Bollfilter 2200 User manual

1/32
Operating and installation instructions
Electronic controller
Type: 2200
Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.de
Date Version Language Order no. Item no.
05.2015 008 en - -
NOTE:
Print document on both sides
Translation of the original operating instructions

2 / 32 Operating instructions Typ 2200
Betriebsanleitung Typ 2200

Operating instructions Typ 2200 3 / 32
Betriebsanleitung Typ 2200
Table of Contents
1 Basic safety instructions for the electronic controller . . . . . . . . . . . . .5
2 Technical data of controller and control cabinet components . . . . . .7
2.1 Power components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.4 Fuse protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Control circuit board inputs / outputs . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 Optocoupler inputs (E1 - E5), terminals 31 - 40 . . . . . . . . . . . . . . . . 8
2.2.2 Live relay outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.3 Potential-free relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1 Device functions and control sequence . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.1 Master switch operation feedback contact. . . . . . . . . . . . . . . . . . . . 10
3.1.2 Control voltage monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.3 Motor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.4 Differential pressure too high, flushing oil treatment cartridge alarm10
3.1.5 DP - too high, backflushing filter (100 %) . . . . . . . . . . . . . . . . . . . . 10
3.1.6 Key C (number of flushes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.7 Multiple flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.8 DP alarm (flushing frequency monitoring) . . . . . . . . . . . . . . . . . . . . 11
3.2 Display for "Operation" mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Text messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.1 Text display after switching on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.2 Text display in "Operation" mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.3 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Setting and operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.1 Setting level - Viewing and selecting parameters . . . . . . . . . . . . . . 13
3.4.2 Setting level - Changing and saving parameters . . . . . . . . . . . . . . . 13
3.4.3 Return to operation level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 List and description of parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.1 P0 Filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.2 P1 Multiple flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.3 P2 Time-controlled backflushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.4 P3 Time-controlled backflushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.5 P4 Back-flushing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.6 P5 Filling time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.7 P6 After-blowing time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.8 P7 Cartridge alarm delay time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.9 P8 DP alarm (flushing frequency monitoring) . . . . . . . . . . . . . . . . . 16
3.5.10 P9 Motor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.11 P10 Back flushing time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.12 P11 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5.13 P12 Testcode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.14 P14 Pressure compensation time . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Description and function of controller. . . . . . . . . . . . . . . . . . . . . . . .19
4.1 Controller type 6.18 / 6.19 / 6.44 . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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4.2 Controllers of types 6.21/6.22/6.23 / 6.24 . . . . . . . . . . . . . . . . . . . . 20
4.3 Controllers of type 6.60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Controllers of type 6.61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Controllers of type 6.62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 Controllers of type 6.64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Controllers of type 6.72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Setting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operating instructions Typ 2200 5 / 32
Betriebsanleitung Typ 2200
1 Basic safety instructions for the electronic
controller
DANGER!
Risk of accidents from improper installation
Installing the controller or the connected equipment improperly may cause the
device to fail and lead to serious or even fatal personal injuries. You must
therefore follow the general safety regulations for equipment in industrial
electrical systems and pay particular attention to the following points:
• The controller must be installed by qualified specialist staff only (as defined
by the guidelines IEC 364, DIN VDE 0105 for electrical equipment).
• The laws, guidelines, directives and regulations for the installation of
electrical equipment which are valid at the location for installation must be
adhered to.
• Settings on devices with protection class IP00 without covers must only be
made by authorised specialist staff when the devices are switched off. The
local regulations for safety and the prevention of accidents must be
observed.
• The controller must only be operated within the permitted area of application.

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Operating instructions Typ 2200 7 / 32
Betriebsanleitung Typ 2200
2 Technical data of controller and control cabinet
components
2.1 Power components
2.1.1 Supply
Supply L1-L2-L3 direct to 4-pole master switch – Q1 (T1-T2-T3)
2.1.2 Motor control
Motor connection U-V-W direct to motor contactor – K1 (2-4-6)
2.1.3 Power supply
2.1.4 Fuse protection
Primary voltages 0 - 220 V, 380 V, 400 V, 440 V, 500 V, 550
V
Secondary voltages
0 V AC - 230 V AC Valve voltage 230 V AC
0 V AC - 115 V AC Valve voltage 115 V AC
0 V DC - 24 V DC Valve voltage 24 V DC
0 V AC - 20 V AC Control circuit board supply voltage
Fuses in the control cabinet
F1 to F3 each 1 A
Fuses on the control circuit board
Fuse F1 0.8 A T (slow-blow)
Fuse F2 2.0 A T (slow-blow)

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2.2 Control circuit board inputs / outputs
2.2.1 Optocoupler inputs (E1 - E5), terminals 31 - 40
2.2.2 Live relay outputs
NOTE
The connections and designations depend on the type of filter and can be found
in the respective circuit diagrams.
2.2.3 Potential-free relay outputs
NOTE
The connections and designations depend on the type of filter and can be found
in the respective circuit diagrams.
2.3 Circuit diagrams
The circuit diagrams for the controller are contained in the appendix of these
operating and installation instructions.
Outputs VE1 - VN1 to VE3 - VN3 Terminals 8 - 13
Outputs A1 - A15 Messages 1 - 5
(change-over contact)
Terminals 16 - 30

Operating instructions Typ 2200 9 / 32
Betriebsanleitung Typ 2200
3 Operation
3.1 Device functions and control sequence
Fig. 3-1 Electronic controller type 2200
Fig. 3-2 Display and operating elements
1 Fastening
2 Display and operating elements
3 Housing
4 Master switch
5 Connection
1 Display screen for text display, 2 lines of 16 characters
2 "Alarm" LED (red)
3 "Service" LED (yellow)
4 "Operation" LED (green)
5 Keypad
1
2
3
4
5
1
2
3
4
5

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NOTE
The three keys on the keypad are assigned to the key references displayed
above them in the second line of the display as follows:
Key C: When pressed, shows the number of flushes
Key F: When pressed, triggers manual flushing
Key Q: When pressed, acknowledges the alarm messages
3.1.1 Master switch operation feedback contact
When the master switch is in the "On" position, a contact is made.
3.1.2 Control voltage monitoring
As soon as the master switch is actuated, the power supply is activated and the
controller is working properly, the green "Operation" LED lights up and the
"Control voltage monitoring" relay is activated. In the event of operating voltage
failure or a fuse fault on the control circuit board, no LED lights up and the
"Control voltage monitoring" relay is no longer activated.
3.1.3 Motor fault
If the measured motor current exceeds the set setpoint value for parameter P9,
a message appears in the display and a potential-free signal is sent to the relay
outputs. The motor and the backflushing function switch off immediately. Once
the fault has been remedied, the user has to acknowledge the alarm message by
pressing the Q key.
3.1.4 Differential pressure too high, flushing oil treatment cartridge alarm
The signal transmitter is a pressure switch contact which is connected to the
"Differential pressure indicator DP too high flushing oil treatment" optocoupler
input. If the message is active for a longer period than the time set in parameter
P7, an alarm message appears in the display. Once the fault has been remedied,
the user has to acknowledge the alarm message by pressing the Q key.
3.1.5 DP - too high, backflushing filter (100 %)
The signal transmitter is a pressure switch contact which is connected to the
"Differential pressure indicator DP too high, backflushing filter" optocoupler input.
If the message is active for longer than 2 seconds, an alarm message appears
in the display screen and the red "Alarm" LED lights up. Once the fault has been
remedied, the user has to acknowledge the alarm message by pressing the Q
key.
3.1.6 Key C (number of flushes)
When key C (number of flushes) is pressed, the number of flushing cycles which
have been performed is shown on the display screen for 3 seconds.
3.1.7 Multiple flushing
The number of parameterised chambers is worked off with each flushing
command.

Operating instructions Typ 2200 11 / 32
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3.1.8 DP alarm (flushing frequency monitoring)
If "DP flushing" has been activated before the "Time-controlled backflushing"
time elapses, the "DP alarm" message appears on the display screen and the
yellow "Service" LED lights up.
3.2 Display for "Operation" mode
The green "Operation" LED lights up once the power supply has been switched
on and the controller is at operation level ("Operation" mode).
3.3 Text messages
3.3.1 Text display after switching on
After a short delay, the parameterised controller type is displayed in the second
line of the display.
Boll & Kirch Company name
xxxxxxxxxx Programme number
6.18/6.19/6.44 Controller type 0
6.21/6.22/6.23/6.24 Controller type 1
6.60 Controller type 2
6.60 Alarm DP Controller type 3
6.60.07/6.72.07 Controller type 4
6.60.07/6.72.07 AL. DP Controller type 5
6.61 Controller type 6
6.61 Alarm DP Controller type 7
6.61.07 Controller type 8
6.61.07 AL. DP Controller type 9
6.62 Controller type 10
6.62 Alarm DP Controller type 11
6.64 Controller type 12
6.64 Alarm DP Controller type 13
6.64.07 Controller type 14
6.64.07 AL. DP Controller type 15
6.72 Controller type 16
6.72 Alarm DP Controller type 17

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3.3.2 Text display in "Operation" mode
When flushing has been triggered, the following messages appear in the first line
(depending on the source):
When flushing has been triggered, the following messages may in the second
line (depending on the source):
NOTE
3S indicates that the remaining flushing/after-blowing time is 3 seconds.
If the C key is pressed, the following message appears on the display screen:
The number of flushing cycles is saved and backed up in the event of a mains
failure.
forced fl. 00:01 Remaining time till forced flushing is triggered 00 h
01 min
C - F - Q Reference to keys
Mains flushing When flushing is triggered by "Power supply on"
Manual flushing When flushing is triggered by the F key
forced flushing When flushing is triggered by time-controlled
backflushing
DP flushing When flushing is triggered by backflushing filter
differential pressure
Flush. time 3S Remaining flushing time
After bl. t. 3S Remaining after-blowing time
No.of flushes
xxxxxx cycles Number of flushing cycles

Operating instructions Typ 2200 13 / 32
Betriebsanleitung Typ 2200
3.3.3 Alarm messages
NOTE
• The red "Alarm" LED lights up every time an alarm message is issued.
• All alarm messages are saved and backed up in the event of a mains failure.
• The alarm message and the operation messages are shown alternately in
the second line of the display, switching every 2 seconds.
• When the Q key is pressed, all alarm messages are deleted, but only if the
respective cause of the alarm has been remedied. If the cause of the alarm
is not remedied, the alarm message appears again.
Alarm messages in the display:
If the flushing frequency monitoring is switched on:
3.4 Setting and operation
3.4.1 Setting level - Viewing and selecting parameters
In order to access the setting level "Selecting and viewing parameters" press
keys  and  together until the green "Operation" LED is extinguished
(approximately 3 seconds). The first display line shows the parameter and the
second line shows the parameter value. All parameters can now be displayed by
repeatedly pressing the key  or .
3.4.2 Setting level - Changing and saving parameters
In order to access the setting level "Changing and saving parameters", press the
middle key until the green "Operation" LED flashes (approximately 3 seconds).
The parameter can now be changed by repeatedly pressing the key  or . In
order to save the value and return to the setting level "Selecting and viewing
parameters", press the middle key until the green "Operation" LED is
extinguished (approximately 3 seconds).
3.4.3 Return to operation level
In order to access the operation level, press keys  and  together until the
green "Operation" LED lights up (approximately 3 seconds).
Motor fault In the event of a "Motor fault" alarm
DP too high In the event of "Differential pressure too high Filter
100 %"
Cartridge alarm In the event of "Differential pressure too high flushing
oil conditioning 100 %"
DP alarm DP alarm backflushing triggered by differential pressure
75 %

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3.5 List and description of parameters
3.5.1 P0 Filter type
3.5.2 P1 Multiple flushing
NOTE
This parameter is only visible with filter type P0 = 6, 7, 8, 9, 10, 11, 12, 13, 14, 15.
3.5.3 P2 Time-controlled backflushing
3.5.4 P3 Time-controlled backflushing
Adjustable in steps of one Range 0 - 17
Factory setting Initial value 0
Text display, line 1 P0 filter type
Text display, line 2 6.18/6.19/6.44
Adjustable in steps of one Range 1 - 99 x
Factory setting Initial value 1
Text display, line 1 P1 multiple fl.
Text display, line 2 XXX chambers
Adjustable in steps of one hour Range 0 - 59 h
Factory setting Initial setting 2 h
Text display, line 1 P2 forced flush.
Text display, line 2 XXX hours
Adjustable in steps of one minute Range 0 - 59 min
Factory setting Initial value 0 min
Text display, line 1 P3 forced flush.
Text display, line 2 XXX minutes

Operating instructions Typ 2200 15 / 32
Betriebsanleitung Typ 2200
3.5.5 P4 Back-flushing time
NOTE
This parameter is not visible with filter type P0 = 1.
3.5.6 P5 Filling time
NOTE
This parameter is not visible with filter type P0 = 0 and P0 = 1.
3.5.7 P6 After-blowing time
NOTE
This parameter is only visible with filter type P0 = 4, 5, 8, 9, 14, 15.
Adjustable in steps of one second Range 5 - 100 s
Factory setting Initial value 20 s
Text display, line 1 P4 flushing time
Text display, line 2 XXX seconds
Adjustable in steps of 10 seconds Range 10 - 600 s
Factory setting Initial value 180 s
Text display, line 1 P5 Filling time
Text display, line 2 XXX seconds
Adjustable in steps of one second Range 5 - 100 s
Factory setting Initial value 30 s
Text display, line 1 P6 After blow. t.
Text display, line 2 XXX seconds

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3.5.8 P7 Cartridge alarm delay time
NOTE
This parameter is only visible with filter type P0 = 4, 5, 8, 9, 14, 15.
3.5.9 P8 DP alarm (flushing frequency monitoring)
NOTE
This parameter is only visible with filter type P0 = 3, 5, 7, 9, 11, 13, 15, 17.
3.5.10 P9 Motor fault
NOTE
This parameter is only visible with filter type P0 = 0, 6, 7, 8, 9, 12, 13, 14, 15.
Adjustable in steps of 10 seconds Range 10 - 600 s
Factory setting Initial value 30 s
Text display, line 1 P7 Cartridge al.
Text display, line 2 XXX seconds
Setting Off / On
Factory setting Initial setting "On"
Text display, line 1 P8 DP alarm
Text display, line 2 Off
or
Text display, line 2 On
Adjustable in steps of 0.01 A Range 0.10 to 0.99 A
Factory setting Initial value 0.4 A
Text display, line 1 P9 Motor fault
Text display, line 2 0000 mA

Operating instructions Typ 2200 17 / 32
Betriebsanleitung Typ 2200
3.5.11 P10 Back flushing time
NOTE
This parameter is only visible with filter type P0 = 1, type 6.21/6.22/6.23/6.24.
Setting: ND 32 = 1 / ND 40 = 2 / ND 50 = 3 (ND = nominal diameter)
A certain control time is selected from a table according to the nominal diameter.
The parameter is not required if the setting is P0  1.
NOTE
For filter type 6.21/6.22, the backflushing time must generally be set to ND 50=3.
3.5.12 P11 Language
You can select from German, English, French and Spanish.
Adjustable in steps of one Range 0 to 2
Factory setting Initial setting ND 32 = 1 s
Text display, line 1 P10 flush.time
Text display, line 2 ND=XX =XX sec
Setting D German
ES Spanish
FFrench
GB English
Factory setting Initial setting D German
Text display, line 1 P11 Language
Text display, line 2 GB English

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3.5.13 P12 Testcode
NOTE
This parameter is only visible with filter type P0 = 0.
NOTE
The test code switches the controller to a test mode which is provided for
authorised persons only.
3.5.14 P14 Pressure compensation time
NOTE
This parameter is only visible with filter type P0 = 12, 13, 14, 15.
Adjustable in steps of one Range 0 to 250
Factory setting Initial value 0
Text display, line 1 P12 Testcode
Text display, line 2 XXX
Adjustable in steps of one second Range 0 to 99 s
Factory setting Initial value 10 s
Text display, line 1 P14 PET
Text display, line 2 XXX seconds

Operating instructions Typ 2200 19 / 32
Betriebsanleitung Typ 2200
4 Description and function of controller
4.1 Controller type 6.18 / 6.19 / 6.44
Inputs
Pressure switch "DP reached, backflushing filter"  75 %
Pressure switch "DP too high, backflushing filter"  100 %
Outputs
Motor
Flushing valve
Potential-free contacts
Functional description 6.18, 6.19 and 6.44
See the operating instructions for the filter's function.
Flushing is triggered by:
Special attributes
•All alarms are displayed and signalled and saved via potential-free contacts.
•If the controller is in parameterisation mode, flushing cannot be triggered
manually.
•If the "Controller type" parameter is changed, the functions are re-started.
1) "Control voltage monitoring" alarm Output A1, A2, A3
2) Collective fault, comprising: Output A4, A5, A6
- "Maximum differential pressure reached" alarm
and
- "Motor fault" alarm
3) "Motor fault" alarm Output A7, A8, A9
4) "Flushing active" message Output A10, A11, A12
1) Key F
2) The forced flushing time elapsing
3) Pressure switch "DP reached, backflushing filter"

20 / 32 Operating instructions Typ 2200
Betriebsanleitung Typ 2200
4.2 Controllers of types 6.21/6.22/6.23 / 6.24
Inputs 6.21/6.22/6.23 and 6.24
Pressure switch "DP reached, backflushing filter"  75 %
Pressure switch "DP too high, backflushing filter"  100 %
Outputs 6.21/6.22/6.23 and 6.24
Flushing valve
Potential-free contacts and messages 6.21/6.22/6.23 and 6.24
Functional description 6.21/6.22/6.23 and 6.24
See the operating instructions for the filter's function.
Flushing is triggered by:
Special attributes
•All alarms are displayed and signalled and saved via potential-free contacts.
•If the controller is in parameterisation mode, flushing cannot be triggered
manually.
•If the "Controller type" parameter is changed, the functions are re-started.
1) "Control voltage monitoring" alarm Output A1, A2, A3
2) "Maximum DP reached" alarm Output A4, A5, A6
1) Key F
2) The forced flushing time elapsing
3) Pressure switch "DP reached, backflushing filter"