of frequent unloading from occurring，equipment needs a delay process before it enters a unloaded
status. User may set it based upon its requirement. It can be set in a range of 0~10s.
 Stop delay
Press“Stop” key when machine is in a loaded or unloaded status，it will stop after a“stop delay” time.
 Stop/restart
Machine will reserve a certain length of delay time when it stopped or after occurrence of a major fault. Machine can
be restarted only after this“Stop/restart” time. At this time equipment will show“ready to start” and a waiting time
countdown. Restoring equipment electric power can also clear this waiting state.
 Drain valve interval、drain valve opening
T1 T
As shown in the above picture： T1——time interval for drainage valve opening, during this period of time the
valve remains in an open state.
T ——time interval for drainage valve closing, during this period of time the valve remains in a
closed state.
 Fan motor start/stop
In a consideration of energy saving requirement：fan motor will start when machine temperature reaches a setting set in
“Fan motor start”；and stop when machine temperature reaches a setting set in“fan motor stop”.
 Y-start time
Is star-start time for main motor.
 Front bearing alarm
A value for high front bearing temperature alarm. This alarm value will be effective only after“front bearing high
temperature alarm)” function is enabled。
3.3 Parameter under directory “User’s parameter” (Table 3.3)

Table 3.3
parameter unit Parameter range Factory setting Note
16
Pressure unit —— Mpa,Psi,Bar Mpa ☆

Language select —— Chinese，English Chinese
date —— —— ——
time —— —— ——
Oil filter use time reset —— —— ——
Oil sep. use time reset —— —— ——
Air filter use time reset —— —— ——
User‟s code —— 0~9999 1010
Factory setting reset —— —— ——
Saved as factory value —— —— —— Factory para.，for manufacturer only
Rated pressure Mpa 0.52~1.40 0.75 Factory para，for manufacturer only
Pressure differential Mpa 0.00~1.00 0.30 Factory para，for manufacturer only
warning
Trial function —— ON/OFF OFF Factory para，for manufacturer only
Trial time h 0~2000 300 Factory para，for manufacturer only
A/E injection temp. —— ON/OFF ON Factory para，for manufacturer only
enable
Inlet vacuum —— ON/OFF ON Factory para，for manufacturer only
PTC fault —— ON/OFF OFF Factory para，for manufacturer only
PTC fault —— ON/OFF OFF Factory para，for manufacturer only
Run hour h 0~999999 0 Factory para，for manufacturer only
change air filter Bar －0.00~－0.99 －0.03 Factory para，for manufacturer only
P4 enable —— ON/OFF OFF Factory para，for manufacturer only
Front bearing temp. —— ON/OFF ON Factory para，for manufacturer only
enable
T5 enable —— ON/OFF ON Factory para，for manufacturer only
T5 T6 alarm ℃ 100-167 160 Factory para，for manufacturer only
Note：“☆” indicates that this parameter can be modified when running.
 Pressure unit
This equipment provides three units of pressure for user to select, they are：MPa、Bar、PSI。
 Language option
This equipment offers interface in both Chinese or English for customer to select.
 Date、time
When equipment requires to modify real time, it can be done through this parameter.
 Oil filter time reset、oil separator time reset、air filter time reset
User needs to reset use time for those three types of filter after any maintenance is done on them.
 User code
User code is factory set to：1010. User can change it as required.
 Factory setting reset
To reset parameters to factory settings. Once factory settings are restored it requires to cut power off and then resume
power supply.
 Saved as factory value
To set a value of current parameter to factory setting.
 Rated pressure
A manufacturer‟s parameter.
17
 Pressure differential warning

When sump pressure — package discharge pressure>pressure differential warning setting，controller will give out a
“fine separator plugged” warning.
 Trial function、trial time
Both parameters of“trial function”and“Trial time”can be viewed and changed by manufacturer.
When“Trial time”minus equipment use time is less than 200 hour，it will give out a Trial time Up warning with a
countdown.
When equipment use time reaches“Trial time”，it will give out a Trial Time Up warning and the equipment cannot be
further used.
 A/E injection temperature enable
 When“A/E injection temperature enable”is set to ON， A/E injection temperature sensor input will be detected and a
relevant alarm would be generated.
 When it set to OFF，A/E injection temperature will not be checked, and A/E injection temperature sensor may not be
switched on. Meanwhile, A/E injection temperature is displayed as“-.—℃”.
 Inlet air vacuum
When“Inlet air vacuum”is set to ON，should the vacuum be abnormal，it will give out an alarm and then shutdown.
When it is set to OFF，this vacuum will not be detected, and vacuum sensor may not be switched on. Meanwhile,
vacuum is displayed as“-.-- Bar”.
 PTC fault
When“PTC fault”is set to ON，it will alarm if PTC short- circuits.
When it is set to OFF，PTC short-circuit fault will not be detected.
 PTC hi-temperature
When“PTC hi-temperature”is set to ON，it will alarm if PTC has high temperature.
When it is set to OFF，PTC hi-temperature alarm will not be detected
 Run hour
Run hour can be set（for maintenance purpose）。
 Change air filter
When this value is greater than inlet air vacuum，it will give out a“Change air filter”warning.
 P4 enable
When“P4 enable”is set to ON，if P4 is abnormal，it will alarm and then shutdown.
When it is set to OFF，P4 sensor will not be detected，and may not be switched on. Meanwhile，P4 is displayed as
“-.-- MPa”
。
 P5 enable
“-.-- MPa”
。
 P6 enable
“-.-- MPa”
。
 Front bearing temperature enable
When“Front bearing temperature enable”is set to ON，front bearing temperature sensor will be detected, and a relevant
alarm would be generated.
When it is set to OFF，front bearing temperature will not be detected，and front bearing temperature sensor may not
18
。
be switched on，meanwhile，front bearing temperature is displayed as“-.—℃”
 T5 enable
When“T5 enable”is set to ON，if T5 is abnormal，it will alarm and then shutdown.
When it is set to OFF，T5 sensor will not be detected，and may not be switched on. Meanwhile，T5 is displayed as
“-.--℃”.
 T6 enable
When it is set to OFF，T6 sensor will not be detected，and may not be switched on. Meanwhile，T6 is displayed as
“-.--℃”.
 T5 T6 alarm
When T5 or T6 is greater than this setting，it will alarm.
 T2 enable
When it is set to OFF，T2 sensor will not be detected，and may not be switched on，meanwhile，T2 is displayed as
“-.-- ℃”。
3.4 Parameters under directory “Element calibration” (Table 3.4)

Table 3.4
Default Default
parameter Range parameter range
value value
Pack. Press. slope -5~+5 0 Pack press. zero -5~+5 -2
Sump press. slope -5~+5 0 Sump press. zero -5~+5 -2
Inlet vacuum slope -5~+5 0 Inlet vacuum zero -5~+5 -2
Pack. Temp. slope -5~+5 -2 Pack. Temp. zero -5~+5 -2
A/E temp. slope -5~+5 -2 A/E temp. zero -5~+5 -2
A/E inj. Temp. slope -5~+5 -2 Frt. Brg. Temp. zero -5~+5 -2
Analog qty. 1 slope -5~+5 -2 Analog qty. 1 zero -5~+5 -2
Analog qty. 2 slope -5~+5 -2 Analog qty. 2 zero -5~+5 -2
Source voltage slope -5~+5 0 Source voltage zero -5~+5 -2
P4 slope -5~+5 -2 P4 zero -5~+5 -2
P5 slope -5~+5 -2 P5 zero -5~+5 -2
P6 slope -5~+5 -2 P6 zero -5~+5 -2
Frt. Brg. Temp. slope -5~+5 -2 Frt. Brg. Temp. zero -5~+5 -2
T5 slope -5~+5 -2 T5 zero -5~+5 -2
T6 slope -5~+5 -2 T6 zero -5~+5 -2
4、Control principle
4.1 Main machine control mode
There are three control modes for starting/stopping an air compressor：local control、remote control、and communicated
remote control.
When machine is in a stopping status，control mode for the compressor can be selected through setting on controller.
In any running state under any control mode you can use Stop key on the local machine control panel to stop the
compressor that facilitates dealing with emergency in case any failure occurs.
4.1.1 Local control
When it is set to“Local control”mode，with the controller displaying a default main picture, pressing “Start” key on the
panel will start the air compressor system operation；when the system is in a running state, with the controller displaying
a default main picture，by pressing “Stop” key on the panel，the compressor system will be running unloaded for a length
19
of time set (delay) before stopping.

4.1.2 Remote control
Remote control is basically as same as local control, with an exception that machine start/stop can be controlled and
done through a remote switch.
“Start” key on control panel must be pressed to confirm when it is set to“remote control”
、after initial power-on and
after removing a failure to confirm.
“remote control”status signals are output.
When air compressor is in“Remote control”mode，
4.1.3 Communicated remote control
“Start” key on control panel must be pressed to confirm when it is set to“remote control”
、after initial power-on and
after removing a failure .
After the controller is set to “communicated remote control” mode, if it receives remote control and monitoring
through serial communication input port 1，a network control can be realized. Communication protocol refers to
appendix.
When air compressor is in“communicated remote control”mode，“remote control”status signals are output.
What important for communicated remote control status：

1、Its start signal must be sent in a communication command and machine then can be started ；
2、It is the communication command that determines to perform loading/unloading, while pressure band set on
the controller will not work；
3、When package pressure is higher than rated pressure setting，it will automatically switched to unloaded state；
4、When communication line is interrupted，it will automatically switched to local control mode where pressure
band will work；
4.2 Fan motor control
Fan motor control is depending on temperature of main machine when it is starting，when the main machine stops, fan
motor will naturally stop.
After fan motor is started，it will keep operating as long as airend discharge temperature remains above a target
temperature；and fan motor will automatically stop when airend discharge temperature drops below shutdown temperature.
5. Air compressor working states & fault states

5.1 Working states
Compressor‟s working states are displayed in a place as shown in fig.5.1.1 & 5.1.2 below:
Norm. run pack. Press. 0.67 Mpa ↓ 0.56 Mpa -main menu-
ON-OFF A/E disch. Temp. 50 ℃ 32℃ fault record curt .time
In loading PORO local control shutdown para. set comm.. para.
menu return select
Fig. 5.1.1 Fig.5.1.2
1、 Shutdown：
Compressor has no alarm & fault，Run indicator lamp is out，while a text“compressor shutdown”is displayed
in state cell.
2、 Start：
Upon pressing “Start” key，compressor is started in a star-delta mode。Run indicator lamp lights，and a
text ”start in process” is displayed in state cell.
20
Star-delta switching time can be set by the user.

3、 Loading：
Compressor is running in loading state，Run indicator lamp lights，and state cell displays“in loading”.
4、 Unloading：
Compressor is running in unloading state，Run indicator lamp lights，and state cell displays“in unloading”.
5、 Sleeping operation：
Compressor has unloaded for a period of time as long as a set sleeping shutdown time, it shutdowns for
sleeping，Run indicator lamp out，and state cell shows“In sleeping”.
6、 Delayed stop：
Press “Stop” key when machine in running，it will switch into a “delayed stop” state, Run indicator lamp is out，
and state cell shows“Delayed stop”.
7、 Manually enforced loading：
Press “enforced loading” key when compressor in operation，it will be loaded，Run indicator lamp lights，and
state cell indicates“Locally controlled loading ”
；
When package discharge pressure is greater than unloaded pressure setting, this enforced loading ends.
8、 Manually enforced unloading：
Press “enforced unloading” key when compressor in operation，it will be unloaded，
Run indicator lamp lights，
and state cell indicates“Locally controlled unloading ”
；
When machine stops or press “enforced loading” key, an enforced unloading ends.
9、 Remote control loading
When compressor is in operation, and remote control loading enable is effective，it is in a remote control
loading/unloading state. When “remote control loading” key is 1，compressor is running loaded. Run indicator lamp
；When package discharge pressure is greater than unloaded
lights，state cell shows“Remote control loading”
pressure setting and the remote control loading enable is ineffective, as well as pressing “remote control unloading”
key and then machine stops，an enforced loading ends.
10、Remote control unloading
When compressor is in operation, and remote control loading enable is effective，it is in a remote control
loading/unloading state. When “remote control loading” key is 0，compressor is running unloaded. Run indicator
；When remote control loading enable is ineffective、and
lamp lights，state cell shows“Remote control unloading”
pressing “remote control loading” key and then machine stops，an enforced unloading ends.
11、Modulated operation
When compressor is operating loaded in MOD control mode，it is in a modulated running state: run indicator
；
lamp lights, and state cell indicates“Running in Modulation”
Modulated operation function（MODULATION）as an auxiliary function to On/Off regulation, by enabling a
regulation valve function, will make compressor pressure output tend to be stabilized, and its output capacity to
more closely satisfy customer‟s real demands.
12、PORO function
If a power-off takes place when compressor is running while PORO function is enabled，the compressor will
enter PORO state once it regains power supply, and then automatically start after a PORO delay time.
5.2 Minor fault warning

Controller „s LC status cell displays corresponding minor fault warning messages alternatively. Minor fault will not
lead to shutdown，just giving out a hint that maintenance is required for air compressor.
21
List of minor fault warnings：
No. warning Controller hint Causes
Air filter‟s set use time is up；
1 Air filter warning Plugged air filter Air filter is plugged with foreign material；
Too short a filter time setting.
Oil filter‟s set use time is up；
2 Oil filter warning Plugged oil filter Oil filter is plugged with foreign material；
Too short a filter time setting.
Separator‟s set use time is up；
Fine oil separator Sump pressure — pack. disch. press > 0.3MPa
3 Plugged oil separator
warning Separator is plugged with foreign material；
Too short a separator time setting.
Hi-disch. temp. Hi-disch. temp. A/E disch. temp. greater than or equal to temp. warning
4
warning warning setting
5 Change air filter Change air filter Inlet air vacuum < setting
6 Plugged oil filter Plugged oil filter P5－P6>=0.14MPa
5.3 Major fault shutdown

When a major fault auto shutdown occurs，controller‟s interface indicates an alarm message for the major fault that
occurring currently，and compressor cannot be restarted at this time. Remove the fault and then press “conform” key twice
to quit the major fault alarm page.
List of major fault shutdown alarms：
No. fault Controller‟s hint Causes

1、motor hi-temp alarm
resistance>=3.5KΩ，
1 Motor PTC hi-temp. Motor PTC hi-temp. Restore resistance to 2.1KΩ。
2、contacts open
22
1、bad PTC resistor

2、PTC resistance=<50Ω in running,
restore it to 150Ω
2 Motor PTC fault PTC fault
3、PTC resistance=<140Ω upon
powered, restore it to 150Ω
4、contact short circuit
3 Hi-disch temp. shutdown Hi-disch temp. shutdown A/E disch. temp. ≧protection setting
Main motor overload Main motor overload
4 Main motor current overloaded
shutdown shutdown
Fan motor overload
5 Fan motor overload shutdown Fan motor current overloaded
shutdown
1.SD/M contactor close when stops

6 Starter SD/M fault Starter SD/M fault
2.SD/M contactor open when starts
1.SD contactor close when stops.

7 SD starter fault SD starter fault
2.SD contactor open when starts.
1.M contactor close when stops.

8 M starter fault M starter fault
2.M contactor open when starts.
9 Check motor rotation Check motor rotation Wrong motor rotation
10 Hi-disch. pressure. Hi-disch. pressure Pack. disch. press. ≧protection setting

11 Low sump pressure Low sump pressure Sump press. ≦protection setting
Unloaded sump press. ≦protection
12 Low unloaded sump press. Low unloaded sump press.
setting
13 Trial time ends Trial time up Run hour greater than trial time
Fault remote start switch，in normally

14 Remote start alarm Remote start alarm
close state
Fault remote stop switch，in normally
15 Remote stop alarm Remote stop alarm
open state
16 P1sensor fault P1 sensor fault Press. sensor short circuit、broken circuit
17 P2 sensor fault P2 sensor fault Press. sensor short circuit、broken circuit

19 T1 sensor fault T1 sensor fault Press. sensor short circuit、broken circuit
22 Emergency stop Emergency stop Emergency stop button punched
23
23 Control power fault Check control power

24 Hi-front brg. Temp. Hi-front brg. Temp.
Frt. brg. temp. sensor short circuit、
25 T4 sensor fault T4 sensor fault
broken circuit
26 T5 sensor fault T5 sensor fault Temp.sensor short circuit、broken circuit
27 T5 hi-temp. shutdown T5 hi-temp. shutdown T5>T5 T6 alarm setting
29 T6 sensor fault T6 sensor fault Temp.sensor short circuit、broken circuit
30 T6 hi-temp. shutdown T6 hi-temp. shutdown T5>T5 T6 alarm setting
Big press. differential Big press. differential
31 Sump press.－pack. press.>=0.2Mpa
before/after sep. before/after sep.
32 Hi-sump pressure Hi-sump pressure Sump press.－rated press.>=0.2Mpa
Hi-2-nd stage pressure
33 Hi-2-nd stage pressure alarm P4>=0.69Mpa
alarm
Appendix 1：Serial Communication protocol

This controller provides a RS485-2(801-803 ports）communication interface，and adopts MODBUS
communication protocol. Users can realize a centralized control through computer or PLC，to set controller
run commands，read or change relevant control parameters，and view controller working states and etc.
Use RTU mode，including 8 digit of data、(without check bit)、and 1stop digit.
Calibration mode：to use CRC calibration.
List of Modbus register
register(40×××) variable Read/Write Range Note
001 Control status R/W
003 Pack. disch. press. R
004 Sump pressure R
007 A/E temp. R
010
064 Run hour( h) R
065 Loaded time (h) R
066 Run hour(10k h) R
067 Loaded time(10k h) R
097 Measuring unit R
100
112 Unloaded pressure R/W
113 Loaded pressure R/W
114 Control mode R/W
24
Star-delta starting
115 R
time
116 Sleeping time R/W
118
Remote function
119 R
switch
PORO function
121 R 0/1 0：off；1：on
switch
122 PORO time R/W 10~120
125
129
130
131
132
134 Machine address R
254 Software version R
Read out number of
255 Number of warning R
warning
Number of warning Read out number of
256~270 R
record alarm
40001 control status：

Bit0： Bit6：alarm (R)
0：without alarm
1：with alarm
Bit1：run/stop (R/W) Bit7：warning (R)
0：stop 0：without warning
1：run 1：with warning
Bit2：load /unload (R/W) Bit8：
0：unload 0：non On/Off mode
1：load 1：On/Off mode
Bit3：regulation valve (R) Bit9-12：
0：valve not acts
1：valve acts
Bit4：
Bit5：long idle (R) Bit13-15：
0：not in“long idle”
1：in “long idle
25
Appendix 2：
Table of warning contrast：
No. Controller hint

1 Plugged air filter
2 Plugged oil filter
3 Plugged fine sep.
4 Hi-disch temp. warning
5 Change air filter
6 Plugged oil sep.
Table alarm contrast：
No. Controller hint No. Controller hint No. Controller hint

8 PTC fault 22 Remote stop alarm 35 T5 sensor fault
9 Motor PTC hi-temp. 23 P2 sensor fault 36 T5 hi-temp. shutdown
10 Hi-disch temp. shutdown 24 P3 sensor fault 37 T6 sensor fault
12 Starter SD/M fault 25 T1 sensor fault 38 T6 hi-temp. shutdown
26
Main motor overload Big press. differential

13 26 T2 sensor fault 39
shutdown before/after sep.
Fan motor overload
14 27 T3 sensor fault 40 Hi-sump pressure
shutdown
15 Check motor rotation 28 Emergency stop 41 Hi-2-nd stage press. alarm
16 Hi-disch. pressure 29 M starter fault 42 P4 sensor fault
17 Low sump pressure 30 SD starter fault 43 P5 sensor fault
Low unloaded sump
18 31 Check control power 44 P6 sensor fault
pressure
19 Trial time up 32 Hi-frt. Brg. temp.
20 Remote start alarm 33 T4 sensor fault
21 P1sensor fault 34 T4 hi-temperature
Machine model Start-up date Start-up record 1 Start-up record 2
Work log 1
Work log 2
Work log 3
Work log 4
（Over）
27

KT Controller Manual - M45-75

Uploaded by

Copyright:

Available Formats

KT Controller Manual - M45-75

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KT Controller Manual - M45-75

Uploaded by

Copyright:

Available Formats

Ingersoll-Rand

7 Thank you for your using

4、 Stop key：Press this key in any page to stop compressor。

6、 LC arrow key：used to scroll pages up or down，or to modify a parameter value。

7、 Power on indicator lamp：it is lighting when controller power supply is normal；

8、 Running indicator lamp：it is lighting when air compressor is operating normally.

Controller type“KT―GL―09B”、part number“CPN: 19067875”、and software version “VER:BG-V100”。

1.3 Controller’s ports

1.5 Electrical diagram:

1.6 Description of terminals

No. Function defined Note

No. Function defined Note

No. Function defined Note

No. Function defined Note

506 Draining valve signal Normally open/ DO

No. Function defined Note

No. Function defined Note

Analog output terminals

904 GND Current output

No. Function defined Note

No. Function defined Note

Enter code ☆P4 enable ☆P5 enable

☆T5 enable ☆T6 enable

2.2 How to operate on LC display interface

0.56 Mpa -run param.- ↓

①、How to change a numerical parameter

0.56 Mpa -run param.- ↓

0.56 Mpa -run param.-

②、How to change a functional parameter

0.56 Mpa -control setting- ↓

0.56 Mpa - control setting -

0.56 Mpa - control setting - 0.56 Mpa - control setting -

2.3 Initialized interface

Thank you for your using

Fig. 2.4.1 Fig. 2.4.2

Position 1：operation states of air compressor : standby、running、ready to start

Position 5：compressor‟s current status（including loading、unloading、shutdown、sleeping，and minor fault warning

Position 6：when machine auto restart（PORO）is enabled，text“PORO”will be displayed，otherwise leaving blank

2.5 Menu pages

0.56 Mpa -main menu-

2.6 Fault record

0.56 Mpa -fault record-

0.56 Mpa -fault record-

0.56 Mpa -fault record- ↓ 0.56 Mpa -fault record- ↓

Fig. 2.6.3 Fig. 2.6.4

0.56 Mpa -fault record- ↓

Press “return” key to return to the upper level.

2.7 Current time

0.56 Mpa -current time- ↓

2.8 Parameter setting

Code setting is in two grades，including a user‟s code（default：1010，changeable）and a factory code（9195）.

0.56 Mpa -code input-

Note：the” key value” here will be used for code upgrading.

0.56 Mpa -param. setting-

For method of parameter checking & changing refer to section 2.2.2.

2.9 Browsing of common parameters

2.10Display of major fault alarm

0.56 Mpa maj. Fault alarm ！

3、Parameter lists and descriptions

Note：“☆” indicates that this parameter can be changed when in running.