Summary of Contents for Mattei MAESTRO XS
- Page 1 MAESTRO USER’S MANUAL TECA2G-007 ING. ENEA MATTEI SpA Strada Padana Superiore 307 – 20090 VIMODRONE (MI) Tel +39 – 02253051 (16 lines) – Fax +39 – 0225305243 E-mail: info@mattei.it www.mattei.it...
- Page 2 Ing. Enea Mattei S.p.A. reserves the right to modify the product, instructions and information contained in this manual at any time without any obligation to update previously supplied goods. Assistance and Spare parts M.T.A. s.p.a. C.so Italia, 47 Verdello/Zingonia (BG) - ITALY tel.
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Page 3: Table Of Contents
S U M M A R Y GENERAL ........................4 1.0 Introduction ......................4 1.1 Identification codes....................4 VIDEO TERMINAL AND KEYPAD .................. 5 ENABLING THE COMPRESSOR..................7 3.1 ENTERING THE CODE ..................7 OPERATING MODES..................... 8 4.1 CONTINUOUS mode..................... 9 4.2 AUTOMATIC mode (factory setting)............... -
Page 4: General
G E N E R A L Chapter GENERAL 1.0 Introduction This manual has been written for customers who wish to learn more about how the “ MAESTRO ”electronic board works. The manual provides information on HW and SW characteristics and operating methods. MAESTRO is a programmable control unit which adapts compressor operation to the specific requirements of the air line it is connected to. -
Page 5: Video Terminal And Keypad
D E S C R I P T I O N T E R M I N A L Chapter VIDEO TERMINAL AND KEYPAD MAESTRO is fitted with a terminal which acts as a user interface, providing information on the status of the compressor and allowing the various management parameters to be programmed. -
Page 6: Technical Specifications
D E S C R I P T I O N T E R M I N A L Technical specifications Display FSTN graphic Backlighting Light-blue LED's Resolution 132 x 64 pixels Keypad Material Silicon rubber Number of buttons Backlit buttons Power input Voltage From basic module via phone cable... -
Page 7: Enabling The Compressor
Chapter ENABLING THE COMPRESSOR Upon delivery, the compressor is protected by an alphanumerical code which must be provided by Mattei and entered the first time it is switched on. The compressor will not work if this code is not entered because, as soon as the compressor is powered, the screen shown in Figure 3 appears with the cursor flashing in the top left-hand corner. -
Page 8: Operating Modes
S O F T W A R E M E N U S Chapter OPERATING MODES MAESTRO is factory set to drive the compressors and deliver compressed air at rated pressure. There are 3 different operating modes, each of which can be selected by the user: continuous;... -
Page 9: Continuous Mode
The internal pressure of the compressor depends (partly) on line pressure and, consequently, on the demand for air; when the latter drops or is nil, line pressure and internal pressure increase. In Mattei compressors, the maximum pressure at which the unit runs no-load can be set (by calibrating a valve). For values slightly below maximum, the suction valve is only “partially”... -
Page 10: Optima Version
4.4 OPTIMA version The OPTIMA version, fitted with an INVERTER, is currently the most flexible product in the MATTEI range of industrial compressors. Generally, speaking, air requirements in a user network are not constant but vary continuously. These variations occur for many reasons, such as different usage, maintenance and reprogramming frequencies, underuse and/or overuse caused by different production cycles and work shifts. -
Page 11: Menu Structure
S O F T W A R E M E N U S Chapter MENU STRUCTURE In order to communicate with the user, MAESTRO features carious menus that allow the compressor to be monitored and programmed. These are divided by function and not all of them can be accessed by the final customer. - Page 12 S O F T W A R E M E N U S Main Menu 0 - Monitor Configuration 1 - User Settings Settings Service Languages Auto-prog. 2 - Advanced 3 - Clock 4 - Historical 5 - Network 6 - Info Let us now see how to move between the menus, assuming we wish to modify the maximum pressure of the system.
- Page 13 S O F T W A R E M E N U S Press <Esc> in the [Monitor] menu. The [Main] menu page appears listing all the menus of the control software. As the maximum pressure value to modify is in the [User/Settings] menu, press <...
- Page 14 S O F T W A R E M E N U S Once selected, the cursor moves next to the variable to modify. Press < > or < > to decrease or increase its value. To change it to 7.5 bar, press < > until “007.5bar” appears. ↵...
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Page 15: Monitor ] Menu
S O F T W A R E M E N U S 5.1 [ MONITOR ] menu The [ Monitor ] menu is the heart of the entire software application and displays the operating parameters of the compressor. It also shows the operating status, operating hours, etc.. Given the importance of the menu, if the user accesses other sections of the software for any reason and the terminal keypad is not used for a certain period of time, the system automatically reverts to the first page of the menu. - Page 16 S O F T W A R E M E N U S Continuing to scroll the menu pages by pressing the arrow down button, the following data is displayed: • Chamber pressure • Compressor running hours • Compressor charging hours The following page is only displayed if the temperature probe of the second compressor is enabled (if there are two compressors), or if the dryer is enabled.
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Page 17: Main ] Menu
S O F T W A R E M E N U S 5.2 [ MAIN ] menu Access this menu by pressing ESC on the first page of the [ Monitor ] menu. As the menu list comprises several items, just part of it is visualised. The other items can be visualised by using the arrow buttons to scroll the menu. - Page 18 S O F T W A R E M E N U S 5.3.2 [Settings] submenu This submenu is used to configure basic compressor settings, such as: • Maximum Pressure • Minimum Pressure • No-load Run Time These variables can always be modified. 5.3.3 [Service] submenu This submenu is used to set compressor service times.
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Page 19: Clock ] Menu
S O F T W A R E M E N U S 5.3.5 [Self - programming] submenu This submenu is used to return certain parameters to their factory settings. These are: • Maximum pressure • Minimum pressure • No-load Run Time •... - Page 20 S O F T W A R E M E N U S The page shown to the side is used to select the compressor operating mode: • None (no selection) • 5 days • 7 days 5.5.1 [5 Days] submenu The 5-day mode provides access to page which is used to configure compressor starting and stopping times.
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Page 21: Historical ] Menu
S O F T W A R E M E N U S 5.5.2 [7 Days] submenu The 7-day mode provides access to page which is used to configure compressor starting and stopping times for Mondays. Similarly to the 5-day mode, 3 operating time bands can be set though, unlike the previous mode, these are only valid for the selected day. -
Page 22: Network ] Menu
S O F T W A R E M E N U S 5.6.2 [Modifications] submenu The service engineer may use this submenu to check whether modifications have been made to the configuration parameters and whether these modifications may have been the cause of the fault. As shown to the side, every modifications page displays a set of data concerning the modified variable, in particular: •... - Page 23 S O F T W A R E M E N U S Select “Group A” to configure group A compressors. Possible selections are: • Sequence • Cascade • Equalisation • Flow rate If the “Sequence” mode is selected, programmed rotation of the first compressor can be selected.
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Page 24: Historical
An event of this kind must be carefully assessed by the technical assistance service. Attention: if a failure occurs that stops the compressor due to faulty sensor, do not bypass it by connecting the wires together. If possible, replace the sensor, otherwise consult the Mattei technical assistance service. -
Page 25: Event Messages
H I S T O R I C A L 6.1.3 Event messages As previously mentioned, if a fault occurs, a message is displayed on the video and the compressor may stop depending on the type of fault involved. In both cases, a message is displayed on the video informing the user that there is a problem with the compressor. -
Page 26: Saved Event Messages
H I S T O R I C A L Press <Esc> to return to the [Monitor] menu and start the compressor. First check out why the compressor stopped, of course, and if, after enabling the compressor, it stops again, do not start it again. Carefully examine the compressor and, if any doubts arise, contact the technical assistance service. - Page 27 H I S T O R I C A L Message Action Type Reason Emergency Stop Block Digital The emergency button on the electric panel has been pressed. Oil Level Low Block Digital Low oil level in chamber (The quantity of oil is lower than that required to ensure correct operation). Motor Overload Block Digital...
- Page 28 H I S T O R I C A L Message Action Type Reason Chamber Probe Failure Block Software Fault in the pressure probe mounted on the compressor chamber. Also indicates an interruption in the connection. Line Probe Failure Block Software Fault in the pressure probe mounted on the radiator.
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Page 29: Video Connection Management
Mattei has found a way round this problem. If for any reason communication between the basic terminal and the video terminal fails for more than 30 seconds, the compressor stops immediately. -
Page 30: Start-Ups Submenu
H I S T O R I C A L 6.4 Start-ups submenu This submenu is used to monitor the start-ups performed by the compressor during its operating lifetime. In particular, the following can be monitored: • The total number of start-ups performed by the compressor. •... -
Page 31: Password Management
When requested, it must be entered in the template shown below ↵ ↵ User password is: < > < > < > < > < > < > The service password is not given to the final user as the service menus are reserved to Mattei. -
Page 32: Weekly Programming
W E E K L Y P R O G R A M M I N G Chapter WEEKLY PROGRAMMING MAESTRO can be used to automatically start the compressor using the on- board clock. To use this function, access the [Clock] menu and select one of the following 2 modes: 5 day mode 7 day mode... -
Page 33: 5-Day Programming
W E E K L Y P R O G R A M M I N G 8.2 5-day programming In the 5-day mode, the compressor can only be used on standard working days, Monday to Friday, with identical time bands for each of those days. Example: Start at 08:00 >>>>>... -
Page 34: 7-Day Programming
W E E K L Y P R O G R A M M I N G 8.3 7-day programming In the 7 day mode, different operating time bands can be configured for every day of the week. unlike the mode described above, this optimises compressor flexibility. -
Page 35: Special Programming
W E E K L Y P R O G R A M M I N G 8.5 Special programming In the 7 day operating mode, time bands allowing constant operation for two or more days can be configured if continuous operation during the week is required. Example: Monday Band 1 Start at 08:00 >>>>>... -
Page 36: Checking Entered Times
W E E K L Y P R O G R A M M I N G Fig. 9 By entering “Personal” in one of the 3 available time bands (see fig. 10), after reaching the end of time band programming, that is, when the cursor returns to the top left-hand corner of the screen, press <... - Page 37 W E E K L Y P R O G R A M M I N G Now increase the hours and minutes values to reach the required stop time. ↵ Press < > until the cursor returns to its original position and then press <Esc>...
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Page 38: Hour Counters
H O U R C O U N T E R S Chapter HOUR COUNTERS MAESTRO is fitted with a number of hour counters which, as well as calculating operating hours, also manage maintenance frequencies of compressor parts subject to wear. For this purpose, the following two types of hour counters are available: •... -
Page 39: Enable Hour Counter
H O U R C O U N T E R S 9.1.1 Enable hour counter The “enable” hour counter shows the number of hours the compressor has been enabled or made available for operation. This hour counter also considers the periods in which the compressor is not on because it has stopped during the operating cycle. -
Page 40: Modifying Timers
C O U N T E R S 9.2.1 Modifying Timers Enter the [1.3.1 Service] menu to set the required maintenance frequency, through always referring to Mattei recommendations. ↵ After accessing the page, the cursor flashes in the top left-hand corner. Press <... -
Page 41: Maintenance Signal
H O U R C O U N T E R S 9.3 Maintenance Signal When one of the hour counters reaches the set number of hours, it gives the user a visual signal that servicing is required (e.g.: oil). The screen displays an icon alongside a description of the type of fault. -
Page 42: Remote Controls
R E M O T E C O N T O R L S Chapter REMOTE CONTROLS MAESTRO can remotely control some compressor management and status functions, such as enabling and disabling, fault signalling, etc.. 10.1 Remote enable The compressor is usually enabled or disabled with the “On/Off” button of the keypad. However, it is also possible to enable the compressor with a digital contact in another room. - Page 43 R E M O T E C O N T R O L S Figure 15 shows a simple method of connecting the remote enable command in which a switch is used to achieve the function. If open the compressor is disabled If closed the compressor is enabled Fig.
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Page 44: Remote Signalling
On some models, these signals are already present by default as the expansion board is already installed by Mattei. This information can be directly obtained from the electric screen supplied with the compressor. These signals are provided by closing N.O. contacts. -
Page 45: Troubleshooting
R E M O T E C O N T O R L S Chapter Chapter TROUBLESHOOTING This chapter gives a description of faults that may occur to MAESTRO . They are divided into: General faults Dryer-related faults Inverter-related faults Network faults For every category, the problems that may arise are listed together with the possible reasons and any remedies for eliminating the fault on site without having to replace the electronics as the problem may have... -
Page 46: Generic Problems
MAESTRO switches on but the No programme Run the programme (only Mattei staff) display remains blank Video terminal faulty Replace video terminal Video terminal addressing incorrect Correct the address (Only Mattei staff). -
Page 47: Dryer Malfunctions
Replace the dryer fuses. fall in operating values The dryer compressor does not work. Check the dryer input voltage. Call the Mattei assistance service. The dryer fans do not work The cooling system is insufficient for Call the Mattei assistance service. - Page 48 T R O U B L E S H O O T I N G NOTES: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________...
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